KW910-M

SYNCHRO INTERFACE

AMI MARINE (UK) LTD

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Document Date Modification Number (where applicable)

Issue Brief Record of Change and Reason for Change
1 28.05.03 Original Issue
2 03.12.03 Addition of Option Table
3 09.06.06 Addition of Front Cover

NOTE: All alterations must be verified by re-authorisation and approval of the complete
document.

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SYNCHRO INTERFACE

KW910-M

TECHNICAL MANUAL

CONTENTS

INTRODUCTION ..............................................................................................................................................7
SPECIFICATION ..............................................................................................................................................7
INSTALLATION GUIDE....................................................................................................................................9
SYNCHRO INPUT SK1. ...............................................................................................................................9
SW1 FUNCTION CONFIG TABLE ...............................................................................................................9
ALIGNMENT OF SYNCHRO ........................................................................................................................9
DATA INPUT SK3 .......................................................................................................................................10
DATA OUTPUT SK3 ...................................................................................................................................10
POWER SK2...............................................................................................................................................10
SW2 FUNCTION CONFIG TABLE .............................................................................................................11
KW910 RUDDER SENSOR ANGLE INTERFACE ........................................................................................12
FIRST STEPS .............................................................................................................................................12
READING AND ADJUSTING THE EPROM ...............................................................................................12
CHECKING THE RUDDER SYNCHRO SCALING OR CALIBRATION.....................................................12
TRANSLATION TABLE ..............................................................................................................................13
ENTERING THE TRANSLATION TABLE...................................................................................................13
USEFUL EXTRAS.......................................................................................................................................14
SETTING TO WORK AND TESTING.............................................................................................................14
CIRCUIT BOARD ...........................................................................................................................................15

AMI MARINE (UK) LTD

Unit 2
Tower Lane
Eastleigh
Hampshire
SO50 6NZ
United Kingdom

Tel No: +44 (0) 23 8048 0450

Fax No: +44 (0) 23 8065 1126

Email: [email protected]

Web: www.amimarine.net

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INTRODUCTION

The interface converts synchro transmission to NMEA 0183 or IEC 61162 data.
Applications include

• Gyro compass for radar, ECDIS and heading displays.

• Rudder Sensor Angle used with a VDR.
• Telegraph, pitch, rudder demand; The “XDR” sentence can be used for many
synchro systems.
• Wind speed and direction
• Log speed

The interface is a precision device, and does not require alignment in the 1:1 mode. The
interface can convert gyro ratios such as 90:1. A DIP switch selects reference voltages
over the range of 40 to 220 and signals from 40 to 90. The function and choice of data
output is set by a second DIP switch.

SPECIFICATION

INPUT 1: Synchro 40 to 550 Hz. Reference 40 to 220v. Phases 40 to 90 volts.

Loading resistors 91K to 270K ohm per phase. 22K reference.
The phases have a common connection at centre of the three phase scaling
resistors to the power input 0v. Reference input is isolated by transformer.
We can supply KW910’s for voltages outside the range mentioned and for
extreme precision.

Conversion 12 bits, 0.1 degrees.+/- 0.5 degrees. Conversion rate 40 per

second.

INPUT 2: NMEA 0183 port. 4800 baud.

Gyro option: Programmed for all NMEA heading sentences input.

Rudder Sensor Angle option: Input a 2nd rudder angle (or rudder demand)

Wind option: Use a 2nd interface to input speed or direction.

XDR option: A second transducer value can be input.

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OUTPUT: 5v CMOS 5 mA via 47 ohms. NMEA 0183, RS422, RS232 compatible.

Data is 4800 baud NMEA 0183 format, plus an Anschutz Coursebus option.
Generally 1 per second. Refer to option list.

Gyro options: $HEHDT, $HEROT, $HCHCC, $HCHDM.

Rudder sensor angle: RSA does not necessarily = actual rudder angle.
Outputs a $ERRSA synchro transducer angle sentence with two values, first
the interface’s own angle, the second field taken from the first field entered
via the NMEA input port

Wind option: $WIMWV. The interface outputs wind speed OR direction.

The other field can be filled by input from the NMEA input port.

XDR option: More than 8 XDR identities, switch selectable. Outputs a

$ERXDR synchro transducer angle sentence with two values, first the
interface’s own angle, the second field taken from the first field entered via
the NMEA input port

POWER: 9 to 32 v DC at 0.2 amps.

