MARINE

1101/1201 Autopilot System

Technical Manual
Version 1.0

Comnav Marine Ltd. #15 – 13511 Crestwood Place, Richmond, BC, Canada V6V2G1 Document PN 83668
Tel: 604-207-1600 Fax: 604-207-8008
World Wide Web: www.comnavmarine.com E-mail: comnav@comnavmarine .com

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 TABLE OF CONTENTS
1. 1101/1201 GENERAL SPECIFICATIONS........................................................................................ 3

2. TROUBLESHOOTING....................................................................................................................... 4
2.1 PROBLEMS DURING INITIAL DOCKSIDE SETUP:................................................................................ 4
2.2 CIRCUIT BOARD REPAIRS:............................................................................................................... 4
3. CIRCUIT DESCRIPTION .................................................................................................................. 5
3.1 HEAD ............................................................................................................................................. 5
3.1.1 General Description: .................................................................................................................. 5
3.1.2 Disassembly/Re-Assembly .......................................................................................................... 5
3.1.3 Button Replacement:................................................................................................................... 5
3.2 1101 SPU PN 82888 REV. 2 (2 PCB VERSION) ................................................................................ 6
3.2.1 General Description: .................................................................................................................. 6
3.2.2 Disassembly/Re-assembly (2 pcb version).................................................................................. 7
3.2.3 Signals to and from the Distribution Unit .................................................................................. 7
3.2.4 Signals to and from the Control Head ........................................................................................ 7
3.2.5 Signals to and from the Compass ............................................................................................... 8
3.2.6 Signals to and from the Remotes ................................................................................................ 8
3.3 1101/1201 SPU............................................................................................................................... 9
FOR 1101: PN 82888 REVISION 3 (1 PCB VERSION) ..................................................................................... 9
FOR 1201: PN 83747 REVISION 1 (1 PCB VERSION) ..................................................................................... 9
3.3.1 General Description: .................................................................................................................. 9
3.3.2 Disassembly/Re-assembly (1 pcb version).................................................................................. 9
3.3.3 Signals to and from the Distribution Unit .................................................................................. 9
3.3.4 Signals to and from the Control Head ...................................................................................... 10
3.3.5 Signals to and from the Compass ............................................................................................. 10
3.3.6 Signals to and from the Remotes .............................................................................................. 10
3.3.7 Signals from the SERIAL DATA Output ................................................................................... 11
4. CONNECTIONS ................................................................................................................................ 12
4.1 REMOVING CONNECTORS FROM THE SPU. .................................................................................... 12
4.2 REMOVING THE BACK SHELL TO VIEW THE WIRES ......................................................................... 13
4.3 HEAD TO SPU ............................................................................................................................... 14
4.4 DISTRIBUTION BOX TO SPU .......................................................................................................... 15
4.5 COMPASS AND SERIAL DATA CONNECTIONS TO SPU .................................................................... 16
5. DEALERS TEST BENCH ................................................................................................................. 17

6. FINAL TEST PROCEDURE ............................................................................................................ 18

7. APPENDIX A...................................................................................................................................... 21
7.1 PROBLEM SOLVING GUIDE FORM .................................................................................................. 21
8. APPENDIX B...................................................................................................................................... 22
8.1 SPU DRAWINGS/SCHEMATICS FOR 82888 REV 2, (2 PCB VERSION) ............................................ 22
8.1.1 Processor Board (B Board) ...................................................................................................... 22
8.1.2 Backplane Board (C Board) ..................................................................................................... 22
9. APPENDIX C...................................................................................................................................... 23
9.1 SPU DRAWINGS AND SCHEMATICS FOR 82888 REV. 3 AND 83747 (1 PCB VERSION) ................... 23
9.1.1 Bill of Materials........................................................................................................................ 23
9.1.2 Board Layout ............................................................................................................................ 23
9.1.3 Schematic.................................................................................................................................. 23

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 1101/1201 Technical Manual

10. APPENDIX D.................................................................................................................................. 24

