COURSEMASTER CM800i User guide

COURSEMASTER
AUTOPILOTS
A
ustralia's world leader in autopilot technolo
gy
CM800iSYSTEM MANUAL
02-09

CM800iSYSTEM MANUAL
Your Coursemaster CM800iautopilot system is engineered for
accurate and reliable steering. But remember that it cannot keep a
lookout.
SAFE NAVIGATION IS ALWAYS YOUR
RESPONSIBILITY.
COURSEMASTER AUTOPILOTS PTY LTD.
2/66 LOWER GIBBES STREET,
CHATSWOOD NSW. AUSTRALIA 2067
ABN 25 001 306 369
Phone [phone]
Fax [phone]
E-mail: [email protected]
Website: www.coursemaster.com
02-09

THE CM800iSYSTEM
The ‘intelligent’ CM800 autopilot system may use CM800ior CM850i
controllers in combination with a CM840 or CM841 Junction Box. This
manual describes the use of each configuration and some details may
therefore not apply to your particular system. It is possible also to upgrade
an earlier CM800 system to the latest version simply by fitting a new
software chip. Apart from the labels on the Control Heads, such a system
will operate as described in this manual. Suitable software is Version 2.12
for standard rudder drives, or Version 2.13 for solenoid steering.
Copyright 2004-2009. This manual, the mechanical and electronic design of the
CM800 autopilot system and its associated software are protected by copyright.
Unauthorised copying may result in prosecution.

QUICK START
•Install and check the system as described in Chapter 3.
•Press the STANDBY key to turn the system on.
•Follow the on-screen instructions to carry out the initial setup
•Press the STANDBY and PILOT keys together to turn off.
•Steer to the desired course and press PILOT.
•Use the course knob and/or arrow keys to change or trim the
course.
•To steer a course set by a GPS system, press NAV.
•Use the MODE key for access to alternate displays. Hold the
MODE key for 2 seconds to display the menu options.
•Hold the PILOT key down for two seconds to activate the DODGE
function. Use the arrow keys to dodge.
•Hold the PILOT key down for three seconds to activate the
autotack function.

CM800iSYSTEM MANUAL
CONTENTS
1. SYSTEM DESCRIPTION
1.1 Introduction to autopilots 1-1
1.1.1 The Reference Course 1-2
1.1.2 Steering Control 1-2
1.1.3 Power Steering 1-4
1.1.4 Options 1-4
1.1.5 Working with other Equipment 1-5
1.2 The CM800i System 1-6
1.3 Optional attachments 1-8
2. OPERATING INSTRUCTIONS
2.1 The Control Panel 2-1
2.2 Getting Started 2-2
2.2 Normal Operation 2-5
Switching on
Switching off
Adjusting the course
Dodge
Autotack
Auto Navigation
Remote steering
Wind Vane steering
2.4 The Mode key 2-9
Sea state
Rudder factor
Navigation display
2.5 Program Menus 2-11
2.6 Alarms 2-17
2.7 Recommended Settings 2-18

CONTENTS
3. INSTALLATION
Step-by-step Summary 3-1
3.1 Junction Box 3-2
3.2 Controller 3-4
3.3 Compass options 3-5
3.4 Rudder Transducer 3-7
3.5 Attachments 3-8
3.5.1 Remote Steering 3-8
3.5.2 Rate Gyro 3-9
3.5.3 Second Controller 3-9
3.5.4 Rudder Angle Indicator 3-10
3.5.5 Remote Alarm 3-10
3.5.6 NMEA Interfaces 3-10
3.6 Steering Drive 3-11
3.6.1 Chain driven mechanical 3-12
3.6.2 Solenoid-controlled hydraulics 3-14
3.6.3 Hydraulic System with Reversing Pump 3-14
3.6.4 Hydraulic linear drive 3-18
4. TROUBLE-SHOOTING
4.1 General 4-1
4.2 Error messages 4-1
4.3 Other faults 4-3
4.4 Fuses 4-4
5. SYSTEM SPECIFICATIONS 5-1
6. MAINTENANCE AND WARRANTY 6-1

CHAPTER 1 SYSTEM DESCRIPTION
1.1 INTRODUCTION TO AUTOPILOTS
The main function of a marine autopilot is to hold the heading of a vessel on a
reference course which is held in the memory of the autopilot. When it is operating, the
autopilot continuously compares the vessel’s heading with a reference course, and if
they are different, it applies helm to bring the vessel back on course. Since there has to
be a compromise between the accuracy of course holding and the activity of the
rudder, the autopilot has controls which let the user set the balance between these two
factors.
The four basic components of an autopilot are a compass, an electronic control box, a
rudder angle sensor (transducer) and the steering drive. See Fig 1.1. In a CM800i
system, the electronics are housed in two cases - a Junction Box containing most of
the system and a Controller (Control Head), which is mounted near the steering station.
RUDDER
STEERING DRIVE
RUDDER STEM
CONTROL
POWER
TRANSDUCER
COMPASS
Figure 1.1 Basic components of a marine autopilot.

