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CLASSIFICATION: Commercial In Confidence
Document
Issue
1
2
3
4
Date
15.08.02
14.10.05
15.11.07
16.05.08
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CLASSIFICATION: Commercial In Confidence
CONTENTS
INTRODUCTION ........................................................................................................ 7
SPECIFICATION ........................................................................................................ 7
MAIN TRANSFORMER .............................................................................................. 8
ANSCHUTZ ADAPTER .............................................................................................. 9
PRE - INSTALLATION CHECKS.............................................................................. 10
INSTALLATION NOTES........................................................................................... 10
TESTING THE REPEATERS ................................................................................... 12
TESTING THE GYRO .............................................................................................. 13
OPERATIONAL CHECKS ........................................................................................ 14
CHANGING BETWEEN No 1 to No 2 input.............................................................. 15
PRINCIPLES OF OPERATION ................................................................................ 16
MEASURING PHASE SHIFT ON OUTPUT ............................................................. 18
FINAL TEST PROCEDURE ..................................................................................... 19
TRANSFORMER SETUP ......................................................................................... 20
BOARD LAYOUT ..................................................................................................... 21
Email:
technical@amimarine.net
Web:
www.amimarine.net
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MAIN TRANSFORMER
The transformer is multi tapped as best shown in the schematic showing various
connections. The standard transformer gives a 115v ref. 90v signals output but this
is normally REDUCED by selecting the 132v mains input tapping. This runs the
synchro repeaters at a reduced voltage and we have found that under-rating is
beneficial. The exact voltage applied is not critical and you will be checking that the
repeaters follow later.
The output can be fine-tuned with the addition of another transformer. Anschutz
repeaters use 50v/20v or 60v/24v. We have an adapter for those voltages. See
below.
The KW903s reference output is intended to drive synchros, not high power course
recorders etc. If the ships equipment draws high power from the reference supply fit
an external reference transformer and disconnect the KW903s reference supply.
You may find such an external transformer already exists in the old system such as
Kurs and may be reused.
If the standard transformers do not produce exactly what is required we can make
transformers to suit your exact need.
DO NOT CONNECT SYNCHROS UNTIL YOU HAVE CHECKED THE KW903
OUTPUT!
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ANSCHUTZ ADAPTER
BL
GY
R1
INPUT
R2
FROM KW 903
S1
S2
R
BK
BN
S3
R1
OUTPUT
R2
TO REPEATERS
S1
BL
GY
S2
S3
R
BK
BN
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ohms
S1 - S2 =
S2 - S3 =
R1 - S1 =
S3 - S1=
INSTALLATION NOTES
POWER
Measure power supply input. If the voltage varies from 110/220 the synchro output
will vary in the same ratio. The KW903 transformer has taps, which may be used to
adjust the output voltage.
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GYRO INPUT
If the gyro has an NMEA 0183 output connect it to NMEA channel 2. This will be
selected as No. 1.
NMEA data to 0.1 deg provides a smoother output than
stepper.
Connect stepper input to SK5. For DC input set jumpers J1, J2, J3 to full wave
rectification. This handles either polarity and rectified unsmoothed DC.
For 90x 400 Hz contactless transmission set the three jumpers for half wave
rectification.
Set J4 and J5 to suit the gyro input. These jumpers indicate the gyro type at switchon and have no effect if changed after switch-on.
For NMEA heading input instead of stepper the jumpers do not matter.
90x contactless transmitter as in SR220
Its Reference R1, R2 is supplied with 115v 400Hz.
Do not connect its R1, R2 to KW903!
Connect transmitter N to KW903 stepper common
Connect S1, S2, S3 to S1, S2, S3
Jumpers J1, J2, J3 to half wave rectified.
If KW903 output turns wrong way final test reverse S1, S2.
Note stepper input LEDs may not go out entirely. This is ok for 90x NOT ok for DC
stepper!
SECOND GYRO OR MAGNETIC BACK UP
Connect the NMEA input to NMEA Channel 1. It will be selected as No2. This
channel is programmed to use all valid heading inputs, including Cetrek proprietary
data. (Channel 2 only accepts gyro $HEHDT).
