Marine ComNav CT2-40A User manual

Marine Ltd.
CT2-40A
MOTOR CONTROLLER
PART NUMBER 20350001
DOCUMENT PART NUMBER 29010024
ComNav R
Permanent Magnet zShunt Field Compound zD.C. Motors
ComNav
Installation Instructions
Version 3.3
ComNav Marine Ltd. #15-13511 Crestwood Place. Richmond, B.C. Canada. V6V-2G1
Telephone: [phone] Facsimile: 604-207-8008
Web: www.comnavmarine.com E-mail: [email protected] Document PN 29010024

Introduction:
CT2-40A Motor Controllers are designed to connect a ComNav Autopilot to a steering system
using a permanent magnet, shunt field, or compound reversing D.C. Motor.
CT2-40A Motor Controllers feature dynamic braking, current limiting and thermal protection of the
MOSFET driving transistors while allowing full power acceleration and drive when needed. CT2
Motor Controllers can be used with 12, 24 and 32 VDC battery systems.
CT2 Motor Controllers also feature automatic field control for use with Shunt Field and Compound
Reversing D.C. Motors. The field of the motor is energised any time the Autopilot is turned on.
Installation:
WARNING
To ensure that the CT2 Motor Controller case will stay watertight, it is very important
that you use round cables in all three watertight cable fittings. The two large cable
fittings will require a cable with an outer diameter ranging from 5/32"(4.0mm) to
13/32"(10.0mm). The smaller cable fitting will require a cable with an outer diameter
ran
g
in
g
from 3/32"
(
2.5mm
)
to 1/4"
(
6.5mm
)
.
For mounting, a #10 size hole is provided in each foot of the 2T Motor Controller box.
The Autopilot and the CT2 Motor Controller must be run from the same source of power,
although they do not need to be powered from the same breaker. In fact, for installations that use
two drive units, it is preferable to power the Autopilot and each CT2 Motor Controller from a
separate breaker. This way either or both drive units may be selected to operate independently
from the Autopilot.
To provide power to the CT2 Motor Controller, use #12 AWG wire if the combined run from the
breaker to the box and from the box to the motor, is 25 feet or less. If the combined run is greater
than 25 feet use #10 AWG wire. Run the power lead from a 50 Amp breaker to the CT2 Motor
Controller.
If the Autopilot is powered from the same breaker as the CT2 Motor Controller, run a
separate wire from the breaker to the Autopilot as shown in the diagram. DO NOT run the power
lead to the Autopilot from the CT2 Motor Controller. Before providing power to the Autopilot, refer
to the Autopilot Installation and Operation Manual for the appropriate wire gauge.
21/09/2007 Page 1 of 10 29010024V3.3(2T Drive Box).doc

For the correct interconnection of the CT2 Motor Controller and the Autopilot refer to
Figures 2 through 4. A four-conductor, #24 AWG cable with shield will be satisfactory. The shield
of the cable should be terminated to the JOG COMMON terminal (or V-) in the Autopilot
distribution box and unterminated at the other end.
If Jog Levers are used to override the Autopilot, connect them to the terminals provided in the
Autopilot distribution box (see enclosed diagrams or the Autopilot manual).
If the drive system is a Rotary Drive or Linear Actuator, the clutch of the rotary drive, or the
lockup solenoid of the linear actuator, should be wired to the Switched Power and Jog Common
terminals in the Autopilot distribution box (refer to the interconnection diagram in your ComNav
Autopilot Installation and Operation Manual).
TESTING:
Close the breaker which provides power to the Type CT2 Motor Controller. It is normal to
hear a pop when the breaker is closed as the large capacitors in the CT2 Motor Controller charge
up.
To ensure correct rudder direction movement, place the Autopilot master select switch in the
POWER STEER position and press either the red or green ARROW key. The rudder should move
in the correct direction. If not, reverse M1 and M2 leads from the CT2 Controller to the motor.
Refer to the Autopilot Installation and Operation manual, and complete the Dockside Setup
procedure for the autopilot. After completing the Dockside Setup procedure, measure the hard-
over to hard-over time of the drive system.
To measure the maximum hard-over to hard-over time of the drive system, place the
Autopilot master select switch in the POWER STEER position and hold the red or green ARROW
key to make the rudder move fully from Port to Starboard or vice versa.
If the hard-over to hard-over time is less than 8 seconds, the rudder must be slowed down by
decreasing the pumpset displacement, or changing to a smaller pumpset / slower acting drive
unit.
If the hard-over to hard-over time is more than 16 seconds, the rudder must be sped up by
increasing the pumpset displacement or changing to larger pumpset / faster acting drive unit.
When the hard-over time is between 8 - 16 seconds, testing of the CT2 Motor Controller Drive Box
is complete.
21/09/2007 Page 2 of 10 29010024V3.3(2T Drive Box).doc