System Description 1-2
Modern autopilots perform other functions as well and this introduction explains how
these fit in with the basic function and how they provide a wider range of options for the
user.
1.1.1 THE REFERENCE COURSE
When the autopilot is first turned on, it rests in an idle (STANDBY) state in which it
displays the heading, but does not steer the vessel. It is activated by switching it into
the PILOT state. At the moment this is done, the current heading is put into memory as
the reference course and the autopilot starts steering to hold the heading on this
reference course. The user can change the reference course at any time and the
heading will swing round to match the new course.
There are two other ways of setting the reference course. If the autopilot is connected
to a GPS navigation receiver, the heading is then controlled to place the vessel on a
direct track between the origin waypoint and the next waypoint. The third option may
be used on yachts fitted with a compatible wind instrument. In this case, the reference
course adjusts itself to maintain a constant apparent angle to the wind.
1.1.2 STEERING CONTROL
When the vessel swings off course or the reference course is changed, the autopilot
should apply helm in a way which brings the vessel onto course quickly, but without
overshooting the reference course. The correct rudder angle depends on the amount
of the error, the speed of the vessel, its size and the effectiveness of its rudder.
Automatic Tuning
In an auto-tuning autopilot, such as the CM800i system, this choice of the appropriate
rudder correction is made automatically. The autopilot uses data about the type of
vessel, which is entered during the set-up operation. Then, as the vessel travels, the
autopilot continuously monitors the accuracy of course holding and the level of rudder
activity. It then chooses internal settings which achieve the best compromise between
these two measures of performance. These is also an option to operate in a manual
tuning mode, in which case, the following comments apply.

System Description 1-3
Rudder Factor (Manual)
The sensitivity or RUDDER FACTOR sets how many degrees of helm are applied for a
given course error. A mid-range rudder factor setting applies half a degree of helm for
each degree off course. In large or slow vessels it would be more and in light, fast
boats it may be less.
Setting the rudder factor too high causes oversteering or ‘snaking’ as illustrated in Fig
1.2. Too low a setting causes understeer and a sluggish response. Fortunately, most
vessels tolerate a range of settings and still steer well.
UNDERSTEER
REFERENCE
COURSE
OVERSTEER
Figure 1.2. Illustration of oversteer if the rudder factor is set too high and understeer if
it is set too low.
Sea State (Manual)
The SEA STATE setting is influenced by the sea conditions and the weight of the
vessel. The NORMAL applies helm in proportion to the course error and the rate of
turn. The ROUGH mode is used when the vessel rolls and yaws in a heavy sea.
Rudder activity is quietened down by not reacting to small heading shifts, but full
control is applied as the shift becomes larger. The rate of turn component in the helm
correction is adjustable and is important for vessels whose helm response is slow
and/or continue to turn for some time after helm is removed. When there is a turn-rate
(or counter rudder) component, normal helm is applied to start the vessel turning. As
the turn rate builds up, the helm is backed off. When the vessel is close to the
reference course, reverse helm or counter-rudder is applied to stop the turn.

System Description 1-4
The action of the rate or counter-rudder during a turn is illustrated in Fig 1.3.
Generally, when the rate component is increased, vessels hold a course better but
react to changes in the reference course more slowly. Counter-rudder also improves
control for most vessels operating in a following sea.
REFERENCE
COURSE
NORMAL RUDDER
NEUTRAL RUDDER
COUNTER RUDDER
Figure 1.3 Rudder action during a turn in the RATE mode.
Autotrim
Vessels often show a steering bias or offset, which can be due to weather, propeller
torque or towing a load off-centre. The autopilot responds to this by progressively
trimming the centre position of the rudder until the average heading of the vessel
equals the reference course.
1.1.3 POWER STEERING
Since the autopilot controls a power steering system, options are available to use this
to steer the vessel by hand while away from the main wheel. This can be done by a
hand-held device on a cable or a permanently mounted second steering station.
1.1.4 OPTIONS
An autopilot commonly uses a fluxgate compass for its heading measurement. Such
compasses, though effective, suffer from acceleration errors and a very effective way
to reduce these errors is to combine a fluxgate with a rate-of-turn gyro. A further
option is to fit a pickup device (slave) on the ship’s compass and take advantage of its
dynamic performance and the fact that it has been magnetically compensated.
Alternatively, this autopilot may take its heading in digital form from a ship’s gyro or

