CT2 Drive Box Owners Manual

CT2 Drive Box Owners Manual
ComNav
R
Marine Ltd.
CT2-40A
MOTOR CONTROLLER
PART NUMBER 20350001
DOCUMENT PART NUMBER 29010024
Permanent Magnet z Shunt Field Compound z D.C. Motors
ComNav
Installation Instructions
Version 3.3
ComNav Marine Ltd. #15-13511 Crestwood Place. Richmond, B.C. Canada. V6V-2G1
Telephone: 604-207-1600
Facsimile: 604-207-8008
Web: www.comnavmarine.com E-mail: sales@comnav.com
Document PN 29010024
Introduction:
CT2-40A Motor Controllers are designed to connect a ComNav Autopilot to a steering system
using a permanent magnet, shunt field, or compound reversing D.C. Motor.
CT2-40A Motor Controllers feature dynamic braking, current limiting and thermal protection of the
MOSFET driving transistors while allowing full power acceleration and drive when needed. CT2
Motor Controllers can be used with 12, 24 and 32 VDC battery systems.
CT2 Motor Controllers also feature automatic field control for use with Shunt Field and Compound
Reversing D.C. Motors. The field of the motor is energised any time the Autopilot is turned on.
Installation:
WARNING
To ensure that the CT2 Motor Controller case will stay watertight, it is very important
that you use round cables in all three watertight cable fittings. The two large cable
fittings will require a cable with an outer diameter ranging from 5/32"(4.0mm) to
13/32"(10.0mm). The smaller cable fitting will require a cable with an outer diameter
ranging from 3/32"(2.5mm) to 1/4"(6.5mm).
For mounting, a #10 size hole is provided in each foot of the 2T Motor Controller box.
The Autopilot and the CT2 Motor Controller must be run from the same source of power,
although they do not need to be powered from the same breaker. In fact, for installations that use
two drive units, it is preferable to power the Autopilot and each CT2 Motor Controller from a
separate breaker. This way either or both drive units may be selected to operate independently
from the Autopilot.
To provide power to the CT2 Motor Controller, use #12 AWG wire if the combined run from the
breaker to the box and from the box to the motor, is 25 feet or less. If the combined run is greater
than 25 feet use #10 AWG wire. Run the power lead from a 50 Amp breaker to the CT2 Motor
Controller.
If the Autopilot is powered from the same breaker as the CT2 Motor Controller, run a
separate wire from the breaker to the Autopilot as shown in the diagram. DO NOT run the power
lead to the Autopilot from the CT2 Motor Controller. Before providing power to the Autopilot, refer
to the Autopilot Installation and Operation Manual for the appropriate wire gauge.
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29010024V3.3(2T Drive Box).doc
For the correct interconnection of the CT2 Motor Controller and the Autopilot refer to
Figures 2 through 4. A four-conductor, #24 AWG cable with shield will be satisfactory. The shield
of the cable should be terminated to the JOG COMMON terminal (or V-) in the Autopilot
distribution box and unterminated at the other end.
If Jog Levers are used to override the Autopilot, connect them to the terminals provided in the
Autopilot distribution box (see enclosed diagrams or the Autopilot manual).
If the drive system is a Rotary Drive or Linear Actuator, the clutch of the rotary drive, or the
lockup solenoid of the linear actuator, should be wired to the Switched Power and Jog Common
terminals in the Autopilot distribution box (refer to the interconnection diagram in your ComNav
Autopilot Installation and Operation Manual).
TESTING:
Close the breaker which provides power to the Type CT2 Motor Controller. It is normal to
hear a pop when the breaker is closed as the large capacitors in the CT2 Motor Controller charge
up.
To ensure correct rudder direction movement, place the Autopilot master select switch in the
POWER STEER position and press either the red or green ARROW key. The rudder should move
in the correct direction. If not, reverse M1 and M2 leads from the CT2 Controller to the motor.
Refer to the Autopilot Installation and Operation manual, and complete the Dockside Setup
procedure for the autopilot. After completing the Dockside Setup procedure, measure the hardover to hard-over time of the drive system.
To measure the maximum hard-over to hard-over time of the drive system, place the
Autopilot master select switch in the POWER STEER position and hold the red or green ARROW
key to make the rudder move fully from Port to Starboard or vice versa.
If the hard-over to hard-over time is less than 8 seconds, the rudder must be slowed down by
decreasing the pumpset displacement, or changing to a smaller pumpset / slower acting drive
unit.
If the hard-over to hard-over time is more than 16 seconds, the rudder must be sped up by
increasing the pumpset displacement or changing to larger pumpset / faster acting drive unit.