10.1 DISTRIBUTION BOX DRAWINGS AND SCHEMATICS ........................................................................ 24
10.1.1 Bill of Materials.................................................................................................................... 24
10.1.2 Board Layout ........................................................................................................................ 24
10.1.3 Schematic.............................................................................................................................. 24
11. APPENDIX E.................................................................................................................................. 25
11.1 TEST BENCH WIRING DIAGRAM .................................................................................................... 25

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 1101/1201 Technical Manual

1. 1101/1201 General Specifications

The Specifications for the 1101/1201 Autopilot Systems define the basic capabilities and
operational limits of the equipment. These are as follows:
Operating Voltage: 10 VDC to 30 VDC
For use with 12 or 24 VDC Battery Systems

Operating Current: 250 mA nominal at 12VDC, tested in STANDBY

MODE. No external devices energized
Operating Temperature Range: 5° to 140° F (-15 to +60° C)

Heading Resolution: 0.25 Degrees

Heading Accuracy: ± 2.0 Degrees

Course Set Resolution: 1.0 Degrees

PORT/STBD Output Type: Open Collector, 3 Amps Max.

Speed Control Output: 2.50 VDC for No Movement

5.00 VDC for Maximum Speed to Port
0.0 VDC for Maximum Speed to Starboard
(10K ohm Source Impedance)
Navigation Input: NMEA 0183 (4800 BAUD):RMA, RMB, RMC, APB
APA, XTE, BOD, WBD, HSC, VBW, VHW, VTG

Navigation Outputs: NMEA 0183 (4800 BAUD):APHDG.

TTL level, Serial Clock and Data
Rudder Angle Indicator Output: 2.5 mA max
Size of Control Head
Width: 7 inches (178 mm)
Height: 3 5/8 inches (92 mm)
Depth: 1 3/8 inches (35 mm)
(1 ½ inches (76 mm) required behind unit for cabling)
Weight of Control Head: 1 lbs (450 gm)

Size of Signal Processing Unit

Width: 8.25 inches ( 210 mm)
Height: 3.75 inches ( 95 mm)
Depth: 2.25 inches ( 57 mm)
(3 inches (76 mm) required behind unit for cabling)

Weight of Signal Processing Unit: 2.2 lbs (1 Kg)

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 1101/1201 Technical Manual

2. Troubleshooting
In order to isolate the problem quickly it always helps to have as much relevant data as possible
about the vessel and its’ accessories. The Problem Solving Guide Form (see Appendix A) can be
used to compile all the necessary information together.
**If an alarm occurs, the Error Checking section in the users manual should be consulted.**

2.1 Problems during initial Dockside Setup:

A. Autopilot does not turn on
1. Check for power in the Distribution box terminals labeled POS and GND for correct
voltage. This voltage should be the same as the voltage across the terminals on your
batteries.
2. Make sure the main plug is properly plugged into the back of the Autopilot receptacle
labeled “Distribution Box”
3. Check the Fuse. If the fuse is blown, check the polarity of Power input cable, making sure
the battery positive goes to the terminal marked POS. and the Battery negative goes to the
terminal marked GND. Replace the blown fuse.
B. Autopilot displays Redo Rudder Setup
1. With the unit in STBY mode, measure the feedback signal for the voltage between the
terminal marked +5V and POS’N in the Distribution box. When rudder is in Dead Ahead
position you should read 2.5 Volts.
2. Check that the Rudder Follower Arm is above the cable gland when rudder is Dead
Ahead.
3. Check for continuity of Rudder Feedback cable. Rectify as necessary and restart the
setup process by switching the pilot off and then performing a full reset. Complete the
dockside setup.

2.2 Circuit Board Repairs:

The circuit boards in the 1101/1201 SPU are delicate, and can be damaged if not handled
properly. The most chance of damage occurs in the process of replacing components. Following
the proper procedure as outlined below will minimize the chance of damaging the circuit board.
When handling circuit boards from the 1101/1201 Autopilot you should always use static
prevention measures, especially while repairing a circuit board. This consists of a grounded mat
for working on, the use of a soldering iron with a grounded tip and the wearing of a grounded
wrist strap. Failure to observe these procedures could cause additional damage to the CMOS
circuitry present on most of the circuit boards.
The best type of soldering iron to use is one with a thermostatically controlled tip. We recommend
using an 800 degree Fahrenheit tip. For desoldering, we recommend using a vacuum desoldering
tool such as a "Soldapult." Heat the joint until the solder is molten, if necessary adding a little
fresh solder, and then place the tip of the desoldering tool over the joint and activate it. If the joint
is not completely cleaned (you should be able to see through the hole), then resolder the joint and
try again. NEVER use the desoldering tool twice without resoldering the joint in between. When
all the pins of the device to be removed are desoldered, free them by wiggling with a pair of pliers
or an "Exacto" knife. Properly done, you should then be able to lift out the device by hand. Insert
the new device, and resolder carefully, making sure that each joint is fully soldered.