System Description 1-5
other electronic heading sensor. The autopilot has built-in facilities for automatic or
manual compass calibration.
When connected into an NMEA data system, the autopilot can receive navigation data,
as mentioned above or wind direction data. Some of this data, which is not used for
autopilot operation, is displayed on the autopilot screen for convenience. The autopilot
generates output data containing the current heading, which can be fed into an
instrument or radar system.
Autopilots intended for yacht use have an automatic tacking feature which is useful for
single-handed sailing.
A second control head may be fitted to the autopilot to provide parallel operation from
two stations.
1.1.5 WORKING WITH OTHER EQUIPMENT
The physical and electrical environment in a boat can be harsh. This autopilot has
been engineered with this in mind and tolerates poorly regulated power supplies,
overloaded steering, radio transmitters, radars and the like. Conversely, it has also
been engineered to operate without causing interference to radio receivers and other
communications equipment. Coursemaster autopilots carry a CE mark to indicate
compliance with the relevant EMC standards. The installation sections of this manual
have been carefully developed to minimise problems when the autopilot is in this
environment. Please study and follow them!

System Description 1-6
1.2 THE CM800i SYSTEM
The core of the CM800i system is built by connecting a Controller to a Junction
Box. There is a choice between two versions of the Controller and two versions of the
Junction Box. A comparison of their features between is shown in Fig 1.4 below.
STBY
PILOT
PORT STBD
COURSEMASTER 800
NAV
STBY REF 123
123
NAV
O
PORT STBD
COURSEMASTER 850
NAV
123
NAV
O
STBYMODE MODE
PILOT
STBY REF 123
COURSE
CM800i Controller CM850i Controller
CM840 Junction Box CM841 Junction Box
Figure 1.4 Comparison between Controller and Junction Box versions.
•Two course indicators
•Knob and keys for course adjustment
•Three course indicators
•Keys for course adjustment
•For 12 - 24 volt systems
•Drive current 30A max.
•Dual Controller sockets
•Dual Remote ports
•Fluxgate or slave or digital
heading
•Footprint 256 x 136 mm
•For 12 volt systems
•Drive current: 20A
•Can operate two parallel Controllers
•Single Remote Port
•Fluxgate or slave or digital heading
•Footprint 204 x 136 mm

System Description 1-7
The shape of the final system is determined by the optional attachments and many
combinations may be set up. Figs 1.5 shows a full system based on either the CM840
or CM841 Junction Box.
The core system components are shown with shading.
JUNCTION BOX
NAVIGATION
SYSTEM
CM 840/841
CM 427
CM655 / 653 / 654
REMOTE
CONTROL
12/24 V
POWER
STEERING
DRIVE
CM 120/125
RUDDER TX
CM 626
RATE GYRO
CM 530/630
REMOTE
ALARM CM551
CM800/850 CONTROLLER
NMEA
CM 428
FLUXGATE COMPASS or
SLAVE
SECOND CONTROLLER
RUDDER METER CM656 WHEEL STEERINGJOG LEVER
RADAR/
PLOTTER
WIND
INSTRUMENTS
DIGITAL
HEADING
CM437
RATE GYRO COMPASS
or
OPTIONAL
Figure 1.5 Autopilot system using the CM840 or CM841 Junction Box. Note that only
one of the remote controls shown may be connected to a CM840
and that the CM840 operates only from a 12 V supply.
CM437
RATE GYRO COMPASS

