CT7 Interface

for P Series Autopilot Systems

Installation & Operation Manual

COMPLIES WITH
CE REGULATIONS

PN 29010079

ComNav CT7 Interface Installation & Operation

Welcome

Welcome
Congratulations on your purchase of ComNav Marines CT7 Interface for P Series
Autopilot Systems!
At ComNav, we are proud of our prominence as a leader in the design and manufacture of
marine autopilot systems. Developed by the same experienced design team that created the
Commander P2 & Admiral P3 Autopilot Systems, the CT7 Interface extends the capabilities
of those P Series Autopilot Systems to allow use with several additional types of vessel
heading control systems
We are confident that our dedication to performance and reliability will ensure your
satisfaction with the CT7 Interface.

ComNav Marine Ltd.

Warranty Notice
The Warranty for the CT7 Interface is contained within the Warranty of your P Series
Autopilot System. Prior to the installation and/or operation of the CT7 Interface, ensure that
you read, understand, and accept the conditions of the P Series Autopilot System warranties
as detailed in the Warranty Information of that system, and the specific items in that
Warranty which apply to Control Boxes.

Operators Warning
The P Series Autopilot System (with or without the CT7 Interface) will steer your vessel.
However it is only an aid to navigation. Its performance can be affected by many factors
including equipment failure, environmental conditions, and improper handling or use. An
autopilot system does not reduce your responsibility for the control of the vessel when
underway. You must always be in a position to monitor the course, supervise the autopilot,
and resume manual control if the need to do so arises.
Whenever underway, your vessel must be under the control of a qualified and alert person.

General Notice
This document, ComNav part number 29010079 Version 2 Revision 1, is the approved
Installation and Operation Manual for use with CT7 Interface for P Series Autopilot Systems.
Where versions of this manual exist in other languages, the English version shall be
considered authoritative.

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ComNav CT7 Interface Installation & Operation

Welcome

Document History
Revision

Date

By

1R0

22 June 2006

2R0

11 October 2007

DTO

brand name change

added more info on Z-Drives & Electric Wheel
added new details in the Typical Wiring figures
updated General Specifications
updated information on SPU connectors & wiring
added more explanation of the various ways the CT7 can
be wired

2R1

07 March 2008

DTO

fix minor typos, control references, signal names

updated to latest manuals template

Document PN 29010079 V2.1

DC

Description
First Release

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ComNav CT7 Interface Installation & Operation

Table of Contents

Table of Contents
Welcome .......................................................................................................................................................1
Document History........................................................................................................................................2
Table of Contents ........................................................................................................................................3
List of Figures ..............................................................................................................................................5
List of Tables................................................................................................................................................6
About this Manual........................................................................................................................................9
Typefaces, Common Phrases & Terms ___________________________________________________________9
Manual Format _____________________________________________________________________________10

System Overview .......................................................................................................................................13

Installation..................................................................................................................................................17
Technical Requirements ______________________________________________________________________17
Power Supply ____________________________________________________________________________17
Special Tools_____________________________________________________________________________17
Mounting __________________________________________________________________________________18
Wiring ____________________________________________________________________________________18
Wire Gauge ______________________________________________________________________________18
Wiring the System _________________________________________________________________________19
Connectors ______________________________________________________________________________19
SPU CT7 Cable ________________________________________________________________________20
Switched B+ & Rudder Follower ______________________________________________________________20
ON/OFF Thrusters ________________________________________________________________________21
Electronic Thruster Controls _________________________________________________________________21
Proportional (Analog) Thrusters ______________________________________________________________21
Azimuth Drives ___________________________________________________________________________22
Isolated Analog Power Supply _______________________________________________________________22
420 mA Current-loop Outputs _______________________________________________________________22
Electric Wheel Interface ______________________________________________________________________23
ELECTRIC WHEEL Mode Enable ____________________________________________________________23
Setup _____________________________________________________________________________________24
Switch Settings ___________________________________________________________________________24
Switch #1 Setup _______________________________________________________________________25
Switch #2 Invert Channel A Output ________________________________________________________25
Switch #3 Bow Output Positive/Negative____________________________________________________25
Switch #4 Stern Thruster Positive/Negative__________________________________________________25
Switch #5 Channel A Control Source_______________________________________________________25
Switch #6 Channel B Control Source_______________________________________________________25

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Table of Contents

Autopilot System Parameters _______________________________________________________________

Dockside Menu ________________________________________________________________________
Thrust Type (Thruster Type) ____________________________________________________________
Thrust MIN (Thruster Minimum) __________________________________________________________
Thrust MAX (Thruster Maximum) _________________________________________________________
Auto Menu ____________________________________________________________________________
Thruster Assist_______________________________________________________________________
Thruster Gain________________________________________________________________________
Electrical Adjustments _____________________________________________________________________
On/Off & Electronic Thrusters _____________________________________________________________
Proportional Thrusters ___________________________________________________________________
Azimuth Drive Systems __________________________________________________________________
Rudder Simulator Setup _______________________________________________________________
Adjustment of Electric Wheel Gain ___________________________________________________________
Final Steps________________________________________________________________________________

26
26
26
26
26
26
26
26
27
27
27
27
27
29
29

Care & Maintenance ..................................................................................................................................33

Cleaning and Appearance ____________________________________________________________________
Protection of Wires and Cabling _______________________________________________________________
Periodic Checks____________________________________________________________________________
Fuse Replacement _________________________________________________________________________

33
33
33
34

Appendices ................................................................................................................................................37
Appendix 1________________________________________________________________________________
General Specifications_____________________________________________________________________
Appendix 2________________________________________________________________________________
Warning Messages _______________________________________________________________________
Appendix 3________________________________________________________________________________
Diagnostic LEDs _________________________________________________________________________
Appendix 3________________________________________________________________________________
Typical Wiring Diagrams ___________________________________________________________________
CE COMPLIANCE __________________________________________________________________________

37
37
38
38
39
39
41
41
51

Index ...........................................................................................................................................................55
User Settings & Notes...............................................................................................................................59
User Settings ______________________________________________________________________________ 59
User Notes________________________________________________________________________________ 60

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List of Figures

List of Figures
Figure 1 Exploded View Showing Removal of P Series SPU Wiring Cover ............................................................19
Figure 2 CT7 Wiring Label .......................................................................................................................................19
Figure 3 SPU CT7 Cable.....................................................................................................................................20
Figure 4 CT7 Switches & Trim-pots .........................................................................................................................24