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 1101/1201 Technical Manual

3. Circuit Description

3.1 HEAD

3.1.1 General Description:

The 1101 (1201) Control Head provides a convenient user interface. The twelve push-button
user controls on the face-plate provide comprehensive yet easy-to-use inputs to the 1101/1201
SPU. A sixteen position rotary switch also allows a user to have effective “hands-on” control of
the Autopilot.
The pushbuttons and rotary switch are interfaced to a microprocessor which, with the built-in
software, sends the appropriate information to the 1101/1201 SPU via either the HEAD port or
the REMOTE port on the SPU.
The 1101 (1201) Control Head receives a data clock from the SPU for clocking out the serial data
as well as clocking in serial data from the REMOTES.
Display data is received with the display clock from the SPU and is processed for display on the
LCD display on the face-plate of the Control Head. Light Emitting Diodes (LED) behind the LCD
provide backlighting.

3.1.2 Disassembly/Re-Assembly

In general it is not recommended that a dealer disassemble the Head unit. Special precautions
are taken at the factory to seal the unit.
NOTE:
IF THE 1101 or 1201 CONTROL HEAD IS DISMANTLED IT WILL NOT BE COVERED UNDER
WARRANTY.

3.1.3 Button Replacement:

If one of the buttons is sticking, gently remove it from the gasket with a knife / small screwdriver.
Remove any burrs from the outside edge of the button. Spray a small amount of SILICON
lubricant on the button and replace into the gasket. Push the button down several times to
remove any air pockets between the gasket and the button.
See Figure 1 on the following page:

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 1101/1201 Technical Manual

Co
AU mN
PIL av
TO
O
TS

Figure 1 Removing a Button

3.2 1101 SPU pn 82888 Rev. 2 (2 pcb version)

Note that the 1201 does not come with a 2 pcb SPU version; only the 1 pcb version. See next
section.

3.2.1 General Description:

This section refers to the 1101 SPU 82888 Revision 2, which consists of two boards. The 1101
SPU 82888 Revision 3 or higher consists of only one board and is covered in the next section.
The first one is the Processor board, which includes the microprocessor, EPROM and RAM and
the second one is the Backpanel board, which includes the connections to the distribution box,
the Head, the Auxiliary Head and the Compass and the Drive circuitry for a solenoid system.
You can find the schematics for the two boards in the 1101 SPU Rev.2 in Appendix B and for the
Distribution board in Appendix E.

Appendix B includes the 1101 Rev. 2, SPU Boards (2pcbs) – Processor PCB (B board),
and the Control board (C board).
Appendix E is the Distribution Board - Terminal connections and RAI interface circuitry.

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3.2.2 Disassembly/Re-assembly (2 pcb version)

Disassembly:
Disassembly of the 1101 SPU is a straightforward process. First remove the two Phillips screws
from the rear of the autopilot and pull off the rear cover. Remove the four screws that secure the
chassis to the front cover. Carefully separate the front cover from the chassis. The two main
boards are connected by a 24 pin header as well as a ribbon cable. The Silicone used to hold one
of the boards should be carefully cut free with an exact-o knife. Carefully separate the two
boards, by pulling them apart to disconnect the header pins. If you need to disconnect the ribbon
cable, gently separate the connector on the end of the ribbon cable from the jumper on the
processor board. Use a screwdriver to gently pry the two apart if necessary. DO NOT pull on the
cable itself. The E-PROMS can now be replaced or the unit tested on the ComNav Test Bench.
Re-assembly is the reverse of disassembly. Reapply Silicone to secure the second board to the
chassis.

