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COURSEMASTER CM80i System Manual

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COURSEMASTER
AUTOPILOTS
Australia's world leader in autopilot technology
CM80i SYSTEM MANUAL
04-08

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Summary of Contents for COURSEMASTER CM80i

  • Page 1 COURSEMASTER AUTOPILOTS Australia's world leader in autopilot technology CM80i SYSTEM MANUAL 04-08...
  • Page 2 CM80i SYSTEM MANUAL Your Coursemaster CM80i autopilot 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 Gibbes Streeet, CHATSWOOD NSW. AUSTRALIA 2067...
  • Page 3 Version 1.26 Junction Box software or higher. The dynamic performance of the autopilot has been optimised for use with a CM437 Rate Gyro Compass. Copyright 2003, 2005, 2008. This manual, the mechanical and electronic design of the CM80i autopilot system and its associated software protected copyright. Unauthorised...
  • Page 4 QUICK START • Press the STANDBY key to turn the system on. • Hold down the STANDBY and PILOT keys together to turn the system off. • Steer to the desired course and press PILOT. • Use the arrow keys to change course. •...

  • Page 5: Table Of Contents

    1.1.1 Conventional autopilots 1.1.2 Steering Control 1.1.3 The ‘intelligent’ autopilot 1.1.4 Course holding and turning 1.1.5 Options 1.1.4 Working with other Equipment 1.2 The CM80i System 2. OPERATING INSTRUCTIONS 2.1 The Control Head 2.2 Getting Started 2.3 Normal Operation Switching on...
  • Page 6 CONTENTS INSTALLATION Step-by-step Summary 3.1 Junction Box 3.2 Control Head 3.3 Rate Gyro Compass 3.4 NMEA Interfaces 3.5 Steering Drive 3-12 TROUBLE-SHOOTING 4.1 General 4.2 Error messages 4.3 Other faults 4.4 Fuses SYSTEM SPECIFICATIONS MAINTENANCE AND WARRANTY...

  • Page 7: Quick Reference

    QUICK REFERENCE INSTALLATION • Mount the Junction Box as described in Sect 3.1 • Mount the Control Head as described in Sect 3.2 • Mount the Compass as described in Sect • Install the Steering Drive as described in Sect 3.5. •...
  • Page 8 THE MENU CONTROL MODE - NORMAL / ROUGH RUDDER FACTOR RATE FACTOR RATE GYRO OFF / ON HEADING ADJUST AUTO COMPASS CALIBRATION MANUAL COMPASS CALIBRATION COLD START RUDDER LIMITS TURN RATE HELM ALERT STEER DRIVE HEADING SOURCE NMEA OUTPUT MAGNETIC VARIATION TUNE MONITOR OFF/ON AUTO BALANCE OFF/ON...

  • Page 9: System Description

    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.
  • Page 10 Figure 1.1 Basic components of a conventional marine autopilot. The four basic components are a compass, an electronic control box, a rudder angle sensor (transducer) and the steering drive. A Junction Box, mounted below decks, contains most of the system electronics and a Control Head, mounted at the steering station provides the interface with the user.

  • Page 11: Steering Control

    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 vessel onto course quickly, without overshooting the reference course. The correct rudder angle depends on the amount of the error, the speed of the vessel, its size, the effectiveness of its rudder and the weather conditions.

  • Page 12: The 'Intelligent' Autopilot

    1.1.4 COURSE HOLDING AND TURNING The CM80i is mainly intended for light vessels in the 5 - 10 m range. These have two features that affect course holding and turning. First, they are more responsive to wind load and wave effects than heavy vessels and can yaw quickly when hit by a wind gust, for example.

  • Page 13: Options

    1.1.5 OPTIONS As an alternative to using the standard rate gyro compass, the CM80i has an option to use a digital heading input, which would typically come from a GPS compass. Note that the course-over-ground data available from GPS navigation systems does not respond quickly enough to be used as the primary heading input.

  • Page 14: Working With Other 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.

  • Page 15: The Cm80I System

    1.2 THE CM80i SYSTEM The core of the CM80i system consists of Control Head, Junction Box, Rate Gyro Compass and Steering Drive. The system, together with its optional attachments is illustrated in Fig 1.2 below.
  • Page 16 RATE GYRO COMPASS RADAR / PLOTTER DIGITAL HEADING NAVIGATION Figure 1.2 The CM80i system. CM840 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.

  • Page 17: Operating Instructions

    The autopilot is intended for hydraulic steering systems, of which there are a number of options. A suitable drive may either by supplied by Coursemaster or the autopilot may be connected to an existing steering drive on the vessel. One of the recommended pumps, supplied by Coursemaster, is a 0.6...

  • Page 18: The Control Head

    2.1 THE CONTROL HEAD The Control Head (Fig 2.1) contains a text display and four keys. The use of these controls is described in this chapter. Switch off Switch on Pilot/ Standby/Menu select Auto-navigate Mode STBY PILOT PILOT Reference Heading Course Turn controls/adjust settings Figure 2.1 The Control Head Panel.
  • Page 19 To switch on for the first time, press the STANDBY key. The system enters a set-up mode so that the size of the vessel can be entered and the steering gear calibrated. The screen shows the prompt: COLD START PRESS STBY Press STANDBY and the screen reads: PROCEED >...