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ComNav CT7 Interface Installation & Operation

List of Tables

List of Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7

Minimum Recommended Wire Gauges......................................................................................................18

Fuse Replacement Guide...........................................................................................................................34
General Specifications ...............................................................................................................................37
Messages ...................................................................................................................................................38
Diagnostic LEDs.........................................................................................................................................39
User Settings..............................................................................................................................................59
User Notes .................................................................................................................................................60

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ComNav CT7 Interface Installation & Operation

Introduction

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ComNav CT7 Interface Installation & Operation

About This Manual

About this Manual

This manual provides essential information for the safe and reliable operation of the
ComNav CT7 Interface for P Series Autopilot Systems. You are urged to read this
manual in its entirety before you use your CT7 Interface for the first time, and to keep it
handy until you become thoroughly familiar with the operation of your system.
A number of steps in this manual require use of the setup menus and operational
displays on the Control Head of the P Series Autopilot System. Please refer to your
P Series Installation and Operation manual for instructions.

Typefaces, Common Phrases & Terms

Throughout this manual, you will see a number of different typefaces used, and several
commonly-used words & phrases with very specific meanings, to describe concepts &
actions that are fundamental to the operation of the autopilot. Please take a moment to
become familiar with the following items:
Modes of Operation
Specific modes of operation are placed in bold uppercase lettering.
Example: POWER STEER mode.
Button
Buttons and controls on the P Series Control Head and the CT7 are placed in uppercase
lettering.
Example: the TURN button.
System Component
Specific System Components are capitalized.
Example: The Control Head, or a Fluxgate Compass
LCD Display
Text that appears in the P Series Control heads LCD display is in quotation marks.
Example: Move Rudder to Port
press or momentary press
Press and release the indicated button.
double-press
Press and release the indicated button twice in rapid succession.
press and hold
Press and hold the indicated button for a minimum of one-half of a second.
maintain
Hold the indicated button for as long as required to achieve a given result.
Example: To dodge an obstacle in the vessels path, press either the PORT
ARROW or STARBOARD ARROW button, and maintain it in that position until the
vessel has passed clear of the obstacle.

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About This Manual

Manual Format
This manual has been formatted to be printed on both sides of the pages of the manual,
on standard Letter-size paper (8.5 x 11).
If you have obtained this manual as a soft-copy, please note that it is in Adobe Portable
Document Format (pdf), and so may be viewed & printed with Adobe Reader, or
compatible pdf-format viewers.
When printing this manual, select duplex printing (or the equivalent term used by your
printers software driver), so that it will be printed double-sided on the paper. If your
printer does not have built-in duplexing capability, you can still print this manual doublesided by following the instructions that came with your printer for doing hand duplexing.
When printing this manual with Reader, you may wish to print the main body & the
Typical Wiring Diagrams (between pages 43 to 50) on larger size paper (if your printer
supports such).
Those diagrams are quite detailed and so their original size, as drawn, is Tabloid-size
paper (11 x 17). The diagrams are most useable if they are printed on that size of
paper. However, for publishing reasons, it was necessary to include them in this manual
at Letter-size (in Landscape orientation).
To obtain them at a larger size, print just those pages with the printer/driver parameters
set manually to Tabloid (or the appropriate equivalent term for your printer/driver).
You could also use the enlarge feature of a photocopier to make copies of the diagrams
at a larger size, from prints done at Letter-size.
Lastly, a pdf document containing just the diagrams at large size is available, on special
request. Please contact your ComNav Dealer if you would like to obtain a copy of that
document.

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ComNav CT7 Interface Installation & Operation

System Overview

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ComNav CT7 Interface Installation & Operation

System Overview

System Overview
This section gives a brief description of the CT7 Interface, and its major elements & their
functions.
The CT7 is an optional extension to ComNavs P Series autopilot systems.
It is designed to be used when the vessel is equipped with Bow and/or Stern Thrusters, or
when the vessel is equipped with an Azimuth drive (also known as Z-Drive ). It is capable
of operating a number of different types of thruster-control solenoid valves including On/Off
and Proportional types and Azimuth Drive control systems. The CT7 has standard-voltage
outputs, current loop outputs and optically-isolated analog outputs.
The CT7 also contains circuitry for interfacing an Electric Wheel to a P Series autopilot
system, and a Rudder Simulator (which is typically needed when the CT7 is interfaced to
Azimuth Drives).
The CT7 is specifically designed to be directly compatible with, and complementary to,
ComNavs P Series autopilot systems, in features, operation, and appearance. It connects
directly to the P Series Signal Processor Unit (SPU), via a dedicated cable that carries power
to the CT7 main circuitry, and all control/data signals. There are two dedicated connectors
on the CT7 for the power supply for the thruster(s) or Azimuth Drive.
The P Series SPU has built-in setup & operational firmware support for the CT7 Interface; the
firmware is used whenever a CT7 is connected to the SPU, via the J7 - THRUSTER INTERFACE
connector.
The major elements of the CT7 Interface are as follows:
SPU Interface: this contains all the control & status circuits which connect to the P Series
Signal Processor Unit.
Power Supplies:
- The main section of the CT7s circuitry is powered directly by the P Series SPU.
- Two separate drive power supply circuits are provided. One is for On/Off
Thrusters. The other for Proportional Thrusters or Azimuth Drives; this one is
optically isolated from the main CT7 supply, and includes an optional splitter
circuit, for use if the vessel only has a single-ended Proportional/Azimuth supply.
On/Off Thruster Interface: this section contains digital logic circuits, controlled by the SPU,
which drive high-power MOSFET output transistor pairs. There are a total of four pairs,
for Bow & Stern and Port & Starboard On/Off solenoids, which can be wired either in
common-positive or common-negative fashion.
Proportional Thruster or Azimuth Drive Interface: this section is a mix of digital logic &
analog circuits, controlled by the SPU. There are two sets of outputs from this section,
each set having a pair of outputs, for interfacing two Bow & Stern Thrusters, or Port &
Starboard Drives:
- Voltage outputs: each output is optically isolated, and may be independently
adjusted for output voltage range & polarity. An automatic change-over relay
circuit, controlled by the SPU, allows the use of manual Thruster/Drive controls
when the SPU is off or in STANDBY mode.
- Current-loop outputs: these two non-isolated circuits have a nominal range of 4 to
20 mA.
Electric Wheel Interface: this circuit allows most types of analog-output Electric Wheels to
be used to steer the vessel when the P Series autopilot system is running in POWER
STEER mode. An optional WHEEL MODE enable switch may also be connected to the
CT7.
Rudder Simulator: this circuit primarily intended for use with Azimuth Drives creates
the Rudder Follower Unit (RFU) signal that the P Series SPU requires, in cases when it is
not possible to use a regular RFU with the drive.