When the hard-over time is between 8 - 16 seconds, testing of the CT2 Motor Controller Drive Box
is complete.
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29010024V3.3(2T Drive Box).doc
TROUBLESHOOTING:
•
Check with a voltmeter that voltage is present between Terminals J1, V+ and J1, V- (the
battery voltage).
•
If no voltage is present, check that there is power to the breaker panel, and that the breaker
for the motor is turned on. Recheck the wiring from the breaker panel to the CT2 Drive Box.
•
If voltage is present, use an ohmmeter to check the 30 AMP Fuse (F1). Check the 1 AMP
Fuse (F2) as well. If either is faulty, replace with the same size fuse.
•
If fuses are OK check the voltage between Terminal J1 (V-) and Terminal J2 (+5V) for the +5
volts from the Autopilot. Check that the voltage between Test Points TP3 and TP4 is between
12 and 13.5 volts. Check that the voltage between Test Points TP1 and TP4 is 15 to 20 volts
higher than the voltage between Terminals J1 (V+) and J1 (V-) (the battery voltage).
If all test voltages are correct, connect the Port or Starboard terminal (J2, STBD or J2, PORT)
momentarily to the battery negative terminal (J1, V-) - the motor should run.
•
If the motor doesn't run:
1.
If the motor is a Shunt Field or Compound Motor, check that full (within a volt) battery
voltage appears between J1, Field+ and J1, Field- when there is +5V between J2, +5V and
Test Point TP4. If there is no voltage, disconnect the field connection to the motor and
check for a short circuit between the field wire and motor leads, or for a nail or staple
through the cable.
2.
Check that the full input voltage appears between the M1 and M2 terminals while the Port
or Starboard terminal is connected to the V- terminal. The polarity of the voltage will
depend on whether the Port or Starboard input is activated.
3.
If the voltage is present the motor may be faulty. Connect the motor leads directly to the
battery briefly to confirm whether it runs in both directions. If it does not run, contact your
dealer or the supplier of the drive system for assistance. If it does run, the CT2 Motor
Controller may be faulty. Contact your Dealer or ComNav Marine for assistance.
4.
If there is no voltage present the CT2 Motor Controller may be faulty. Contact your Dealer
or ComNav Marine for assistance.
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29010024V3.3(2T Drive Box).doc
•
If the motor runs:
1.
Check the outputs from the Autopilot for correct operation. The red and green output
diagnostic LED's in the Autopilot distribution box should come on as described in the
ComNav Autopilot Installation and Operation Manual.
2.
If the diagnostic LED's do come on and the rudder still will not move, examine the wiring
between the Autopilot and the CT2 Motor Controller again. Check for open or short circuits.
Check for nails or staples which may have penetrated the cable.
3.
If the diagnostic LED's do not come on, you may have a faulty Distribution Box or Control
Head. Contact your Dealer or ComNav Marine for assistance.
Electrical Noise:
The CT2 Motor Controller uses high current switching transistors to control the motor. Every effort
has been made to reduce or eliminate the generation of electrical noise by the motor controller. If
some noise is heard on the vessel radios, and it is traced to the motor controller, a ground lug has
been provided to bond it to the vessel's grounding system. In most cases, this should eliminate
any electrical noise.
Specifications:
Operating Voltage Range:
Operating Temperature Range:
Current Limit:
Normal Operating Current:
Field Control:
10 to 40 volts D.C.
-10 degrees C to +70 degrees C
50 Amps for 1 second
30 Amps (CT2-40A model) maximum, thermally limited
Up to 5 Amps maximum. Overcurrent and Short Circuit
Protected
Note:
When the maximum operating limits are exceeded, the output from the CT2 Motor Controller will
automatically be turned off. This will allow the internal temperature of the output driving transistors
to fall back into the safe operating area and power will then be re-applied to the motor. This
happens in a fraction of a second, with a very strong pulsating effect to the steering gear. This will
only happen if the steering gear goes hard-over or is in some way jammed and will not move.