TROUBLESHOOTING:
•Check with a voltmeter that voltage is present between Terminals J1, V+ and J1, V- (the
battery voltage).
•If no voltage is present, check that there is power to the breaker panel, and that the breaker
for the motor is turned on. Recheck the wiring from the breaker panel to the CT2 Drive Box.
•If voltage is present, use an ohmmeter to check the 30 AMP Fuse (F1). Check the 1 AMP
Fuse (F2) as well. If either is faulty, replace with the same size fuse.
•If fuses are OK check the voltage between Terminal J1 (V-) and Terminal J2 (+5V) for the +5
volts from the Autopilot. Check that the voltage between Test Points TP3 and TP4 is between
12 and 13.5 volts. Check that the voltage between Test Points TP1 and TP4 is 15 to 20 volts
higher than the voltage between Terminals J1 (V+) and J1 (V-) (the battery voltage).
If all test voltages are correct, connect the Port or Starboard terminal (J2, STBD or J2, PORT)
momentarily to the battery negative terminal (J1, V-) - the motor should run.
•If the motor doesn't run:
1. If the motor is a Shunt Field or Compound Motor, check that full (within a volt) battery
voltage appears between J1, Field+ and J1, Field- when there is +5V between J2, +5V and
Test Point TP4. If there is no voltage, disconnect the field connection to the motor and
check for a short circuit between the field wire and motor leads, or for a nail or staple
through the cable.
2. Check that the full input voltage appears between the M1 and M2 terminals while the Port
or Starboard terminal is connected to the V- terminal. The polarity of the voltage will
depend on whether the Port or Starboard input is activated.
3. If the voltage is present the motor may be faulty. Connect the motor leads directly to the
battery briefly to confirm whether it runs in both directions. If it does not run, contact your
dealer or the supplier of the drive system for assistance. If it does run, the CT2 Motor
Controller may be faulty. Contact your Dealer or ComNav Marine for assistance.
4. If there is no voltage present the CT2 Motor Controller may be faulty. Contact your Dealer
or ComNav Marine for assistance.
21/09/2007 Page 3 of 10 29010024V3.3(2T Drive Box).doc

•If the motor runs:
1. Check the outputs from the Autopilot for correct operation. The red and green output
diagnostic LED's in the Autopilot distribution box should come on as described in the
ComNav Autopilot Installation and Operation Manual.
2. If the diagnostic LED's do come on and the rudder still will not move, examine the wiring
between the Autopilot and the CT2 Motor Controller again. Check for open or short circuits.
Check for nails or staples which may have penetrated the cable.
3. If the diagnostic LED's do not come on, you may have a faulty Distribution Box or Control
Head. Contact your Dealer or ComNav Marine for assistance.
Electrical Noise:
The CT2 Motor Controller uses high current switching transistors to control the motor. Every effort
has been made to reduce or eliminate the generation of electrical noise by the motor controller. If
some noise is heard on the vessel radios, and it is traced to the motor controller, a ground lug has
been provided to bond it to the vessel's grounding system. In most cases, this should eliminate
any electrical noise.
Specifications:
Operating Voltage Range: 10 to 40 volts D.C.
Operating Temperature Range: -10 degrees C to +70 degrees C
Current Limit: 50 Amps for 1 second
Normal Operating Current: 30 Amps (CT2-40A model) maximum, thermally limited
Field Control: Up to 5 Amps maximum. Overcurrent and Short Circuit
Protected
Note:
When the maximum operating limits are exceeded, the output from the CT2 Motor Controller will
automatically be turned off. This will allow the internal temperature of the output driving transistors
to fall back into the safe operating area and power will then be re-applied to the motor. This
happens in a fraction of a second, with a very strong pulsating effect to the steering gear. This will
only happen if the steering gear goes hard-over or is in some way jammed and will not move.
21/09/2007 Page 4 of 10 29010024V3.3(2T Drive Box).doc

6
5
4 3 2 1
1
M2
M1
- +
1
2
3
4
6
FIELD+
5
FIELD-
MOTORMONITOR
+5V
STBD
PORT
3
2
+
-
UNSW.PWR
PORT
STBD
SW.PWR
SPDCNTL
+5V COM
MOTORMON(1001,1101,1201)
JOGPORT
JOGSTBD
JOGCOM
12/24VDC
JOGLEVER
(NOTSUPPLIED)
BATTERY
30AFUSEORBREAKER
+
-
1
2 3 4
10-40VDCMOTOR
AUTOPILOT
DISTRIBUTIONBOX
Figure 2 Connection to Permanent Magnet Motor
21/09/2007 Page 5 of 10 29010024V3.3(2T Drive Box).doc