System Description 1-8
CM840 or CM841 Junction Box
The Junction Box contains the control microcomputer, the interfaces with other system
components and the steering drive electronics. All system cables are terminated in the
Junction Box. The drive system is robust and is designed to drive mechanical,
hydraulic pump and solenoid controlled steering systems.
CM800i or CM850i Controller
The Controller has six push-buttons to control the system and displays information on
the current operation of the autopilot.
Compass Options
The CM437 Rate-Gyro Compass combines a fluxgate compass and rate gyro in a
single package. This combination should give the best steering performance over a
wide range of conditions. Alternatively, the CM427 contains just a fluxgate compass.
Both use a floating toroid sensor with built-in drive electronics.
Rudder Transducer
The standard rudder transducer is a CM120 which is suitable for recreational vessels.
For commercial vessels, the heavy-duty CM125 is recommended. Both are fully
sealed potentiometer types and are interchangeable.
Steering Drive
There are many mechanical or hydraulic steering options. A suitable drive may either
by supplied by Coursemaster or the autopilot may be connected to an existing steering
drive on the vessel.
1.3 OPTIONAL ATTACHMENTS
Rate Gyro
TheCM626 Rate Gyro is a vibrating crystal type which works in conjunction with the
fluxgate compass or slave to give more precise steering control in all sea states. It
provides a very stable short-term heading output which is independent of pitch and roll
in the vessel. The fluxgate output is then used to correct for drift in the gyro so that
long-term stability is also achieved. Using the rate gyro overcomes the 'southerly
heading' softness encountered in the southern hemisphere, or the converse problem in
the northern hemisphere. The rate gyro also quietens rudder activity in a heavy swell.
This option is not relevant if a CM437 is fitted.

System Description 1-9
Compass Slave
If desired, the CM437 or 427 compass may be replaced by a CM428 compass slave
mounted above the ship’s card compass.
Remote Steering
A number of remote steering options are available. The CM654 is a hand-held unit with
a cable and the CM655 is a panel-mount version of the CM654. Both are fitted with a
steering knob and a three-position switch (PILOT-STANDBY-HAND/REMOTE). The
CM653 is a cable-connected remote without a switch. It comes into service
automatically whenever the knob is turned away from the centre position.
The CM551 is a panel-mounted Jog Lever and the CM656 is heavy-duty steering
wheel hub suitable for a full power-steer second station. Finally, a mode switch to
switch between STANDBY and PILOT is available as a CM553.
One remote steering control may be connected to a CM840 Junction Box and two may
be used with a CM841 Junction Box.
Second Controller
A second Controller may be fitted. This may be either a CM800 or a CM850. Each
Controller operates with equal priority. The system may be switched ON or OFF from
either station and both Controllers show the same display.
Controller Mounting Kit
The Controller(s) are supplied ready for dashboard mounting, but an optional bracket
kit, CM705, is available for mounting it as a free standing unit.
Rudder Angle Indicator
This indicator gives an analog display of the rudder angle and may be located either
with the Controller or on another part of the vessel. It is available in two versions:
CM530 and CM630.
Remote Alarm
A piezoelectric beeper is available which repeats the internal alarms generated by the
autopilot.

CHAPTER 2 OPERATING INSTRUCTIONS
2.1 THE CONTROL PANEL
The front panels of the two Controllers (Figs 2.1 and 2.2) contain a text and graphics
display, and course error lamps keys. The CM850i also has a course adjust knob,
while the CM800i has an ‘on course’ indicator. The use of the controls is described in
this chapter.
STBY
PILOT
PORT STBD
COURSEMASTER 800
NAV
STBY REF 123
123
NAV
OMODE
COURSE
Switch on
Cancel pilot
Cancel alarms
Switch off
Engage Pilot
Cancel alarms
Trim course
Dodge
A
djust settings
Select display
Auto tack
Auto navigate
Wind vane
Trim course
Dodge
Adjust settings
Off Course > 8 de
g
.
System status Heading Rudder angle
On course
Dodge set
Figure 2.1 The CM800iController panel.

Operating Instructions 2-2
_______________________________________________________________
Switch on
Cancel pilot
Cancel alarms
Switch off
Engage Pilot
Cancel alarms
Trim course
Dodge
A
djust settings
Select display
Auto tack
Auto navigate
Wind vane
Trim course
Dodge
Adjust settings
Off Course > 8 de
g
.
System status Heading Rudder angle
Trim course 5 deg
PORT STBD
COURSEMASTER 850
NAV
123
NAV
O
STBY MODE
PILOT
STBY REF 123
Dodge set
Figure 2.2 The CM850iController panel.
2.2 GETTING STARTED
Before operating the autopilot for the first time, it must be installed and adjusted as
described in Chapter 3. (If optional attachments and interfaces are being used, these
can be fitted after initial trials of the system.)
To switch on for the first time, press the STANDBY key. The system enters a set-up
mode to ensure that the steering drive and rudder transducer have been phased
correctly. After the SELF TEST display, the screen shows the system setup prompt:
SYSTEM SETUP
PROCEED >
SKIP <
There are two choices. If you wish to examine some of the features without carrying out
the setup, select SKIP by pressing the left arrow. This will bypass the setup and let you
scroll through the displays, but there will be no response to the PILOT key. The system
will return to SYSTEM SETUP the next time it is turned on.
To carry out the setup, select PROCEED by pressing the right arrow.