ENCLOSURE: Duck Egg blue diecast box 222 x 155 x 55 mm for indoor bulkhead
mounting.

CABLE ENTRY: Glands for 7 mm diameter cables.

FEATURES: LEDs on data in and out plus bicolour status led. Connections are lift-off
terminal blocks.

RATIOS, SCALE OFFSET AND ALIGNMENT:

Synchro is generally assumed 1:1 with a synchro natural zero = 0 degrees,
midships etc. The KW910 may be adjusted for an offset angle by inserting a
correction in the EPROM. The ratio, or calibration scale, can be changed by
various means such as keying a table of 360 values into the EPROM or
changing the mathematics of a multiplication. This allows synchro angle to
be translated into rudder angle, for instance. More precise details are given
in the option table, and an application note is available for engineers familiar
with binary and hexadecimal programming.

ALIGNMENT: For ratios other than 1:1 an optional extra 4 button keypad is required and
may be fitted in the factory at the time of order for a small extra charge

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INSTALLATION GUIDE
The unit may be fitted where convenient. It is a good idea to minimise the length of wiring
of the analogue output to avoid pick up of interference.

If the KW910 has a keypad and needs to be aligned then it should be fitted near a
display, for example the radar. The box should be grounded. The connectors lift off to
ease wiring up. The enclosure must be earthed.

SYNCHRO INPUT SK1.

You are advised to use miniature overall screened cable and earth the screen.

SW1 FUNCTION CONFIG TABLE

Reference voltage selection. 0 = off. 1 = on.

SW1 1 2 3 4 5 6 7 8 9 10 11 12
Reference
voltage
40 – 100 1
101-220 0

Phase or signal maximum voltage selection

SW1 1 2 3 4 5 6 7 8 9 10 11 12
Phase
voltage
40-60 1 1 1 1 1 1 1 1 1 1
61-75 0 1 0 1 0 1 0 1 0 1
76-90 0 0 0 0 0 0 0 0 0 0

ALIGNMENT OF SYNCHRO
The synchro natural zero position must be found by adjusting the wires to R1, R2 and S1,
S2, S3. There are 12 combinations possible.

The KW910 is a precision device and if the exact synchro angle is not output the synchro
itself needs to be turned. Alternatively an offset may be entered in the eprom as
described for the RSA interface, or as a 12 bit binary value in some cases.

For gyro ratios other than 1:1 a keypad is fitted to the interface. Hold Align for three
seconds, keep holding and use the INC and DEC buttons.

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DATA INPUT SK3

The NMEA 0183 or proprietary input is wired to the data A & B input. If you have any
doubt about the data read it on a PC. Ideally ground the cable screen at the sending end,
but if this is not possible ground it with a short connection elsewhere, to avoid radiating
radio interference.

When used for synchro gyro heading this port can be used for a back-up heading input.
The rudder angle from a second RSA interface can be input, when the data out gives dual
rudder sensor angles. Similarly with the XDR option.

DATA OUTPUT SK3

If the receiving device is RS232 rather than NMEA 0183 it grounds the data line. For
RS232 use the A and 0 connection.

There have been several instances of the output of the KW910 being blown due to
connecting the data out to ground. That could ground the ship’s DC supply via the
interface. Switch on and make sure no voltage exists between SK3 and the data wire,
before making the connection. The output resistor R12, 47 ohms, being burnt out is a
sure sign of having applied a high voltage to the data out. Such damage is not covered by
warranty.

The data may be read on a PC or a data reader if the format is NMEA 0183. Caution,
your PC may ground the data line and the interface power source! This will prove that
the correct data is being received by the interface, and so the output will be
correct. Data such as Anschutz Coursebus is not readable.

POWER SK2
9 to 32 volts DC. The data out common is connected to the power 0 volt line.

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SW2 FUNCTION CONFIG TABLE

Refer to the option list and set it according to your need. 1 = on. 0 = off.