6
5 4
3 2 1
1
M2
M1
- +
1
2
3
4
6
FIELD+
5
FIELD-
MOTORMONITOR
+5V
STBD
PORT
3
2
M1
M2
FLD-
+
-
UNSW.PWR
PORT
STBD
SW.PWR
SPDCNTL
+5V
COM
MOTORMON(1001,1101,1201)
JOGPORT
JOGSTBD
JOGCOM
JOGLEVER
(NOTSUPPLIED)
1
2
3
4
10-40VDCMOTOR
SHUNTFIELDMOTOR
AUTOPILOT
DISTRIBUTIONBOX
FLD+
30AFUSEORBREAKER
12/24VDC
BATTERY
-+
Figure 3 Connection to Shunt Field Motor
21/09/2007 Page 6 of 10 29010024V3.3(2T Drive Box).doc

6
5 4
3 2 1
1
M2 M1
- +
1
2
3
4
6
FIELD+
5
FIELD-
MOTORMONITOR
+5V
STBD
PORT
3
2
GREEN
SERIES
WHITE
BROWN
BLACK
RED
M1
M2
FLD-
SHUNT
+
-
UNSW.PWR
PORT
STBD
SW.PWR
SPDCNTL
+5V
COM
MOTORMON(1001,1101,1201)
JOGPORT
JOGSTBD
JOGCOM
+
12/24VDC
JOGLEVER
(NOTSUPPLIED)
BATTERY
30AFUSEORBREAKER
+
-
-
1
2 3
4
10-40VDCMOTOR
COMPOUNDMOTOR
AUTOPILOT
DISTRIBUTIONBOX
Figure 4 Connection to Compound Motor
21/09/2007 Page 7 of 10 29010024V3.3(2T Drive Box).doc

+5V
SHOWNWIRESHOULDBEKEPTINSIDETHEPROCESSORCASE.
TYPICALCONNECTIONSCT2BOXTOPROCESSORBASEDAUTOPILOTS.
+5V
3
CT2BOXANDPROCESSORMUSTBECOMMONGROUND.
J2
STBDIN
PORTIN
2
1
TOM2
TOM1
1A
F2
U1U2
J1
20A
F1
FIELD-
FIELD+
U3
VBOOST
O/C
F/B
6 5 4
1
2
TO+5V
M1
M2
3
4
- +
5
6
TOPROCESSORBOX
TOMOTOR
5
TOBAT12/24/32VDC
5
TOCT2BOX
M2
M1
BLACK- WHITE+
TOBAT12/24/32VDC
PROCESSOR
WHITE
3
GREEN
BLACK
1 2
4BLUE
YELLOW
SHIELD
SHIELD
5
6
4
1 2 3WHITE
8 7 6
5
WHITE
GREEN
BLACK
RED
12RED
9 10 11
GREEN
BLACK
BLUE
Figure 5 Connection to Processor Based Autopilots
21/09/2007 Page 8 of 10 29010024V3.3(2T Drive Box).doc