3.2.3 Signals to and from the Distribution Unit

MOTOR F/B Motor Feedback signals from Remotes to the Distribution Unit.
NAV INPUT Signals from a navigation device in the standard NMEA 0183 format.
RUDDER POSITION Rudder position signal from the Rudder follower.
SPEED CONTROL Proportional signal for rudder control.
SHIELD Outer shield of the cable usually grounded to chassis at one end.
BATTERY (+) Battery power (positive side).
SWT POWER OUT The battery power which can be switched off and on by the processor.
PORT OUT “Open collector” signal that controls the rudder to Port. Ground indicates ON.
STBD OUT “Open collector” signal that controls the rudder to Starboard.
RUDDER POWER +5 volts which is supplied to the Rudder Follower.
BATTERY (-) Battery power (negative side).
RUDDER COMMON Ground signal from the Rudder Follower.

3.2.4 Signals to and from the Control Head

OFF/on When the STANDBY switch in the Control Head is pressed, it drives the OFF/ON
line low, causing the Power circuitry in the SPU to turn the 5 volts line on, turning
the Autopilot on.
SD IN All communications to the autopilot are made through the SPI data line. This
data line sends all relevant data from the Head to the SPU.
DISP CLK Clock for SPI data entering the head. This is an SPI clock and should be running
around 1/32 * E-CLK (62.5 KHz)
KEY Clock Clock for SPI data leaving the head. This is an SPI clock and should be running
at around 1/32 * E-CLK (62.5 KHz)
DISP Data SPI Serial Data into the Head from the SPU.
RKEY Data Transfers SPI Serial Data from the Remotes to the Head.

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PORT Output to tell the head when the rudder is moving Port.
STBD Output to tell the head when the rudder is moving STBD.
ALARM When the buzzer is to sound, the alarm line goes low.
HEAD MODE Line to tell the Interface if it is a Head or a Remote. +5 volts indicates a head,
and 1m ohm resistor to ground indicates a remote.
PWR + 5 Volts.
GND Common.

3.2.5 Signals to and from the Compass

136 KHz P1 Phase 1 Excitation signal to the Compass

13.6 KHz P2 Phase 2 Excitation signal to the Compass.
REFERENCE 2.5 volt reference signal to the Compass.
SINE Sine signal from the Compass.
COSINE Cosine signal from the Compass.
+12 VOLTS Power to the Compass unit.
GND Common ground.

3.2.6 Signals to and from the Remotes

CMD/CTRL Signal used to tell the Remote unit whether it is in control of the system or not.
+5 V + 5 volt power to the Remotes.
DISPLAY CLOCK
ANALOG INPUT
ROTARY SWITCH 0 Signals to tell the SPU which position the Remote rotary switch is in.
ROTARY SWITCH 1 Signals to tell the SPU which position the Remote rotary switch is in.
TURN Signal from the Remote that a Special turn is being initiated.
DODGE Signal from the Remote that a Dodge is being initiated.
PORT P.B. Signal from the Remote that a Dodge or Special turn is to the port direction.
STBD P.B. Signal from the Remote that a Dodge or Special turn is to the starboard .
DISPLAY DATA Data signals that determine what is displayed by the Remote.
GND Common ground.

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3.3 1101/1201 SPU

For 1101: pn 82888 Revision 3 (1 pcb version)

For 1201: pn 83747 Revision 1 (1 pcb version)

3.3.1 General Description:

The 1101 Revision 3/1201 Revision 1, SPU consists of one board. The board includes
microprocessor, EPROM and RAM, and the support circuitry and connectors to the distribution
box, the Head, the Compass, the Serial Data output, the Auxiliary Head, and the Drive circuitry
for a solenoid system. Note that the boards are the same for 1101 or 1201 but the E-PROMS are
different.
You can find the schematics for the 1101/1201 (1 pcb) SPU in Appendices D.
Appendix D is the 1101/1201 SPU Board - Microprocessor, PROM and RAM, connectors
to the Head, Distribution box, Compass, NMEA output etc.
Appendix E is the Distribution Board - Terminal connections and RAI interface circuitry
Note: if the 1101 SPU has two boards it is a revision 2. See the previous section.