  • Page 20: Normal Operation

    operation and sets the initial tuning of the autopilot to values which best suit your vessel. Then press STANDBY again to calibrate the steering. 20 DG STBD USE > Centre the helm. Then watch the steering gear as you press the right arrow.

  • Page 21: Switching Off

    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. STBY If a fault is detected during the self test, the Controller starts beeping and the nature of the fault is displayed after the self-...

  • Page 22: The Menu

    waypoint with minimum cross-track error. Hold the PILOT key down for two beeps to turn on auto navigation. Press it again to turn it off. If valid navigation data is being received, the lower left of the display alternates between the heading to-to-steer and the cross-track error (if present).
  • Page 23 After a COLD START, the system is set in the auto-tune mode of operation in which settings will change automatically to adapt to sea conditions and speed. But if you wish to operate with fixed settings, select one of these options: NORMAL After a COLD START the system is set in the NORMAL...
  • Page 24 CM80i autopilot. (See Chap 1 further information.) RATE GYRO OFF/ON The Rate Gyro option is preset to be ON during the initial set- up. If an older style fluxgate (CM427) is fitted, the Rate Gyro should be turned OFF.
  • Page 25 MAG FIELD MEDIUM If the calibration report shows a low field strength, the compass performance will compromise the course holding of the vessel and you should consult Sec 3.3 for guidance on improving the compass position. Press STANDBY to return to the menu.
  • Page 26 Turn the vessel to a heading which is close to one of the cardinal or inter-cardinal points, ie. 000, 045, 090, 135, 180, 225, 270, or 315. Then use the arrow keys to adjust the deviation up or down until the heading agrees with that of the ship's compass or other reference compass.
  • Page 27 rudder limits. For high-speed vessels, you may wish to reduce the value. HELM ALERT Sets the time interval between Helm Alert alarms to 5, 10 or 15 minutes. A setting of 0 disables the alarm. STEER DRIVE This provides a manual drive to the steering gear and is mainly used for hydraulic bleeding.
  • Page 28 TUNE MONITOR This option enables the display of the operation of the auto- balance feature for propeller torque compensation. monitor is only displayed in the PILOT mode. If the TUNE MONITOR is turned on, a single press of the PILOT key produces the following typical display: H276 ST18...

  • Page 29: Alarms

    2.5 ALARMS The CM80i has a number of alarm functions. When an alarm occurs, the beeper sounds and an alarm message flashes on the display, alternating with the normal information. To cancel an alarm, press the STANDBY or PILOT key. If the system is in PILOT and this key is used to cancel an off-course alarm, for example, the reference course is not changed.

  • Page 30: Installation

    COMPASS FAULT If a fluxgate compass has been selected, the magnetic field being sensed by the compass is above or below preset limits. Further information is given in Chap. 4. NO HEADING DATA If a digital heading input has been selected, a valid heading sentence is not being received.
  • Page 31 present and undamaged. Read all of this chapter before starting and then follow this step-by-step guide: 1. Mount the Junction Box as described in Sect 3.1. Check that vessel voltage is 12volt DC. Take care that the polarity of the battery wires is correct and that the metal parts of the terminal blocks grip the wires and not the insulation.
  • Page 32 screws through the two mounting flanges. To open the case, remove the four screws holding the cover flanges to the base and lift the cover. Before commencing the wiring, isolate the vessel’s power bus from the power supply. Note that all connections to the Junction Box, except for motor and power, are made to removable plugs.
  • Page 33 RUDDER MTR ALM CONTROLLER COMPASS Figure 3.1 Layout of CM 840 Junction Box components and connectors. Note that the CM840 Junction Box is common to several autopilot systems and may have sockets which are not used in the CM80i system.

  • Page 34: Junction Box

    POWER MOTOR + MOTOR - CLUTCH + STEER CLUTCH - DRIVE Figure 3.2 Power and Steer drive connections to the Junction Box. 3.2 CONTROL HEAD The Control Head is designed for flush mounting on a dashboard as shown in Fig 3.3. Although the face of the controller is weather-proofed, it is recommended that it not be mounted where it is exposed directly to rain or spray.
  • Page 35 Clamping bar Clamp screws Panel cut-out Weather seal Figure 3.3 Mounting detail for the Control Head Cut a 75 mm (3”) dia hole in the dashboard. If necessary, the clamping bar may be removed from the rear of the Control Head case before inserting it into the hole.
  • Page 36 cable length to accommodate a change in the component positions at some later date. After cutting, strip each wire before connecting it as shown in Fig 3.4. Check that the insulation is not caught in the terminal clamps. SCREEN SCREEN BLUE BLUE WHITE...
  • Page 37 needed to find the best position. Generally, the compass will not perform well if totally enclosed in a steel structure. Further notes on mounting in a steel vessel are given below. Mount the CM437 rate gyro compass, on a vertical surface with its mounting flange towards the bow and the cable entry facing down.
  • Page 38 Figure 3.5. Connections for a CM437 Rate Gyro Compass. Steel Vessels Though the CM80i autopilot is intended for smaller vessels, which are unlikely to be steel, the following notes may be useful in some cases. Steel hulls distort the natural pattern of the earth's magnetic field.