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ComNav CT7 Interface Installation & Operation

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ComNav CT7 Interface Installation & Operation

Installation

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ComNav CT7 Interface Installation & Operation

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ComNav CT7 Interface Installation & Operation

Installation

Installation
Technical Requirements
This subsection describes the technical requirements that should be met before installation of
the CT7 Interface for P Series Autopilot Systems.

Please refer to the Warranty Information for your P Series Autopilot

System before proceeding with installation.

Hazard warning!
CAUTION!
Extreme caution is advised when using tools powered by alternating
current (AC) from main AC supply circuits, regardless of whether the
supply circuits are indoor, outdoor, marine or industrial rated.
Water, especially sea water, is an EXCELLENT conductor of electricity,
and can complete a path to AC Ground through a persons body,
causing injury or death, if a tool malfunctions or short-circuits.

Battery powered tools are STRONGLY recommended

If AC tools are used, they MUST be plugged into a circuit that is
adequately protected against Ground Faults and other safety hazards,
in accordance with local electrical codes.

Power Supply
For reliable operation of the CT7 Interface, your P Series Autopilot System must be powered
from a DC (direct current) power supply, with the correct nominal voltage. The power supply
must be adequately breakered, or fused; if the circuits are fused, a separate autopilot switch
should also be provided. Ensure that adequate wire sizes are used to handle the expected
maximum currents including those required by the CT7.
The main circuitry of the CT7 Interface is then powered (always at 12 VDC) from the P Series
Autopilot Systems Signal Processor Unit (SPU).
Depending on the type of thruster(s) &/or drive(s) on your vessel, a separate drive power
supply may be used; this can be at a nominal voltage different than the P Series SPU supply
voltage. The CT7 provides separate input connectors for the drive power supply one
connection for On/Off Thrusters, and one (optically isolated) for Proportional Thrusters or
Azimuth Drives.

Special Tools
A slot screwdriver with a tip size of ~2.5 mm (0.1) is required, for tightening the small screws
of the wire clamps in the plugs which mate with the CT7s pin-receptacle connectors; this
screwdriver will also be used to flip the levers of the CT7s Configuration switches, and to
adjust its trimming potentiometers.
An accurate voltage meter will be also be needed.
Finally, other general-purpose tools, such as a portable drill, pliers, wire cutters, screwdrivers,
& wrenches, will be required.

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ComNav CT7 Interface Installation & Operation

Installation

Mounting
The CT7 Interface should be mounted in a clean and DRY area, away from heat, moisture,
and water of any kind. The CT7 should be located reasonably close to the P Series SPU,
and at least 1m (3) from any compass, in order to minimize any possible electrical
interference to the compass.
It can be mounted vertically on a bulkhead or horizontally on a deck or shelf.
If mounted vertically, it should be positioned so that all wires and cables will exit from the
bottom of the CT7 (after running sideways, left &/or right as appropriate, from the
connectors under the CT7s wiring cover).
If mounted horizontally, all wires and cables should have a drip-loop formed in them.
Each CT7 is shipped from the factory with a package of four mounting feet and a separate
instruction sheet that includes dimensions for drilling holes to fasten the feet to the vessel.

Wiring
Wire Gauge
Due to the relatively high current requirements of an autopilot system as compared to many
other types of electronic equipment the size of wire used to connect the various
components is very important.
Undersized wiring will result in power losses which can affect overall efficiency and
performance. Refer to Table 1 Minimum Recommended Wire Gauges. If in doubt,
contact your ComNav Dealer for help.

Function / Use

Type / Gauge

Thrusters: 12/24/32 VDC Solenoid Valve

3 X 18 AWG

Azimuth Drives: Reversing Motor

2 X 14 AWG.
(refer to instructions supplied with
the Drive Motor)

Table 1 Minimum Recommended Wire Gauges

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ComNav CT7 Interface Installation & Operation

Installation

Wiring the System

Once the CT7 Interface is securely mounted, begin wiring the system.
Start by removing the Wiring Covers from both the P Series SPU and the CT7. The covers
are held in place by two knurled plastic nuts (see Figure 1).
Set the covers and nuts aside the covers will be re-installed once all the wiring of the CT7 is
complete.

Figure 1 Exploded View Showing Removal of P Series SPU Wiring Cover

Connectors
With the wiring covers off, all the connectors on the P Series SPU & the CT7 are visible.
The CT7s Wiring Label is shown below; please refer to your P Series Installation &
Operation Manual for a picture of the SPU Wiring Label.

ComNav CT7 THRUSTER INTERFACE

RUD.RET
RUD.SIG
STBD
PORT
n/c
SW'D B+

B+

n/c

B-

n/c

VDD
(+VE)

CHASSIS
GND

RTN
SIG
VEE
+5V
(-VE)
ISOLATED
SIM RFU
ON/OFF O/Ps RUDDER
TO SPU
SIGNALS IN SUPPLY IN
SUPPLY

J1

J2

J3

J4

CH B OUT
ISO RTN
CH A IN
CH A OUT
ISO RTN
CHASSIS

J7

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B+ OUT
B- OUT
BOW STBD
BOW PORT
B+ OUT
B- OUT
STERN STBD
STERN PORT
CHASSIS

CH C 4-20 +VE
CH C 4-20 -VE
CH B IN

CONTROL ANALOG
FROM SPU OUTPUTS

Figure 2 CT7 Wiring Label

Document PN 29010079 V2.1

CH D 4-20 +VE
CH D 4-20 -VE

V+ FUSE MONITOR
SETUP MONITOR
STERN PORT/STBD
BOW PORT/STBD
WHEEL POS'N
WHEEL MODE
STERN SPEED
BOW SPEED
SIGNAL GROUND
SYSTEM V+