3.3.2 Disassembly/Re-assembly (1 pcb version)

Disassembly of the 1101/1201 SPU (1 pcb version) is a straightforward process. First remove
the two Phillips screws from the rear of the autopilot and pull off the rear cover. Remove the four
screws which secures the chassis to the front cover. Carefully separate the front cover from the
chassis. The E-PROMS can now be replaced or the unit tested on the ComNav Test Bench.
Re-assembly is the reverse of disassembly.

3.3.3 Signals to and from the Distribution Unit

MOTOR F/B Motor Feedback signals from Remotes to the Distribution Unit.
NAV INPUT Signals from a navigation device in the standard NMEA 0183 format.
RUDDER POSITION Rudder position signal from the Rudder follower.
SPEED CONTROL Proportional signal for rudder control.
SHIELD Outer shield of the cable usually grounded to chassis at one end.
BATTERY (+) Battery power (positive side).
SWT POWER OUT The battery power which can be switched off and on by the processor.
PORT OUT “Open collector” signal that controls the rudder to Port. Ground indicates ON.
STBD OUT “Open collector” signal that controls the rudder to Starboard.
RUDDER POWER +5 volts which is supplied to the Rudder Follower.
BATTERY (-) Battery power (negative side).
RUDDER COMMON Ground signal from the Rudder Follower.

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3.3.4 Signals to and from the Control Head

OFF/on When the STANDBY switch in the Control Head is pressed, it drives the OFF/ON
line low, causing the Power circuitry in the SPU to turn the 5 volts line on, turning
the Autopilot on.
SD IN All communications to the autopilot are made through the SPI data line. This
data line sends all relevant data from the Head to the SPU.
DISP CLK Clock for SPI data entering the head. This is an SPI clock and should be running
around 1/32 * E-CLK (62.5 KHz)
KEY Clock Clock for SPI data leaving the head. This is an SPI clock and should be running
at around 1/32 * E-CLK (62.5 KHz)
DISP Data SPI Serial Data into the Head from the SPU.
RKEY Data Transfers SPI Serial Data from the Remotes to the Head.
PORT Output to tell the head when the rudder is moving Port.
STBD Output to tell the head when the rudder is moving STBD.
ALARM When the buzzer is to sound, the alarm line goes low.
HEAD MODE Line to tell the Interface if it is a Head or a Remote. +5 volts indicates a head,
and 1m ohm resistor to ground indicates a remote.
PWR + 5 Volts.
GND Common.

3.3.5 Signals to and from the Compass

136 KHz P1 Phase 1 Excitation signal to the Compass

13.6 KHz P2 Phase 2 Excitation signal to the Compass.
REFERENCE 2.5 volt reference signal to the Compass.
SINE Sine signal from the Compass.
COSINE Cosine signal from the Compass.
+12 VOLTS Power to the Compass unit.
GND Common ground.

3.3.6 Signals to and from the Remotes

CMD/CTRL Signal used to tell the Remote unit whether it is in control of the system or not.
+5 V + 5 volt power to the Remotes.
DISPLAY CLOCK
ANALOG INPUT
ROTARY SWITCH 0 Signals to tell the SPU which position the Remote rotary switch is in.
ROTARY SWITCH 1 Signals to tell the SPU which position the Remote rotary switch is in.
TURN Signal from the Remote that a Special turn is being initiated.
DODGE Signal from the Remote that a Dodge is being initiated.

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PORT P.B. Signal from the Remote that a Dodge or Special turn is to the port direction.
STBD P.B. Signal from the Remote that a Dodge or Special turn is to the starboard .
DISPLAY DATA Data signals that determine what is displayed by the Remote.
GND Common ground.

3.3.7 Signals from the SERIAL DATA Output

ADIOS CLK Serial clock.

ADIOS DATA Serial data.
NMEA ‘A’ ‘A’ side of NMEA 0183 coded data.
NMEA ‘B’ ‘B’ side of NMEA 0183 coded data.
GND Common ground.

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4. Connections

4.1 Removing Connectors from the SPU.

Figure 2 Removing Connectors

To remove the connectors from the receptacles on the back of the SPU, just squeeze the finger
grip cross-stripes to flex the plastic sides and unlock the tabs. While you are squeezing the sides
slide the connector off. This is the same for both sizes.