Option Switch Ratio Data out Data

00 00 0000 1:1 HEHDT + HEROT Head & ROT 1 per second
01 00 0001 1:1 HEHDT + HEROT Head & ROT 1 per sec + when heading changes
02 00 0010 36:1 HEHDT + HEROT Head & ROT 1 per sec + when heading changes
03 00 0011 90:1 HEHDT + HEROT Head & ROT 1 per sec + when heading changes
04 00 0100 360:1 HEHDT + HEROT Head & ROT 1 per sec + when heading changes
05 00 0101 1:1 HEHDT Heading 10 per second
06 00 0110 1:1 HCHDM Heading 10 per second
07 00 0111 1:1 HCHCC Heading 10 per second
Anschutz
08 00 1000 1:1 Heading 10 per second
Coursebus
Anschutz
09 00 1001 90:1 Heading 10 per second
Coursebus
0A 00 1010 1:1
Rudder sensor Insert offset angle Packed BCD hi-lo 5B-5C
0B 00 1011 1:1 ERRSA
angle 0000 to 3599 Default = 0000 = no offset
Uses Translate table 0
0C 00 1100 1:1 ERRSA Rudder angle
For 4:1 rudder sensor
Translate table 1
0D 00 1101 1:1 ERRSA Rudder angle
As yet unused
Translate table 2
00 1110 1:1 ERRSA Rudder angle
As yet unused
Translate table 3 As yet unused
0F 00 1111 1:1 ERRSA Rudder angle
Change pointer at hi-lo 5D 5E
Identity = 10 as set on the switch
10 01 0000 1:1 ERXDR Transducer angle
Offset 12 bit binary hi-lo 62-63
11 01 0001 1:1 ERXDR Transducer angle “
12 01 0010 1:1 ERXDR Transducer angle “
13 01 0011 1:1 ERXDR Transducer angle “
14 01 0100 1:1 ERXDR Transducer angle “
15 01 0101 1:1 ERXDR Transducer angle “
16 01 0110 1:1 ERXDR Transducer angle “
17 01 0111 1:1 ERXDR Transducer angle “
18 01 1000 1:1 ERXDR Transducer angle “
19 01 1001 1:1 ERXDR Transducer angle “
1A 01 1010 1:1 ERXDR Transducer angle “
200 knots max.
1B 01 1011 1:1 WIMWV Wind speed Scaling set by 5F=250 decimal
60-61 hi-lo = offset 12 bit
100 knots max by look up table. Start address sent
1C 01 1100 1:1 WIMWV Wind speed
at start up
1D 01 1101 1:1 WIMWV Wind direction Wind Direction. 60-61 hi-lo = 12 bit binary offset
rd
100 knots = 1 synchro rev -25 ..0 ..+75. 3 quadrant
Longitudinal is astern
1E 01 1110 1:1 VMVBW
Water speed Loc 62-63 hi-lo = offset binary
Loc 5F = scaling. 250 dec= 100 kts
Longitudinal 48 knots = 1 synchro rev Volts input to NMEA port =
1F 01 1111 1:1 VMVBW
Water speed astern
NOTES
#01. The fastest update is whenever heading changes.
#0B. Rudder sensor angle does not always equal actual rudder angle.
#0C. You can use first an offset angle to correct for synchro angle, then use the translate
table. Translate table is 360 values described in detail later.
#0B – 0F RSA is dual. Input the second angle via NMEA input port.
#1E, 1F. Unused fields are sent as null fields.

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KW910 RUDDER SENSOR ANGLE INTERFACE

HOW TO MAKE THE INTERFACE OUTPUT TRUE RUDDER ANGLE.

The NMEA 0183 RSA sentence is for rudder sensor angle, stating specifically that it may
not equal actual rudder angle. This procedure can be used when the actual rudder angle
is needed, rather than the raw synchro rudder sensor angle.

It is suggested that first you compensate for synchro offset angle, so that when rudder is
midships the angle given out by the KW910 = 0. Next, you can compensate for the rudder
angle and synchro angle not being geared in a one to one relationship. You could do this
all in one operation but this describes how to do it step by step.

FIRST STEPS
Ensure that the LED is steady green. Set config switch to “10” hex, 01 0000 and read the
data out, which will be the transducer sentence XDR. Until you have made sense of how
synchro angle corresponds to rudder angle you can not proceed.

DISCOVER SYNCHRO OFFSET ANGLE.

Move the rudder a few degrees and check that the angle increases for starboard rudder.
If not, then reverse a pair of phase wires. Note the difference between 360.0 and the
indicated XDR angle. This is the correction to put in. For example, at midships if XDR is
167.2 the correction is 192.8.