1234567891011121314151617181920212223242526272820
CONTROL
HEAD
CONTROL
HEAD
CONTROL
HEAD
RUDDERFOLLOWER
UNIT(RFU)
FUSE
FLUXGATE
COMPASS
BATTERY12/24VDC
GREEN
GREEN
YELLOW
WHITE
SHIELD
YELLOW
WHITE
SHIELD
DATA
GND
DATA
GND
+
GND
+
-
S1
COM
S2
ALARM+
GND
FFU-
FFUS
FFU+
ENABLE
1
+BATTERY
2
-BATTERY
3
COMMON
4
MOTOR1(SOLENOID1)
5
MOTOR2(SOLENOID2)
FUSE
5
OFFSET
GAIN
VR5
(DIGITALRAI
OFFSET)
VR6
(CURRENTLIMIT)
VR1
(ANTI-HUNT)
VR3
(ANALOGRAIOFFSET)
VR2
(ANALOGRAIGAIN)
VR4
BLACK
GREEN
WHITE
FORCOMNAV
RUDDERFOLLOWER
INSTALLATIONUSE
1234
124
3
DIPSWITCHES**
5
24/32VDC
12VDC
TO5V
TOPORTIN
TOSTBDIN
TOSOLENOID1
TOSOLENOID2
TYPICALCONNECTIONSCT2BOXTO1500AUTOPILOTS
PCBPN31252
CT2REV.10
+
-
M2
M1
VBOOST
FIELD+
FIELD-
J1
PORTIN
STBDIN
U3
F/B
O/C
+5V
C17
J3
3
6 2
J2
1
4
5 3
1
2
TORFU+5V
5 4
6
30AFUSEOFBREAKER
M2
M1
TO1500BOX
MAGNETMOTOR
5
TOPERMANENT
TOBAT12/24VDC
PLACEASHUNTBETWEENPIN1&PIN2OFJ3
124
35
DIPSWITCHES
UP
DOWN
3
124
24/32VDC
12VDC
1)MakesureitisinUPpositionforsolenoidsetup
2)Keepindownposition.
3)Keepindownposition.Ifusinganalogoutputinterface(A1100),
keepinupposition.
4)Keepindownposition.Ifusingfullfollowup(FFU)tillersteering
option,keepinupposition.
5)Setaspervoltageapplicationshownabove.
**Makesurepoweristurnedofftothepilotsystempriortochanging
dipswitches.
U2
U1
1A
F2F130A
S1S2
2) On the PCB, set DIP SWITCHES (S1-1) to UP to select Solenoid configuration.
3) Remove EndCaps and Enclosure from the CT2 box to expose the CT2 PCB.
4) On the PCB, shift the two-position shunt to between Pin1 and Pin2 of J3.
5) Use a #10 or #12 AWG cable to connect 2 wires from Permanent Magnet Motor to CT2 Box..
6) Use a #22 AWG cable to connect 3 wires from DU 1500 Box to CT2 Box. (See the Diagram below).
7) Install a 30A fuse or breaker in line with power input to CT2 box.
8) Reassemble the units.
INSTALLATION STEPS:
1) Loosen six screws and remove the cover from the DU 1500 Servo unit to expose the PCB.
Figure 6 Connection to 1500 Autopilot
21/09/2007 Page 9 of 10 29010024V3.3(2T Drive Box).doc

Figure 7 Connection to 1510 Autopilot
TYPICALCONNECTIONSCT2BOXTO1510AUTOPILOTS
+5V
3
J2
STBDIN
PORTIN
2
1
TOSOLENOID2
TOSOLENOID1
1A
F2
U1U2
J1
30A
F1
FIELD-
FIELD+
U3
VBOOST
O/C
F/B
6
5 4
1
2
TORFU+5V
M1
M2
3
4
-
+
5
6
TO1510BOX
TOPERMANENT
5
J3
C17
CT2REV.10
PCBPN31252
(SOLENOID2)
(SOLENOID1)
MOTOR2
15
GND
2
MOTOR1
3
CONTROL
HEAD
FLUXGATE
COMPASS
BATTERY12/24VDC
CONTROL
HEAD
CONTROL
HEAD
RUDDER
FOLLOWERUNIT
(RFU)
VR6
5
4
-BATTERY
COMMON
VR2
16
+
17
GND
18
+
19
-
20
S1
21
COM
22
S2
1
+BATTERY
VR4VR1
2412
15AMPFUSE
VR3
5AMPFUSE
12
12
DIP
SWITCHES**
3
1
GREEN
2
YELLOW
3
WHITE
4
SHIELD
5
GREEN
6
YELLOW
7
WHITE
8
SHIELD
9
RED
10
WHITE
11
BLACK
12
DATA
13
GND
14
DATA
TOSTBDIN
TOPORTIN
TO5V
TOCT2BOX
1)MakesureitisinUPpositionforsolenoidsetup.
2)Keepindownposition.
3)Setaspervoltageapplicationshownabove.
Switchshouldbesetto12for12VDC
applicationorsetto24for24VDCapplication.
**Makesurepoweristurnedofftothepilot
systempriortochangingdipswitches.
3
2
1
2412
DIPSWITCHES
2
1
UP
DOWN
M1
M2
TOBAT12/24VDC
30AFUSEOFBREAKER
MAGNETMOTOR
S1
S2
1) Loosen two screws and remove the cover from the DU 1510 Servo unit to expose the PCB.
2) On the PCB, set DIP SWITCHES (S1-1) to UP to select Solenoid configuration.
3) Remove EndCaps and Enclosure from CT2 box to expose the CT2 PCB.
4) On the PCB, shift the two-position shunt to between Pin1 and Pin2 of J3.
5) Use a #10 or #12 AWG cable to connect 2 wires from Permanent Magnet Motor to CT2 Box
6) Use a #22 AWG cable to connect 3 wires from DU 1510 Box to CT2 Box.
(See the Diagram below).
7) Install a 30A fuse or breaker in line with power input to CT2 Box.
8) Reassemble the units.
INSTALLATION STEPS:
PLACEASHUNTBETWEENPIN1&PIN2OFJ3
21/09/2007 Page 10 of 10 29010024V3.3(2T Drive Box).doc