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4.2 Removing the back shell to view the wires

Figure 3 Cable Assembly

Turn the back shell counter clockwise until it is loose from the connector. Pull the back shell
about 12 inches along the wire. Notice that the strain relief is notched. There are four pegs in the
connector that fit into the notches in the strain relief. This connector will not fit together properly if
those pegs are not in the notches. You can carefully pull the strain relief away from the connector
to expose the wires. The wires can now be checked for proper connection.

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4.3 Head to SPU

Plug w ith Backshell
12 Pin Black
C om N av P.N .40844

12 Fem ale Pins,

C om N av P.N .40214

26ft(8 m eters)
8 7 7 8 12 + 1 conductorcable
9 2 1 6 6 1 2 9
C om N av P.N .83018
10 3 4 5 5 4 3 10

11 12 12 11

View along Arrow

D irection

Figure 4 Head Connector

WIRE COLOUR VIKING SIGNALS SIGNALS

CONNECTOR
HEAD AUXILARY
PIN # STATION
BLUE 1 ON/OFF CMND/CTRL
BROWN 2 +5Volts +5 Volts
PINK 3 Display Clock Display Clock
RED with BLUE stripe 4 Head Mode
VIOLET 5 Remote Data Rotary Switch “0”
BLACK 6 Key clock Data Turn/Adj
YELLOW 7 Serial Data IN Dodge/Alarm
RED 8 Port Drive Light Port/up
GREEN 9 STBD Drive Light STBD/Down
WHITE 10 Display Data Display Data
GREY with PINK stripe & 11 Ground Ground
SHEILD DRAIN
GREY 12 Alarm Rotary Switch “1”

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4.4 Distribution Box to SPU

Plug w ith Backshell

12 Pin Black
C om N av P.N .40844

12 Fem ale Pins,

C om N av P.N .40214

10ft(3 m eters)
8 7 7 8 11 + 1 conductorcable
9 2 1 6 6 1 2 9
C om N av P.N .81747
10 3 4 5 5 4 3 10

11 12 12 11

View along Arrow

Direction

Figure 5 Distribution Box Connector

WIRE COLOUR VIKING CONNECTOR PIN # SIGNAL

GREY with PINK stripe 1 Motor Monitor
VIOLET 2 Nav Signal
RED 3 Rudder Position
BLUE 4 Speed Control
SHIELD 5 Shield (Common to
Battery negative)
YELLOW 6 Battery (+)
GREY 7 Switched Power
PINK 8 Port Out
WHITE 9 STBD Out
BLACK 10 Rudder Power
BROWN 11 Battery (-)
GREEN 12 Rudder Common

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4.5 Compass and Serial Data connections to SPU

Plug w ith Backshell

7 Pin Black
C om N av P.N .40830

7 Fem ale Pins,

C om N av P.N .40214

40ft(12.3 m eters)
6 + 1 conductorcable
3
2
7 7
2
3
C om N av P.N .40858
1 1
4 6 6 4
5 5

View along Arrow

Direction

Figure 6 Compass and Serial Data Connector

WIRE COLOUR VIKING SIGNALS TO/FROM SIGNALS FROM

CONNECTOR PIN # COMPASS SERIAL DATA OUT

BLUE 1 Sine AD-10-S CLK

RED 2 13.6 KHz N/C

BLACK 3 13.6 KHz N/C

SHIELD 4 Ground GND

WHITE 5 Reference NMEA ‘B’

YELLOW 6 Cosine AD-10-S DATA

GREEN 7 +12 Volts NMEA ‘A’

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5. Dealers Test Bench

M ain C able to
1001/1101 Processor

SWITCHED POWER
Amps
1001/1101
Distribution
Box
CLOCK DATA ALARM
SIG

FUSE RED GREEN

NAV INPUT

3 Amps JOG RET

2001
Distribution
+ ON 1001/1101 NAV 1
Box
12 VDC
OFF 2001 NAV 2
- WATCH
ALARM

M ain C able
to 2001 Processor

Figure 7 ComNav Test Bench

If you have a ComNav Test Bench, an 1101 or 1201 may be connected to it for testing. This will
help in isolating problems with the 1101 or 1201 SPU. The cable from the 1001/1101 Distribution
box in the Test Bench plugs into the SPU. Also connect a Control Head to the SPU. A compass
will also be required if any of the SINE, COSINE, FILTER, or compass tests are to be done.
Included in Appendix E is the wiring diagram for the test bench.