READING AND ADJUSTING THE EPROM

Read the EPROM via your programmer. All EPROM values are given in hexadecimal

LOCATIONS 5B and 5C = the correction, in packed hundreds, tens, units and tenths. To
make a correction of 192.8 degrees;
5B = 19 hex
5C = 28 hex

Program a new EPROM with the correction and check it out in the KW910. XDR will still
indicate the true synchro angle; that has not been corrected. Set SW2 to “0B”, 00 1011,
and the sentence will change to $ERRSA and midships should now indicate zero
degrees, or very close. The RSA is rounded to the nearest degree.

CHECKING THE RUDDER SYNCHRO SCALING OR CALIBRATION.

Move the rudder. If the ratio between rudder and synchro is 1:1 then the correct rudder
angle will be indicted. If it is not the same then the ratio is not 1:1. You can now make a
translation table, and one is already provided for 4:1 as option “0C”, described as table 0
at start-up.

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TRANSLATION TABLE
The table has 360 values going from 0, midships, to 359, which is a synchro angle of one
degree to port. Make your table, which will look something like this incomplete list.

Negative values are indicated by characters 8 to F, so you can only achieve a rudder
angle of +/- 79 degrees. Impossible angles should be filled with FF.

RSA RUDDER ANGLE. VALUE TO ENTER

00 00 00 hex
01 00 00 hex
02 00 00 hex
03 01 01 hex
04 01 01 hex
05 01 01 hex
06 02 02 hex

102 34 34 hex (That is packed BCD, not decimal value)

and so on through ALL values to extreme starboard rudder travel.

120 out of range FF hex Enter FF for impossible values.
121 out of range FF hex

Hard aport rudder values now appear

239 -40 C0 hex C = -40 to -49
240 -39 B9 hex B = -30 to -39
270 -29 A9 hex A = -20 to -29
305 -15 95 hex 9 = -10 to -19
357 -1 81 hex 8 = -0 to -9
359 0 00 hex midships

ENTERING THE TRANSLATION TABLE

On start up read the message which gives the start location of the table. Example,
$ERTXT,,,RSA TABLE0 2E4C. Table 1is the location where you need to start entering
the table. You will find the locations all preset to zero at first. It is helpful to have an
assistant call out the values as you key them in, and double check that all 360 values are
entered. You can see table 0, the 4:1 table, as a guide.

Once that is program a new EPROM and select option 0D. The angle in the RSA
sentence will correspond to your table.

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USEFUL EXTRAS
Within program MP3 and its later versions locations 5D and 5E point to the translation
table to be used.

The location of RSA TABLE 0 is mentioned at start up and is a table for a ratio of 4:1.
That is, +/- 180 degrees synchro angle corresponds to +/- 45 degrees of rudder angle.
This was used to test the program in development and was chosen because 4:1 exists at
sea. If you want to use it select option 0D.

The location of these tables is not mentioned in this document since they will move if the
program code is changed. The latest location is always output on start up.

SETTING TO WORK AND TESTING.

SWITCH ON!
The status led will go to green if all is OK on 1:1 ratio or NMEA input. For other ratios,
which require alignment, it will not go green until aligned.

DATA OUT:
The Data output led will flash. Read the NMEA heading on a reader or instrument. At
installation time the heading will probably not be the same as the gyro, because the
reference and phase lines are not correct.

ADJUSTING THE PHASES.

You are advised to write down the colour and connection and change S1, S2, S3 plus
reversing R1, R2, until the heading comes right. There are 12 possibilities, and there is no
easy way of determining the correct combination.

The synchro natural zero, 120 and 240 positions occur with zero volts on one phase and
equal voltages across the other.

The KW910 is a precision device, and requires no alignment in the 1:1 mode. If it does
not finally agree with the gyro then the gyro synchro transmitter may be wrongly aligned.

FAIL-SAFE OR BACK-UP.
If the synchro goes faulty the interface will accept, and retransmit, heading from the
NMEA input channel.

NOTE CONCERNING SHARING A SYNCHRO.

The interface input circuit is not isolated from ground or supply. This could have
implications if going in parallel with another electronic interface.

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CIRCUIT BOARD

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