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29010024V3.3(2T Drive Box).doc
Figure 2 Connection to Permanent Magnet Motor
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Page 5 of 10
29010024V3.3(2T Drive Box).doc
6
MOTOR MONITOR
+5V
STBD
PORT
3
2
1
+
M1
M2
FIELD +
FIELD -
4
5
6
5
4
3
2
1
10 - 40 VDC MOTOR
3
2
1
+
BATTERY
12/24 VDC
-
30A FUSE OR BREAKER
(NOT SUPPLIED)
JOG LEVER
4
3
2
1
JOG COM
JOG STBD
JOG PORT
MOTOR MON (1001,1101,1201)
COM
+5V
SPD CNTL
SW. PWR
STBD
PORT
UNSW. PWR
+
-
DISTRIBUTION BOX
AUTOPILOT
Figure 3 Connection to Shunt Field Motor
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29010024V3.3(2T Drive Box).doc
6
MOTOR MONITOR
+5V
STBD
PORT
3
2
1
+
M1
M2
FIELD +
FIELD -
4
5
6
5
4
3
2
1
M1
M2
FLD+
FLD-
SHUNT FIELD MOTOR
10 - 40 VDC MOTOR
3
2
1
+
BATTERY
12/24 VDC
-
30A FUSE OR BREAKER
(NOT SUPPLIED)
JOG LEVER
4
3
2
1
AUTOPILOT
JOG COM
JOG STBD
JOG PORT
MOTOR MON (1001,1101,1201)
COM
+5V
SPD CNTL
SW. PWR
STBD
PORT
UNSW. PWR
-
+
DISTRIBUTION BOX
Figure 4 Connection to Compound Motor
Page 7 of 10
6
MOTOR MONITOR
+5V
STBD
PORT
4
3
2
1
5
1 FIELD -
6 +
5 4 M1
3 M2
2 FIELD +
M1
M2
FLD-
+
COMPOUND MOTOR
10 - 40 VDC MOTOR
3
2
1
-
+
SHUNT
BATTERY
12/24 VDC
-
30A FUSE OR BREAKER
RED
GREEN
21/09/2007
29010024V3.3(2T Drive Box).doc
S E R IE S
BLACK
W H IT E
BROW N
(NOT SUPPLIED)
JOG LEVER
4
3
2
1
JOG COM
JOG STBD
JOG PORT
MOTOR MON (1001,1101,1201)
COM
+5V
SPD CNTL
SW. PWR
STBD
PORT
UNSW. PWR
-
+
DISTRIBUTION BOX
AUTOPILOT
Figure 5 Connection to Processor Based Autopilots
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29010024V3.3(2T Drive Box).doc
TO CT2 BOX
5
TO BAT 12/24/32 VDC
U2
1A
+
M1
M2
F1
20A
U3
V BOOST
PORT IN
STBD IN
J2
1
2
M2 3
FIELD+
FIELD-
O/C
F/B
+5V
6
5
M1 4
+
-
J1
6
5
4
3
2
1
TO +5V
TO M2
TO M1
SHOWN WIRE SHOULD BE KEPT INSIDE THE PROCESSOR CASE.
+5V
CT2 BOX AND PROCESSOR MUST BE COMMON GROUND.
TYPICAL CONNECTIONS CT2 BOX TO PROCESSOR BASED AUTOPILOTS.
U1
F2
BLACK
WHITE
PROCESSOR
12
11
2
1
5
4
3
6
5
4
3
2
1
10
9
8
7
6
RED
BLACK
WHITE
GREEN
SHIELD
RED
BLACK
BLUE
WHITE
YELLOW
SHIELD
BLACK
GREEN
BLUE
WHITE
GREEN
TO PROCESSOR BOX
TO MOTOR
5
TO BAT 12/24/32 VDC
GND
DATA
BLACK
SHIELD
GREEN
WHITE
WHITE
2
3
4
VR1
(ANTI-HUNT)
VR4
VR2
(ANALOG RAI GAIN)
S1
GAIN
COM
4
FFUS
SHIELD
WHITE
YELLOW
GREEN
Figure 6 Connection to 1500 Autopilot
29010024V3.3(2T Drive Box).doc
YELLOW
GREEN
U2
F2
RUDDER FOLLOWER
UNIT (RFU)
FLUXGATE
COMPASS
1A
F1
TO 5V
30A
U3
C17
20
FUSE
VR6
(CURRENT LIMIT)
1
6
5
PORT IN
STBD IN
O/C
F/B
+5V
V BOOST
J2
2
1
FIELD+
M2 3
M1 4
+
-
J1
2
FIELD-
J3
BATTERY 12/24 VDC
5
24/32 VDC
12 VDC
S2
COMMON
6
5
4
3
2
1
3
MOTOR1 (SOLENOID 1)
4
5
MOTOR2 (SOLENOID 2)
DATA
1
1
2
2
3
3 4
4
5
24/32 VDC
12 VDC
TO RFU +5V
TO SOLENOID 2
TO SOLENOID 1
TO 1500 BOX
M2
M1
30A FUSE OF BREAKER
TO PERMANENT
MAGNET MOTOR
5
PLACE A SHUNT BETWEEN PIN1 & PIN2 OF J3
TO BAT 12/24 VDC
1) Make sure it is in UP position for solenoid setup
2) Keep in down position.