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6. Final Test Procedure

Note: only some of the possible tests are done on the Test Bench. All of them would normally be
done in the factory Final Test Procedure.

1. ON/OFF Circuitry
Turn the Autopilot ON. Press and Hold the ON/STBY button on the autopilot Head until the
standby status screen (STBY) comes up on the display. This should take about 3 seconds. Turn
the Pilot OFF. The Autopilot should turn off after holding the button down until the screen goes
blank. This should take about 2 seconds.

2. +12
Turn on the Autopilot. Clip the voltmeter leads to the +12V and GND test hoops on the back
panel PCB of the SPU. The voltmeter should read 12 volts (±1.5 volts). The measured voltage
should not change more than ±0.1 volts for either 12 or 24 volt systems.

3. +5
Clip the voltmeter leads to the +5V and the GND test hoops on the back panel PCB of the SPU.
The voltmeter should read 5.15 volts (±0.15 volts). The measured voltage should not change
more than ±0.05 volts for a 12 or 24 volt system.

4. +2.5V
For the either PCB version, the voltage between the +2.5V test hoop and the +5V test hoop
should be the same as the voltage between the +2.5V test hoop and the GND test hoop ±0.015
volts.
5. STARBOARD
Turn the pilot off. Put a jumper on the Special Test pins of the SPU. Turn the pilot on. You are
now in a limited special test mode. Pressing the right DODGE button on the Head will advance
you into the test, while pressing the left DODGE button will move you back in the test.
Press the right DODGE key until the 5TBD is seen in the bottom right corner of the LCD. At this
point the STBD (Green) LED on the Distribution Box should turn on. The Rudder Angle Indicator
(RAI) on the Test Bench should go to starboard. The signal is heavily damped and may take a
few seconds to move onto the scale. The current reading on the Test Bench Ammeter should go
to about 2 amps.

6. PORT
Press the right DODGE button until PORT is seen in the bottom right corner of the LCD. At this
point the PORT (Red) LED in the distribution box should turn on. The RAI on the Test Bench
should go to port. The current reading on the Test Bench Ammeter should go to about 2 amps.

7. SWITCHED POWER
Press the right DODGE button until 5PuR is displayed on the LCD. The Switched Power LED
(SWI PWR) on the Distribution box should turn on. Perform the load test by pressing the red or

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green JOG buttons on the Test Bench. The current reading on the Test Bench Ammeter should
go to about 2 amps.

8. RUDDER SPEED
Press the right DODGE button until R5Pd is displayed in the lower right corner of the LCD.
Check for Rudder Speed signal on the Distribution box with an oscilloscope. Pick up a ground on
battery negative and probe the screw terminal for SPEED. The signal should be a ramp at about
2.5 volts repeating at about 100 msec.

9. VOLTAGE
Press the right DODGE button until A0xx is displayed in the lower right corner of the LCD. A
reading of 31 on the right side of the reading indicates about 12 volts while a reading of 62 is
about 24 volts.

10. RUDDER FOLLOWER

Press the right DODGE button until A2xx is displayed in the lower right corner of the LCD. The
right side of the reading should read 7E when the rudder is centered. Read the rudder angle on
the Test Bench RAI. The angle can be adjusted by pressing the Test Bench JOG switches. Use
the JOG switch to set the RAI to about 40 degrees Starboard and check that the right side of the
LCD reading is 3E. Check that at about 40 degrees Port, the reading is BE.

11. MOTOR MONITOR

Press the right DODGE button until A3xx is displayed in the lower right corner of the LCD. The
right side of the reading should read 00. Place a 100R jumper between terminals marked +5 V
and MOTOR MON in the distribution box. The right side of the reading should now display FF.

12. COSINE
Press the right DODGE button until A6xx is displayed in the lower right corner of the LCD. A
properly adjusted KVH or ComNav compass should read 7E on the east or west, 62 on north and
9B on south.