J8

WHEEL +VE
WHEEL SIG
WHEEL -VE
ENABLE SIG
ENABLE REF

ELECTRIC
WHEEL

J10

ON/OFF
OUTPUTS

J12

ComNav CT7 Interface Installation & Operation

Installation

Each connector is a pin receptacle, with the pins sized according to how much current will be
carried (bigger pins for higher current). Each pin has a signal name, rather than a number, to
make it easier to match wires with pins (see the Typical Wiring Diagrams, page 43).
Each pin receptacle mates with a matching plug, which in turn has screw-clamp terminals,
into which the wires from the external equipment & devices (battery, drive system, etc.) are
inserted. The plugs allow quick installation & removal of system wiring, yet are fully secure,
once the various cables are strain-relieved and the wiring cover is re-installed.
The CT7 Interface is shipped with all the plugs it requires, pre-installed on the connectors.
Note that the plug screws must be turned counter-clockwise several turns (using the small
slotted screwdriver mentioned on page 17 Special Tools) , to open up the plugs wire
clamp, before a wire is inserted into that clamp; the screw must then be turned clockwise until
the wire is tightly held in the clamp.

SPU CT7 Cable

Because the CT7 Interface can be used for a variety of purposes, exact cable wiring depends
on the intended use. Several diagrams showing typical wiring are included in a later section
of this manual (starting on page 43.
One cable is always used, however: a CT7 must always be connected to a P Series SPU,
via a 10 conductor cable. The cable supplies 12 VDC circuit power to the CT7 (but not the
drive power), as well as carrying various control/status signals between the CT7 & the SPU.
A 2-meter cable is supplied with each CT7. This cable has a 10 position plug pre-wired onto
both ends. The plugs mate with the J7 connectors on both the SPU & the CT7. The
connections in this CT7 SPU cable are as follows:
10 GREY

GREY

WHITE

WHITE

BLUE
VIOLET

VIOLET

10- Conductor Cable

2 meters (6'6")
in Length

YELLOW
PINK
GREEN
BROWN

YELLOW
PINK
GREEN
BROWN

BLACK

10

BLUE

BLACK

RED

RED

NOTE:
PIN 1 IS AT THIS END

Figure 3 SPU CT7 Cable

Switched B+ & Rudder Follower

In some of the possible uses of the CT7 Interface, it is also necessary to connect the CT7 &
the P Series SPU with additional wires:
If the CT7 will be supplying power to Electronic Modules, Valves or Solenoids in
Proportional Thrusters, or with Azimuth Drives, the Switched B+ output from the SPU
must be wired to the CT7 (see diagrams CT7 WIRING FIGS 3A/3B/3C/4/5).
If the CT7 is being used with Azimuth Drives, the Simulated Rudder Follower signals from
the CT7 must be wired to the SPU (see diagrams CT7 WIRING FIGS 4 & 5).
At the CT7 end, these wires should be connected to the indicated pin(s) on the plugs
supplied with the CT7. At the SPU end, the wire(s) should be added, at the indicated pins, to
the plugs already in use on the SPU (more than one wire can be connected to each clamp in
the SPU & CT7 plugs).

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ComNav CT7 Interface Installation & Operation

Installation

ON/OFF Thrusters
Both commonpositive and commonnegative thrusters can be accommodated with the CT7
Interface. It is even possible to have one thruster wired as commonpositive, while the other
is wired commonnegative. See diagram CT7 WIRING FIG 1.

Electronic Thruster Controls

It is possible to wire the CT7 Interface in parallel to the Thruster Control circuits of a number
of popular Thruster manufacturers.
Diagram CT7 WIRING FIG 2 suggests one way that this may be accomplished.
The diodes shown in the circuit are required to provide a circuit path for powering the CT7
output circuit from the power supply of the Thruster Control module(s), while preventing the
CT7 and P Series SPU circuitry from accidentally back-powering the Thruster module(s); the
diodes also isolate the individual modules power supplies from each other, if there are two
such modules.
The diodes must be rated to handle at least the maximum current that Thruster Control
module(s) require to drive their Port/Starboard signal lines. Because the modules are not
supplied by ComNav, their current requirements are not known and so the diodes must be
chosen & supplied by the customer.
Note: the current required by the Thruster Control modules must not
exceed the maximum current that the CT7s On/Off Outputs can handle.
Also, the voltage across the V+ & -VE pins of the modules must not
exceed the CT7s On/Off Drive Input Supply specifications. See General
Specifications on page 37).

Proportional (Analog) Thrusters

The CT7 Interface is equipped with two optically-isolated, high-power analog outputs that can
drive a variety of proportional valves. The outputs are thermally protected and inherently
short-circuit proof. The outputs are also routed through on-board change-over relays,
controlled by the SPU, eliminating the need for additional relay boxes to switch between
autopilot and manual control signals. The analog outputs are capable of driving voltages that
swing both positive and negative, with respect to the ISO GND line.
There are several possible ways in which proportional Thrusters can be wired. See the
diagrams CT7 WIRING FIG 3A, 3B & 3C for some examples.
Certain proportional valves have two solenoid coils with a single common wire. See diagram
CT7 WIRING FIG 4.
Note that the diodes in the diagram are required to direct positive-going (with respect to
ISO GND) voltage to one of the two solenoids, and negative-going voltage to the other
solenoid; the diodes must be rated for at least 1.5 Amps DC. In such cases, one coil is
driven by the CT7s Analog Output Channel B, and the other is driven by an inverted signal
from Channel A.
Because the solenoids are not supplied by ComNav, their current requirements are not
known and so the diodes must be chosen & supplied by the customer.
Note: the CT7s Analog outputs must be used either for Proportional
Thrusters or Azimuth Drives. They can not be used simultaneously for both.