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FINAL MEASUREMENT
When all is satisfactory stop the rotation by selecting B but stop it if possible at a
position where the phase you are measuring is taking maximum current. Switching
from B to A and back quickly will nudge it into place. Complete the checklist with this
value. If you have an oscilloscope also measure the phase shift: (see note.)
TESTING THE GYRO
Switch off. Set the hex switch to 0 and switch on. Toggle the alarm switch and leave
it on. If the alarm sounds the KW903 is indicating a GYRO FAULT!
The stepper input LEDs will be seen to rotate if the gyro turns. NMEA input LEDs will
flash in time with the data input. Align the repeaters to the gyro. Turn and hold the
gyro and check the repeaters move to that position. Swap a pair of wires if it turns
the wrong way.
If the alarm sounds on rapid turns of the gyro it is usually caused by the stepper RTU
being too lightly loaded, so that its internal capacitance cause slow transitions and
false steps. Fit load resistors across the stepper output e.g. 100 ohms.
OUTPUT FOLLOW-UP RATE
The hex switch allows selection of output rotation rate according to the formula
Degrees per second = 2 + Switch setting. Thus 0 = 2 deg/sec 3 = 5 deg/sec. Faster
follow up rates are available up to 9 but are not recommended. Chose a setting one
step faster than the ship can possible turn.
This feature is provided because repeaters may not follow really fast turns, which a
gyro may give in slew mode. Do not confuse this follow-up with input tracking rate.
The KW903 tracks DC stepper at more than 1000 degrees per second but it limits the
output rotation for the sake of the synchro repeaters.
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EXTERNAL ALARM
For safety reasons an independent external alarm should be connected. The
KW903 provides a pair of contact that are held open when all is well. There are a
large range of alarms easily available. We recommend an audible alarm with speech
output e.g. RS 216-3894.
Such an alarm can not detect faults on the synchro transmission system, which could
be caused by a KW903, output failure or a faulty synchro repeater, shorts, etc. This
is so with all transmission systems. To detect such faults a synchro monitor and offcourse alarm should be fitted. The AMI KW950 is recommended.
OPERATIONAL CHECKS
STATUS LED
Green = all ok
Flashing = a problem detected e.g. gyro false steps, gyro
or power interruption, loss of reference in output.
Toggle alarm switch to clear alarm condition.
If alarm returns there Is a problem
Red = Alarm is switched off, or KW903 hardware failure.
The software does not generate red state.
Off = No 5 volt power!
STEPPER INPUT
The LEDs indicate state of gyro input and rotate in
sequence i.e. 001 011 010 110 100 101. LEDs all on or all
off indicates a gyro problem.
NMEA 0183 INPUTS
These LEDs flash in time with the data input.
NMEA 0183 OUTPUT
Flashes at least once per second with each data output it
flashes at a faster rate when the ship turns.
SYNCHRO OUTPUT LEDS
These indicate roughly the state of the synchro output.
The brightness changes but they only go out at exact half
degree positions.
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PRINCIPLES OF OPERATION
The heart of the unit is the microprocessor software in EPROM, which controls the
whole input and output processing. The unit divides into convenient sections.
1
Power supply
Microprocessor
Power supply
The mains A.C. input is fused switched and filtered. The filter capacitors are centre
tapped to earth and must be earthed for safety. The filtering is for EMC reasons.
The multi-tapped transformer is specified to provide secondary voltages for reference
and synchro phases. One 9v winding is used for the 5v logic power supply.
Gyro input interfaces
Stepper gyro signals including A.C. Sperry signals are fed to opto isolators. Their
output goes to ports on the microprocessor. It is entirely up to the software to
process these signals to keep track of turns. Stepper signals give 6 steps per
degree.
The software will cause the alarm condition if a false step state is ever found that
being a gyro fault. The most common reason is the gyros step signals moving slowly
due to capacitance when the stepper output is lightly loaded. Fit some load resistors
to cure it.
The 1:1 synchro interface uses a synchro to digital converter with data transfer via
opto isolators to the microprocessor. Thus the common line of the SDC interface
floats above ground for we do not want to put any ground on the synchro transmitter.
The software is responsible for reading and turning the SDC data into heading. The
SDC chip has a fault indication bit which is active if there is a problem with the
synchro input. Again this causes the alarm state. The 12 bit accuracy gives heading
to better than 0.1 degree. The chip is a high precision device. The synchro input
must be phased and adjusted to achieve precise NMEA output.