13. SINE
Press the right DODGE button until A7xx is displayed in the lower right corner of the LCD. A
properly adjusted KVH or ComNav compass should read 7E on north or south, 62 on east and 9B
on west. Leave the compass reading 7E on north.

14. FILTER
Press the right DODGE button until a four-digit number is displayed in the lower right corner of
the LCD. Turn the compass until the number reads about 2250. Place a digital voltmeter (DVM)
across the SIN and REF test points. Fine-tune the compass so that the voltage on the DVM
meter reads 0 volts. Adjust the filter potentiometer on the SPU card so that 2250 is displayed.
Re-paint the Filter Pot. Turn the Pilot to OFF and remove the Special Test jumper.

15. FLUXGATE COMPASS

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Perform an accuracy test every 20 degrees. Pass if total error is less than or equal to 4 degrees.

16. AUTO ADJUST – ComNav Fluxgate Compass

Place the Fluxgate compass on a Lazy Susan. Place a magnet approximately 3 inches away
from the compass at 45 degrees. Perform an auto adjust. Please see the compass
compensation section of the 1101 Operation and Installation manual for further instructions on
compass compensation. Perform an accuracy test every 20 degrees. Pass if the total error is
less than or equal to 4 degrees.

17. FULL RESET and DOCKSIDE SETUP

Perform a Full Reset and Dockside Setup. Leave the pilot set for a magnetic compass.

18. MAGNETIC COMPASS

Plug a Magnetic compass into the pilot. Select the magnetic compass option in the Dockside
Setup. Adjust Compass adjust to make the autopilot and compass agree. Perform accuracy
tests every 20 degrees. Pass if total error is less than or equal to 4 degrees. Reset the compass
adjust to zero.

19. NAVIGATION INPUT

Feed NMEA 0183 Autopilot sentences into the 1101 distribution box via the NAV INPUT on the
Test Bench. Turn the pilot on and put into NAV mode. After a few seconds double-press the
NAV key. The type of data being received or the name of the 0183 data sentences should be
displayed.

20. HEADING OUTPUT (1 pcb SPUs only)

Connect a cable to the HEADING OUTPUT connector on the 1101/1201 SPU. Note: that the two
board SPU is not supplied with this connector. Connect the ‘scope ground to the cable shield and
the probe lead to the white wire. Data type signals should appear on the ‘scope. Similarly, check
the green lead. Check that the blue lead has data clock pulses on it. The yellow lead should have
bursts of data on it.

NOTE:
The Final test procedure is intended to check all the basic functions of the autopilot. Once the
unit is re-installed on the vessel you must go through the dockside setup procedure and complete
the compass selection and compensation.

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7. APPENDIX A

7.1 Problem Solving Guide Form

Description of Problem:__________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Compass Type:________________________________________________________________
Feedback Type:________________________________________________________________
Drive Unit Type:________________________________________________________________
Nav Input Type:________________________________________________________________
Input Voltage:__________________________________________________________________
Power Source:_________________________________________________________________
Battery:_______________________________________________________________________
Installation Date________________________________________________________________
Rudder Hard over Time:__________________________________________________________
Number of Rudders_____________________________________________________________
Dealer Name__________________________________________________________________

Additional Information:___________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

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8. APPENDIX B

8.1 SPU Drawings/Schematics for 82888 rev 2, (2 PCB Version)

8.1.1 Processor Board (B Board)

Part # 31130

8.1.1.1 Bill of Materials

8.1.1.2 Board Layout

8.1.1.3 Schematic

8.1.2 Backplane Board (C Board)

Part #31145

8.1.2.1 Bill o Materials

8.1.2.2 Board Layout

8.1.2.3 Schematic

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9. APPENDIX C

9.1 SPU Drawings and Schematics for 82888 rev. 3 and 83747 (1
pcb version)
Part #31158

9.1.1 Bill of Materials

9.1.2 Board Layout

9.1.3 Schematic

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10. Appendix D

10.1 Distribution Box Drawings and Schematics

Part # 31158

10.1.1 Bill of Materials

10.1.2 Board Layout

10.1.3 Schematic

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11. Appendix E

11.1 Test Bench Wiring Diagram

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