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Installation

Azimuth Drives
The same optically-isolated, high-power analog outputs used for Proportional Thrusters can
instead be used for Azimuth Drives. The wiring is similar see diagram CT7 WIRING FIG 4.
Note: the CT7s Analog outputs must be used either for Proportional
Thrusters or Azimuth Drives. They can not be used simultaneously for both.
For best Steering performance by a P Series autopilot system, it is always best to have a
Rudder Follower Unit (RFU) connected to the vessels Rudder or, in the case of Azimuth
Drives to the direction mechanism of drive unit itself. Please contact your ComNav Dealer
for further information on ComNavs RFUs which may suit your vessels Azimuth Drives.
However, it is often not possible or even if it is, it is usually not easy to connect an RFU to
Azimuth Drives.
Because of this, the CT7 Interface provides a Rudder Simulator feature, which generates an
RFU signal directly compatible with the P Series SPU from the steering signals sent by
the SPU to the CT7.
Note: the CT7s Rudder Simulator is designed & tested only for use with
Azimuth Drives. Although the Rudder Simulator could in theory be used with
normal drive types, to replace the RFU normally required for such drives,
doing so is not supported or recommended by ComNav.
Wiring of the CT7s RFU signals back to the SPU is via the J4 J4 cable see diagram CT7
WIRING FIG 4.

Isolated Analog Power Supply

The analog outputs of the CT7 Interface are optically isolated from the rest of the CT7
circuitry, and from the P Series SPUs circuitry, if an isolated supply is used as the power
source for the analog outputs.
If the isolated supply is already split into positive and negative halves, it may be wired directly
into J3 ISOLATED SUPPLY IN.
However, the CT7 has available circuitry on board to split a single supply into positive and
negative halves, if the isolated supply is not already split.
Note: if the supply-splitting circuit is used, the maximum positive and
negative analog output voltages will be approximately of the isolated
supply voltage.
Refer to diagrams CT7 WIRING FIG 3A, 3B, 3C & 4 for the Isolated Supply wiring.
Important! If the isolated supply used is already split, remove fuse F5 from
the fuse holder on the CT7. This prevents current from flowing on the supply
return line between the isolated supply and the on-board generated supply
return line (ISO GND).

420 mA Current-loop Outputs

The CT7 Interface provides two current-loop outputs that can be used to drive electronic
steering modules. Typically the outputs will be 4 mA at 45 port rudder, and 20 mA at 45
starboard rudder; 12 mA signifies mid-ship rudder. The outputs can drive loads between 10
and 500 Ohms. See CT7 WIRING FIG 5 for wiring details of the Current-loop outputs.
Note: the CT7s Current-loop outputs are not optically isolated, nor do they
have the change-over & range/polarity features of the analog voltage
Proportional/Drive outputs.

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ComNav CT7 Interface Installation & Operation

Installation

Electric Wheel Interface

The CT7 Interface will accept input from any Electric Wheel that provides an analog signal
from zero to five volts DC, with the mid-ship position equal to 2.5 VDC.
In most cases, 5 VDC power can be supplied to the Electric Wheel from the CT7. However, if
the Electric Wheel requires a different voltage, or if the current draw is greater than 20 mA, a
separate power supply for the Wheel should be uses, and a common signal ground
established between the external power supply and the CT7s J10 Wheel Ref pin.
Wire the Electric Wheel as per CT7 WIRING FIG 6, including a suitable On-Off switch
(customer-supplied) for Electric Wheel Enable wired between J10s ENABLE SIG &
ENABLE REF pins.
Note: that if the CT7 is only being used as an interface for an Electric
Wheel, and you are not controlling Thrusters or an Azimuth Drive, the
CT7 will draw all necessary power from the SPU via connector J7, and
no additional battery connections to the CT7 are required.

ELECTRIC WHEEL Mode Enable

Whenever the Electric Wheel Enable switch is ON (closed), the ELECTRIC WHEEL mode of
the P Series Autopilot System is enabled.
In this condition, the POWER STEER mode of the P Series Autopilot System becomes
ELECTRIC WHEEL mode instead: pressing the PWR STR button on the Control Head
which normally causes the autopilot to enter POWER STEER mode will cause ELECTRIC
WHEEL mode to be entered.
In this mode, the COURSE CHANGE knob and PORT/STARBOARD ARROW buttons on the
autopilot Control Head will be disabled (you can still use them to view and change menu
items, however).
If the autopilot is already in POWER STEER mode when the Electric Wheel Enable switch is
turned ON, the autopilot will enter ELECTRIC WHEEL mode.
To exit ELECTRIC WHEEL mode, change to STANDBY, AUTO, or NAV modes by pressing
the appropriate button.
While in ELECTRIC WHEEL mode, all autopilot Control Heads are forced into Repeater
mode, and the Electric Wheel has sole control of the vessels steering. Unlike regular
Repeater mode though, you cannot take control away from the electric wheel by pressing
the PORT and STARBOARD ARROW buttons on the Control Heads.
While this mode is active, a large letter E will be displayed in the upper left corner of the
Control Head display, where the P Series operating mode indicator is normally shown.

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Installation

Setup
Once the CT7 Interface is installed and wired, there are a few Setup steps that must be done,
in order to use it with your P Series Autopilot System:
Set the configuration switches on the CT7 to configure it for the type of drive on your
vessel.
Set the P Series Autopilot Systems Thruster parameter values that control the CT7s
operation.
For analog voltage outputs to Proportional Thrusters or Azimuth Drives, adjust the range
& polarity of the CT7s outputs to match with your drive systems requirements.
For Azimuth Drives using the CT7s Rudder Simulator feature, adjust the Simulator to
match with the drives steering functions.

Switch Settings
Configuration of the CT7 Interface requires the correct setting of six switches that are located
under the Access Window. To set the switches, first remove the window by prying it gently
out of the chassis.
The six switches are all in one package, at the right of the window (see Figure 4). An
individual switch is Closed when its lever is DOWN, and Open when the lever is UP.
Important! Correct settings of the CT7s switches are necessary for
proper operation of the CT7. Incorrect settings may damage the CT7
circuitry and/or other equipment connected to the CT7.

Figure 4 CT7 Switches & Trim-pots

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Installation

Switch #1 Setup
When Switch #1 is in the DOWN position, and the P Series Autopilot System is turned on, the
CT7 is placed in Rudder Simulator Setup Mode. This switch is only used when the CT7 is
used to control Azimuth drives without a physical RFU, and then only during Dockside Setup
of the P Series Autopilot System. It should be in the UP position at all other times.
Note: the CT7s LED lamp labelled SETUP will be lit whenever this
switch is activated.

Switch #2 Invert Channel A Output

In order to invert the signal from the CT7s Analog Output Channel A with respect to
Channel B, for use with certain types of twin or dual solenoid proportional valves, Switch #2
must be in the DOWN position. Otherwise, Channel A and B have the same voltage-swing
polarity.