NMEA 0183 inputs are also opto isolated before being passed to the microprocessor
which has 2 UARTS to receive the data. The software is written to accept all valid
NMEA sentences from the No 2 Ch 1 input and the standard gyro sentence $HEHDT
on the No 1 Ch 2 input.
It is again the software, which controls the use of No1 or No2 inputs.
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Microprocessor
The Dallas 80C320 features two UARTS for serial data input with instruction
execution at about 2.5 times the original Intel design. One advantage is that clock
speed may be kept low which minimises RFI/EMC problems. IC30 31 32 and 36
must all be good for microprocessor to run the software in the eprom.
IC36 is a voltage and program run monitor known as a watchdog. If the 5v dips due
to power failure it stops the microprocessor and restarts it after power is restored.
IC36 a MAX1232 must also receive frequent stimulation from the microprocessor.
The software tickles the watchdog routinely but if this tickling stops (Failure
accidental short circuit)? for half a second the watchdog will bark and reset the
microprocessor.
The microprocessor shifts data into a serial to parallel shift register IC34 37 this being
the required state of synchro output. Note that should the watchdog go to a reset
condition as at switch on and switch off the shift register is instantly cleared
preventing erroneous operation of the synchro drivers.
The alarm circuit includes buzzer bi-colour led and relay controlled by the
microprocessor program via IC42. The external alarm relay goes to alarm state
when alarm is switched off. This is intentional. A remote alarm should have its own
disable facility.
EMC
I have made mention of the design features which minimise EMC. The ground plane
of the pcb is another feature. All the tests we have made as with all other AMI
products make it easy for us to certify the product as compliant with the EMC
directive.
MEASURING PHASE SHIFT ON OUTPUT
If at all possible we would like to check the phase shift due to reactive loading of the
synchro output. If it is significant we will have to fit capacitors to tune it out. It is
important that this test is done on all new installations until we have built a data base
of what is found in practice. It requires a dual beam oscilloscope of no great
bandwidth. The usual engineers portable scope will be fine.
Do this test from the start of putting the repeaters on line and certainly at the end with
all repeaters connected.
Use the wires on the 1 ohm resistors R71 72 to make the connection.
Connect one channel probe to S1 its earth clip on S2 bottom end of R72 (it is alright
to earth S2 if it is a battery scope all the better). This measures S1 - S2 voltage.
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Connect the second channel to the top end of R72. This measures the voltage
across the resistor to indicate S2 current.
Get a stable picture of two sine waves and draw it on paper. Please try to measure
any phase shift between the two waveforms and fax us with your picture.
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Blue
SK4
0
Black
12V 1A
Orange
Red
12V 1A
Orange
Red
White
Yellow
Violet
Green
SK1
SK3
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UNCONNECTED WIRES
ARE TERMINATED IN
THE TEMINAL BLOCKS
REFERENCE SUPPLY
White
Violet
Black
Black
Black
TERMINAL BLOCK
ON CHASSIS PLATE
110
140
110
SK4
SK2
REFERENCE SUPPLY
SK1
SK3
Orange
Red
White
Yellow
Violet
Green
REFERENCE SUPPLY
Black 0V
White 88V
Violet 50V
Blue
110
Black
Grey
White
Yellow
Violet
Green
White 112V
Violet 86V
Black 0V
12V 1A
SK1
Brown 140
Blue
110
Black
Black
Grey
140
POWER INPUT
CONNECTOR
INPUT: AS SELECTED
REFERENCE OUT: 50 VOLTS
MAX PHASE OUTPUT: 68 VOLTS
Blue
Orange
Red
Green
White
Yellow
Violet
SK3
Orange
Red
White
Yellow
Violet
Green
SK2
INPUT: AS SELECTED
REFERENCE OUT: 112 VOLTS
MAX PHASE OUTPUT: 86 VOLTS
110
Grey
Brown 140
110
Grey
Brown 140
Orange
Red
Brown 140
SK4
POWER INPUT
CONNECTOR
White
Yellow
Violet
Green
SK2
POWER INPUT
CONNECTOR
TRANSFORMER SETUP
BOARD LAYOUT
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