  • Page 39: Nmea Interfaces

    If no position is found giving less than 20 deg deviation, the services of a compass adjuster should be sought. autopilot will not operate satisfactorily with compass deviations above 20 deg. A compass calibration (See Sec 2.5) is recommended after the installation is complete. 3.4 NMEA INTERFACES The Junction Box has two NMEA input ports for navigation and heading data.

  • Page 40: Steering Drive

    3.5 STEERING DRIVE The CM80i system is intended for use with existing hydraulic steering systems. If the CM80i is fitted to a power steering system with solenoid controls, the power steering system must be fitted with a suitable pressure relief valve to prevent damage to the steering if it is driven into the steering stops.
  • Page 41 guidelines will be adequate for most installations. If there is a doubt about the correct way to proceed, consult the manufacturer of the steering gear.
  • Page 42 Typical Steering Systems Two-line systems are by far the most common and are manufactured by many companies worldwide. The best known types include Hydrive, Marol, Morse, Seastar, Seipem, Tenfjord, Teleflex and Vetus. Hydrive Helm Pump or similar, with lock valve Steer Pump Figure 3.7 Connection to a typical two-line system Some two-line systems are supplied with a lock valve as part...
  • Page 43 Procedure 1. Install the pump according to the hydraulic connection instructions, mounting it close to the tubes connecting the helm pump and cylinder. The pump must be mounted with its mounting feet horizontal. 2. Connect the pump to the system tubing using hose and tubing which is rated for the steering system pressures as specified by the manufacturer.
  • Page 44 If the pump fails to run, check first that it is receiving the correct drive voltage from the Junction Box. If the pump runs but does not pump oil, make sure that the system is purged. If that does not succeed, contact your Coursemaster dealer.

  • Page 45: Trouble-Shooting

    4.2 ERROR MESSAGES The CM80i system is programmed to provide a number of messages on its display when a fault occurs. Some of these are warnings arising out of the way the autopilot is being used.
  • Page 46 After each message follows the direct condition which triggers the message, the response of the CM80i to the condition and a list of possible causes. By using this as an aid, many problems can be fixed simply by the owner.
  • Page 47 STANDBY and the message can only be cleared by pressing the STANDBY key after the fault is corrected. Causes. The most likely cause is that the vessel has been allowed to drift while in PILOT and the system continues to apply correction while the helm is ineffective.

  • Page 48: Other Faults

    STANDBY to PILOT. In such cases, the Junction Box should be returned to your dealer or to Coursemaster for repair. Slow Compass Response If the displayed heading is slow to respond to the actual heading and this is accompanied by poor course holding, there could be a Rate Gyro fault.

  • Page 49: Fuses

    the menu) and check again. If the speed of the heading display response now appears normal, check the brown wire connection in the Junction Box and try again with the Rate Gyro turned on. 4.4 FUSES The system has two fuses. The main 20A fuse protects the complete system, while a 0.8A miniature fuse (See Fig 3.1) protects the control electronics against supply surges.

  • Page 50: System Specifications

    5 SYSTEM SPECIFICATIONS AUTOPILOT Supply Voltage Range (nominal) 12 to 14V dc Maximum Supply Voltage Range 10 to 16V dc Supply Current Basic system in STANDBY 0.33A In Pilot with 20% duty 2.5A Compass Fluxgate Typical deviation 2.5 deg rms. Steering Drive Output for 12V supply 10V (min) at rated...
  • Page 51 Recommended rudder response times: Hull length 5 to 10 m 7 to 10 sec. for -20 to +20 deg NAVIGATION INTERFACE NMEA PORTS Data format and sentences to comply with NMEA0183 V3.00 Serial data format: Baud Rate 4800 Character format: start bit, 8 data bits, LSB first MSB (bit 7) = 0, no parity bit, 1 or 2 stop bits...
  • Page 52 AUTOMATIC SENTENCE SELECTION For navigation inputs, the system looks for sentences in this order: BOD and XTE The search stops when the highest sentence in the above list is found. If cross-track data, for example, is missing, the autopilot operates from the heading-to-steer data alone.

  • Page 53: Maintenance And Warranty

    6.2 INSTALLATION OF NEW SOFTWARE It is recommended that software upgrades be installed by a Coursemaster agent, but if this is not possible, the following procedure should be followed carefully by the owner. The memory package containing the software for the main circuit board in the Junction Box has a label beginning CM845V..
  • Page 54 Coursemaster. A return Australian address shall be provided to enable the repaired item to be returned by road freight. Coursemaster shall not be liable for the cost of removing or refitting the item to the vessel. Proof of purchase is required.
  • Page 55 Coursemaster shall not be liable in any event for any consequential or indirect loss or damage incurred resulting from the use and operation of this product. Coursemaster reserves the right to make changes and improvements to this product without incurring any obligation to install similar changes to equipment already supplied.

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