Switch #3 Bow Output Positive/Negative

If the Bow Thrusters are On/Off types, and if they are to be activated by positive voltage on
the signal line, Switch #3 should be in the DOWN position. If the Thrusters are to be
activated by grounding the signal lines, this switch should be in the UP position.

Switch #4 Stern Thruster Positive/Negative

This switch works exactly the same way as Switch #3, but affects the Stern Thruster On/Off
outputs.

Switch #5 Channel A Control Source

This switch selects the type of drive signal generated on the Channel A Analog Output. If the
CT7 is to be used to control an Azimuth Drive or a Proportional Steering Valve with Channel
A, this switch should be in the DOWN position. If the CT7 is to be used to control a
proportional Bow thruster with Channel A, this switch should be in the UP position.

Switch #6 Channel B Control Source

This switch works exactly the same way as Switch #5, but affects Analog Output Channel B.

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Installation

Autopilot System Parameters

CT7-related parameters of the P Series Autopilot System are set up using the Control Head.

Dockside Menu
Thrust Type (Thruster Type)
Selects the type of thruster interface required: On/Off, Prop (Proportional), or None.
Select None if the CT7 Interface is to be used with an Azimuth drive, or as an Electric Wheel
interface.
Thrust MIN (Thruster Minimum)
Selects the minimum voltage (percent of the supply voltage) at the CT7s Analog Output.
Proportional valves often have a minimum voltage/current that must be supplied before the
valves internal spool begins to move. By adjusting this items setting, you can match the
CT7s output voltage for the Bow thruster to the requirements of the valve.
Note: The output voltage for the Stern thruster will be slightly higher, as
a function of the P Series Autopilot Systems IST technology.
If you are using On/Off valves, leave Thrust MIN set to the factory-default value of 30.
Thrust MAX (Thruster Maximum)
Selects the maximum voltage (percent of the supply voltage) at the CT7s Analog Output.
For Proportional Thrusters, you may wish to limit the maximum amount of thrust, in order to
prevent excessive overshoot when the thrusters are used to maintain a course, or change
onto a new course.
If you are using On/Off valves, leave Thrust MAX set to the factory-default value of 70.

Auto Menu
If Thrust Type in the Dockside menu is set to On/Off or Prop, then two additional items will
appear in the Auto menu. They are:
Thruster Assist
Sets the maximum speed at which the CT7s Thruster Assistance feature will be active. This
parameter can be varied in 0.5 Knot steps from 0.5 up to 7.0 Knots, or can be set to Off.
When Thruster Assist is set to some value other than Off, the CT7 will automatically use the
thruster(s) to assist the vessel in maintaining a course, or turning onto a new course.
Note: this feature requires a speed sensor wired into the P Series SPU.
When Off is selected, the P Series SPU will not use Automatic Thruster Assistance. You
may still be able to activate the thrusters manually, depending on how you vessel is equipped
and wired.
Thruster Gain
The options are Low, Medium, and High. Thruster Gain is used to adjust how aggressive you
want the thrusters to be when using Automatic Thruster Assistance.
If On/Off thrusters are used, the Gain setting primarily affects how long the thruster is
activated. If Proportional thrusters are used, the Gain setting primarily affects the minimum
voltage of the Stern thruster output.

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Installation

Electrical Adjustments
This step requires use of various menus and operational displays on the Control head of your
P Series Autopilot System. It also requires use of an accurate Voltage meter, and a small
slot-head screwdriver (see page 17 Special Tools).

On/Off & Electronic Thrusters

The CT7 Interface can directly drive On/Off (Solenoid) & Electronic Thrusters without any
electrical adjustments.

Proportional Thrusters
The CT7 Interface can directly drive some types of Proportional Thrusters without any
electrical adjustments.
However, it will typically be necessary to adjust the maximum voltage that the CT7 outputs, to
match with the input signal voltage requirements of your Thrusters (Electronic modules,
valves, or solenoids). Refer to your Proportional Thruster manuals to determine those
voltages.
Adjustments can be made to the CT7s drive output voltages by adjusting trim-pots CHA (for
channel A output) and CHB (for channel B output). These trim-pots are factory set so that
a rudder command of 45 results in approximately 10.0 Volts, but can be adjusted up or down
(within the upper limit set by the Isolated Supply voltage), as desired.
WARNING: the CT7s Thruster output circuits are high-gain analog amplifiers.
They were designed to work properly with most types of Proportional Thrusters;
but, like all high-gain amplifiers, there is a potential for them to break into
oscillation, when their gain trim-pots are set for maximum gain, if they are
connected to wiring with high inductance and/or capacitance (typically, when long
cable runs are required), or if the wiring is run close to strong sources of RFI or
EMI. If this condition occurs, you should immediately reduce the gain settings
(CHA/CHB trim-pots), and then contact your ComNav Dealer for assistance.

Azimuth Drive Systems

The CT7 Interface can directly drive most Azimuth Drive systems without any electrical
adjustments. Most Azimuth systems are equipped to accept 10 VDC signals, with 0 VDC
equating to the mid-ship position of the Azimuth unit.
Note: outputs are also available for Azimuth systems requiring 4 - 20mA
input signals; these are described on page 22.
However, adjustments can be made to the CT7s drive output voltages, as described above
for Proportional Thrusters.
Rudder Simulator Setup
One adjustment unique to Azimuth Drives is for the CT7s Rudder Simulator feature.
Typically, it will be necessary to adjust the CT7s simulated RFU signal to match with your
vessels Azimuth drives movements.
To adjust the CT7s simulated RFU:
1) Connect the appropriate Switched B+ & Rudder Feedback wires from the P Series
SPU to the CT7s J2 and J4 connectors, as per CT7 Wiring Fig 4. You may also
wish to wire up the plugs for J3 and J8 but DO NOT connect them to the CT7 at
this time.