3) Keep in down position. If using analog output interface (A1100),
keep in up position.
4) Keep in down position. If using full followup (FFU) tiller steering
option, keep in up position.
5) Set as per voltage application shown above.
** Make sure power is turned off to the pilot system prior to changing
dip switches.
UP
DOWN
DIP SWITCHES
TYPICAL CONNECTIONS CT2 BOX TO 1500 AUTOPILOTS
U1
CONTROL
HEAD
CT2 REV. 10
PCB PN 31252
Page 9 of 10
CONTROL
HEAD
CONTROL
HEAD
TO PORT IN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
+
1
GND
FOR COMNAV
RUDDER FOLLOWER
INSTALLATION USE
GND
3
FFU+
VR3
(ANALOG RAI OFFSET)
S2
5
FUSE
GND
2
FFU-
VR5
(DIGITAL RAI
OFFSET)
+
1
ENABLE
OFFSET
-
DIP SWITCHES **
ALARM+
TO STBD IN
+BATTERY
21/09/2007
-BATTERY
S1
1) Loosen six screws and remove the cover from the DU 1500 Servo unit to expose the PCB.
2) On the PCB, set DIP SWITCHES (S1-1) to UP to select Solenoid configuration.
3) Remove EndCaps and Enclosure from the CT2 box to expose the CT2 PCB.
4) On the PCB, shift the two-position shunt to between Pin1 and Pin2 of J3.
5) Use a #10 or #12 AWG cable to connect 2 wires from Permanent Magnet Motor to CT2 Box..
6) Use a #22 AWG cable to connect 3 wires from DU 1500 Box to CT2 Box. (See the Diagram below).
7) Install a 30A fuse or breaker in line with power input to CT2 box.
8) Reassemble the units.
INSTALLATION STEPS:
2
3
4
15 AMP FUSE
5 AMP FUSE
VR2 VR3
Page 10 of 10
U2
F2
1A
BATTERY 12/24 VDC
5
VR1
F1
1
2
2
VR6
30A
S2
DIP
SWITCHES **
TO CT2 BOX
VR4
S1
1
12
3
WHITE
FLUXGATE
COMPASS
GND
DATA
GND
DATA
BLACK
WHITE
RED
SHIELD
WHITE
YELLOW
GREEN
SHIELD
U3
C17
RUDDER
FOLLOWER UNIT
(RFU)
24
GREEN
YELLOW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22
Figure 7 Connection to 1510 Autopilot
29010024V3.3(2T Drive Box).doc
TO PORT IN
CT2 REV. 10
PCB PN 31252
6
5
PORT IN
STBD IN
O/C
F/B
+5V
V BOOST
J2
2
1
FIELD+
M2 3
M1 4
+
-
J1
FIELD-
J3
CONTROL
HEAD
CONTROL
HEAD
CONTROL
HEAD
6
5
4
3
2
1
1
2
2
24
3
12
TO RFU +5V
TO SOLENOID 2
TO SOLENOID 1
TO 1510 BOX
M2
M1
30A FUSE OF BREAKER
TO PERMANENT
MAGNET MOTOR
5
PLACE A SHUNT BETWEEN PIN1 & PIN2 OF J3
** Make sure power is turned off to the pilot
system prior to changing dip switches.
1) Make sure it is in UP position for solenoid setup.
2) Keep in down position.
3) Set as per voltage application shown above.
Switch should be set to 12 for 12 VDC
application or set to 24 for 24 VDC application.
UP
DOWN
1
DIP SWITCHES
TO BAT 12/24 VDC
TYPICAL CONNECTIONS CT2 BOX TO 1510 AUTOPILOTS
U1
1
S2
COM
S1
-
+
GND
+B
AT
TE
RY
-B
AT
TE
RY
CO
MM
M
ON
(S OTO
OL R 1
E
M
N
(SOOTO OID
1)
LE R2
NO
ID
2)
TO STBD IN
21/09/2007
TO 5V
+
1) Loosen two screws and remove the cover from the DU 1510 Servo unit to expose the PCB.
2) On the PCB, set DIP SWITCHES (S1-1) to UP to select Solenoid configuration.
3) Remove EndCaps and Enclosure from CT2 box to expose the CT2 PCB.
4) On the PCB, shift the two-position shunt to between Pin1 and Pin2 of J3.
5) Use a #10 or #12 AWG cable to connect 2 wires from Permanent Magnet Motor to CT2 Box
6) Use a #22 AWG cable to connect 3 wires from DU 1510 Box to CT2 Box.
(See the Diagram below).
7) Install a 30A fuse or breaker in line with power input to CT2 Box.
8) Reassemble the units.
INSTALLATION STEPS:
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