Operating Instructions 2-3
_______________________________________________________________
The next two prompts enter a description of the vessel type, so that the auto-tuning
program starts with values that are best suited for it. The Hull Type is set either to
Displacement or Planing. Displacement hulls sit level in the water over their range of
operating speeds. Planing hulls lift their bow clear of the water at higher operating
speeds. Use the arrow keys to select between the two and press MODE. Then select a
displacement (weight) in ton, which is close to the actual weight of your vessel, using the
arrow keys to step up or down through the range of 1 to 110 ton. Then press MODE.
HULL TYPE
DISPLACEMENT
USE < OR >
DISPLACEMENT
06 TON
USE < OR >
The next two prompts are for storing the mechanical rudder limit positions and the
rudder transducer phasing in the autopilot memory. The stored limits are set 4 degrees
inside the actual stop positions and this ensures that no autopilot operations will push
the steering drive right to the stops.
TURN HELM TO
STBD LIMIT
AND PRESS >
TURN HELM TO
PORT LIMIT
AND PRESS <
04 P 25 S
Turn the helm to starboard until it reaches the mechanical stop. The last line of the
screen shows the helm angle. If it reads PORT instead of starboard, this will be
corrected automatically when you press the right arrow key. Now press the right arrow
key. Note that if the helm angle is less than 10 degrees at the stop, the system will not
respond. After pressing the right arrow, the port limit prompt appears. Now turn the
helm to port until it reaches the mechanical stop. At this stage, the helm direction will
read correctly. Press the left arrow and the final prompt appears:

Operating Instructions 2-4
_______________________________________________________________
29 LIMITS 28
CENTRE HELM
PRESS >
02 S
The top line shows the stored values of the port and starboard rudder limits. Check that
these are close to what you expect and are balanced within 5 degrees. Bring the helm
to the position which your experience shows to be centred - the indicated angle may now
be different from zero. Press the right arrow.
Warning: This action will start the steering drive. Make sure that
it is safe to do so before pressing the right arrow.
Three things now happen. The current helm position is now placed in memory at the
helm centre, the helm then moves to 10 deg port, pauses and then returns to centre.
This operation corrects any small alignment errors in the rudder transducer, stores the
correct drive phasing and completes the setup operation, returning the system to
STANDBY.
Note that if the helm is not centred within 5 degrees, an ‘Off Centre’ alarm will occur and
the setup will not continue. Press STANDBY and re-centre the helm by adjusting the
rudder transducer. Later, when the vessel is at cruising speed, it is recommended that
the HELM ADJUST option be used to fine-tune the helm centre. (Sec 2.5).
If a digital heading is to be used and a fluxgate compass is not connected, a ‘Compass
Fault’ alarm will now appear. Select Menu 3 (See Sect 2.5), scroll down to the
compass type option and select either the magnetic or true digital heading input.

Operating Instructions 2-5
_______________________________________________________________
2.3 NORMAL OPERATION
Press the STANDBY key. The system does a self-test for a few
seconds and displays the version of software fitted to your autopilot.
When the self-test is complete the normal STANDBY display
appears and shows the current heading of the vessel.
SELF TEST
JUNCTION BOX
VERSION 2.04
STBY REF 123
123
If a fault is detected during the self test, the Controller starts beeping
and the nature of the fault is displayed after the self-test period.
Press the STANDBY and PILOT keys together.
With the system in STANDBY, steer the vessel to the desired
heading and press PILOT. The autopilot will now lock onto that
heading and maintain it. The position of the rudder when the PILOT
key was pressed is stored in memory as the effective helm centre.
The display will show 'PILOT' in the top left corner.
Switching
On
STBY
Switching
Off
STBY PILOT
Autopilot
PILOT