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ComNav CT7 Interface Installation & Operation

Installation

2) Remove the Access Window on the CT7. This is easily accomplished by gently
prying the four corners of the window up from the chassis.
3) Turn on the P Series Autopilot System, and enter the Power Steer menu.
4) Select RAI Offset and ensure that it is set to 0 (zero).
5) Exit the Power Steer menu.
6) With the autopilot in STANDBY mode, gently adjust the VREF trim-pot on the CT7
(located immediately above the WHEEL GAIN trim-pot, see Figure 4), so that the RAI
display at the bottom of the Control Heads screen reads 0 (zero) degrees.
7) Enter the Dockside menu. Referring to your P Series manual, follow all of the steps
necessary to set up your autopilot.
8) When it comes time to do the Drive Setup, press the Fn button as usual.
9) When prompted to Move Rudder to Max Starboard, move Switch #1 on the CT7 to
the DOWN (closed) position, and note that the CT7s SETUP LED illuminates.
10) Press the STBD pushbutton on the CT7. You will see the Rudder Angle Indicator
display on the Control Head begin to move. Do not be concerned if it moves in the
opposite direction expected (the P Series SPUs firmware will automatically sort that
out shortly).
11) Continue pressing the STBD button until the RAI reading is at maximum deflection.
Then press the STBD ARROW button on the Control Head.
12) When prompted to Move Rudder to Max Port, press the PORT button on the CT7
and note that the RAI will begin to swing to the other side.
13) Release the PORT button when the RAI reading is at maximum deflection. Then
press the PORT ARROW button on the Control Head.
14) When prompted to Center Rudder, use the STBD button on the CT7 once again to
bring the RAI to the mid-ship position. Use the PORT and STBD buttons to
fine-tune the position of the RAI if necessary.
15) Move Switch #1 to the UP (open) position.
16) Press the Fn button on the Control Head.
17) The autopilot will proceed with the testing of the drive. When prompted to bleed the
system, simply press the Fn button to bypass that portion of the SPUs Drive Setup
process. Once the autopilot has finished measuring the CT7 drive, you should bet a
Drive Test OK message.
18) At this point, press the PORT ARROW button as usual, to return to the Dockside
menu.
19) Exit the Dockside menu by selecting Exit from the menu (the autopilot will restart in
STANDBY mode), or by turning the autopilot off and then on again.
20) Connect J3 to the azimuth supply.
Note: be sure to remove Fuse F5 if the azimuth supply provides an
isolated return.
21) Connect J8 to the appropriate connections on the azimuth drive.

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Installation

22) Monitor the voltage at J8, pins Ch A Out & Ch B Out. Change the autopilot to
POWER STEER mode, and use the PORT ARROW button to move the azimuth
drive to 30 in the port direction.
The 30 should not be taken from the autopilot display at this point it should be
determined by an independent RAI or physical means.
23) Now adjust the RFU GAIN trim-pot so that the autopilot RAI reads 30.
24) Verify the RAI calibration by using the STARBOARD ARROW button to move the
azimuth drive to 30 in the starboard direction and checking the autopilot display.

Adjustment of Electric Wheel Gain

1) Turn the WHEEL GAIN trim-pot on the CT7 all the way counter-clockwise if it is not
already there.
2) Once the CT7 is wired to the autopilot SPU and the Electric Wheel, turn on the autopilot
and enable the ELECTRIC WHEEL mode (by closing the Enable Wheel Enable switch),
and then pressing the PWR STR button, to enter ELECTRIC WHEEL mode).
3) Move the wheel hard over in one direction.
4) Now slowly adjust the WHEEL GAIN trim-pot clockwise until the rudder stops just at the
limits of its travel.
5) If the Wheel Gain is too high, the rudder will reach the limits of travel before the wheel
reaches the limits of its travel, and you will not be able to steer as precisely.

Final Steps
Replace the access window cover on the CT7.
Re-check all cables & wires connected to the CT7 & the SPU:
Are they secure?
Are the plugs fully pushed into the CT7s & SPUs connectors?
Is the polarity of all drive power wiring correct?
If a split Isolated Analog Power Supply is used, is Fuse F5 removed? If a non-split supply
is used, is F5 in?
Re-install the Wiring Covers on the CT7 & the SPU.

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ComNav CT7 Interface Installation & Operation

Care & Maintenance

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ComNav CT7 Interface Installation & Operation

Care & Maintenance

Care & Maintenance

The CT7 Interface for P Series Autopilot Systems has been designed to provide many years
of reliable service. The following periodic care and maintenance tips will help to ensure the
longevity of your CT7.

Cleaning and Appearance

The CT7 Interface should be carefully cleaned on are regular basis with a damp cloth and
mild soap.
Do not use abrasive cleaners or chemicals.
The CT7 is designed to be weatherproof and splash resistant, but it should not be immersed
in water for a prolonged period of time.
Environments exceeding the maximum or minimum temperatures specified in General
Specifications on page 37 MUST BE AVOIDED.
Exposure to prolonged direct sunlight should be avoided in order to prevent damage to the
electronics and housing.

Protection of Wires and Cabling

After installation, ensure that the system components are securely mounted and will not
shake loose due to the vibrations that can be expected in a marine vessel.
Ensure that the cabling and wiring to all system components is well secured with clamps or
alternative fasteners.
Many potential problems can be avoided by ensuring that cabling and wiring do not cause
strain on the connectors.

Periodic Checks
After the first six months of operation a thorough examination of the entire Autopilot system
MUST BE UNDERTAKEN. All electrical connections, cables, clamps, mounting brackets, and
mechanical connections must be secure.
An ANNUAL inspection should be undertaken thereafter.

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ComNav CT7 Interface Installation & Operation

Care & Maintenance

Fuse Replacement
There are 3 types of fuses (5 fuses in total) used on the CT7 Interface. Should a fuse blow,
determine the cause before replacing. Replace fuses only with the same type and rating as
per the table below:

Designator

ComNav Part Number

F1

60810007

Generic Description
Manufacturer(s) & Part Number(s)
1 A Medium Time Delay, 125V or better,
5 x 20mm (DIN 41571, IEC 127))
Bussman GMC 1

F2

F3, F4, F5

60810024

60810012

10A, Non-Time Delay, 125V, x 1-

Bussman ABC-10
3.15 A Medium Time Delay, 125V or better,
5 x 20mm (DIN 41571, IEC 127))
Bussman GMC 3.15A

Table 2 Fuse Replacement Guide

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Appendices

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ComNav CT7 Interface Installation & Operation

User Settings

Appendices
Appendix 1
General Specifications
Parameter

Specification

Dimensions

257 x 184 x 76 mm (10.2 x 7.3 x 2.9)

Operating Voltage

12 VDC
(nominal supplied from the
Commander/Admiral SPU via J7)

Power Consumption

150 mADC typical (in idle sate)

On/Off Drive Input Supply (J1)

5 to 40 VDC

On/Off Drive Outputs

3 Amps (max.)

Analog (Proportional) Isolated Supply Input

+/- 28 VDC (max)

Analog (Proportional) Output

1.5 Amps (Max)

Current Loop Outputs

420 mA nominal,
12 mA @ mid-ship rudder
10 to 500 load impedance

Electric Wheel Input

0-5 VDC,
2.5VDC @ mid-ship rudder
200 to 10 K impedance

Rudder Follower Output

1.04.0 VDC centered at 2.5 VDC

(compatible with all ComNav autopilots)

Electric Wheel Input

0-5 VDC, 2.5VDC @ mid-ship rudder

200 to 10 K impedance

Table 3 General Specifications

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ComNav CT7 Interface Installation & Operation

User Settings

Appendix 2
Warning Messages
There are two warning messages in the P Series Autopilot System that are specific to the
CT7 Interface.
These messages will appear on the P Series Control Head when the associated conditions
occur, if a CT7 is connected to the SPU and Thruster Type in the Dockside Menu is set to
On/Off or Prop (see page 26).

Message
CT7 VOLTAGE LOW
CT7 SETUP ON

Description
The CT7s main supply voltage at the J7 connector,
SYSTEM V+ pin, is below ~8 Volts.
Switch #1 on the CT7 is in the SETUP position (down).
See page 25.

Table 4 Messages

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User Settings

Appendix 3
Diagnostic LEDs
The CT7 Interface is equipped with a number of Light-Emitting Diode (LED) lamps that can
assist in trouble-shooting should a problem arise with the CT7. Refer to the following table:

LED
SYS PWR
VCC

DRV PWR

Description
This LED will be ON whenever the P Series SPU is powered up.
VCC is the voltage supplying the logic circuits on the CT7. The voltage
is nominally 5.25 VDC, and can be measured at testpoint TP2 with
respect to ground (GND, on TP1).
This indicator will be ON whenever there is a supply voltage at the
ON/OFF O/Ps SUPPLY connector, J1.

BOW
PORT, STBD

One or the other of these indicators will be ON whenever the respective

BOW On/Off outputs of the CT7 are On.

STERN
PORT, STBD

One or the other of these indicators will be ON whenever the respective

STERN On/Off outputs of the CT7 are On.

CH A
POS, NEG

One or the other of these indicators will be ON whenever the CH A

Proportional/Drive analog voltage outputs of the CT7 are Positive or
Negative with respect to ISO GND (TP4).

CH B
POS, NEG

One or the other of these indicators will be ON whenever the CH B

Proportional/Drive analog voltage outputs of the CT7 are Positive or
Negative with respect to ISO GND (TP4).

SETUP

This LED will be ON when the CT7 is in Rudder Simulator Setup mode.

Table 5 Diagnostic LEDs

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User Settings

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ComNav CT7 Interface Installation & Operation

Appendices

Appendix 3
Typical Wiring Diagrams
The following diagrams show the various ways in which the CT7 is wired.

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Appendices

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ComNav CT7 Interface Installation & Operation

CE Compliance Statement

CE COMPLIANCE

This product has been tested and is in compliance with the Electro-Magnetic Compatibility
(EMC) standards of the European Community, and bears the CE label. It has been tested
according to the applicable sections outlined under:
Technical standard #IEC945/EN60945,
Marine Navigation Equipment,
General Requirements
Applicable sections for methods of testing and required test results are:
Section 4.5.4:
Radiated Interference
Section 4.5.4:
Immunity to Electro-Magnetic Environment
Annex A, Section A.3:
Immunity to Conducted Audio Frequencies
Annex A, Section A.4:
Immunity to Earth Lead Coupling
Annex A, Section A.6:
Immunity to Radiated Interference
Test results and a declaration of conformity are on file at the ComNav Head Office.
ComNav Marine Ltd.
#15 - 13511 Crestwood Place
Richmond, BC V6V 2G1
Canada

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ComNav CT7 Interface Installation & Operation

Index

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ComNav CT7 Interface Installation & Operation

Index

Index
Azimuth Drives ...................13, 18, 20, 22, 24, 25, 26, 27
Care & Maintenance ................................................... 33
CE Compliance ........................................................... 51
Checks Periodic ....................................................... 33
Current-loop outputs ....................................... 13, 22, 27
Diagnostic LEDs.......................................................... 39
Double-press................................................................. 9
Electric Wheel ........................................... 13, 23, 26, 29
Fuse Replacement ...................................................... 34
Installation ................................................................... 17
LEDs, Diagnostic......................................................... 39
Maintain ........................................................................ 9
Minimum Recommended Wire Gauges ...................... 18
Momentary press .......................................................... 9
On/Off Thrusters ....................................... 13, 21, 25, 27
Power Supply .............................................................. 17

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Press .............................................................................9
Press and hold...............................................................9
Proportional Thrusters ................... 13, 20, 21, 24, 25, 27
RFU Simulator ................... 13, 20, 24, 25, 27, 37, 38, 39
Special Tools .........................................................17, 20
Specifications ..............................................................37
Technical Requirements ..............................................17
Thruster Parameters........................................ 24, 26, 38
Typical Wiring Diagrams..............................................41
User Notes...................................................................60
User Settings ...............................................................59
Warning Messages......................................................38
Warranty ..................................................................1, 17
Wire Gauges................................................................18
Z-Drives .......................................................................13

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ComNav CT7 Interface Installation & Operation

User Notes & Settings

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User Settings & Notes

User Settings
Once your CT7 Interface system has been installed and set up correctly, make a record of all
the settings for future reference, in the tables below

Parameter

Range

Default Value

Dockside Menu
Thrust Type

None, On/Off, Prop.

None

Thrust MIN

0-70%

30

Thrust MAX

100% - Thrust MIN

70

Thrust Assist
(If Thruster Type
is not None)

Off, 0.5 7.0 (Knots)

Off

Thruster Gain

Low, Medium, High

Low

Auto Menu

Table 6 User Settings

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User Settings

ComNav CT7 Interface Installation & Operation

User Notes

Table 7 User Notes

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