DIGITAL TO SYNCHRO CONVERTER

KW960-C
AMI-GFV MARINE

DIGITAL TO SYNCHRO CONVERTER.

KW960-C.

TECHNICAL MANUAL
CONTENTS
1

Contents

Data sheet

Setting to work

Layout and schematics

The schematics are from a screen dump and are not fully readable
The picture shows the KW960C with step up transformer adapter mounted
underneath.

HEAD OFFICE, SALES AND SUPPORT

AMI-GFV Marine Ltd
Parham Drive,
Eastleigh
Southampton
SO50 4NU UK
Telephone 44 (0) 2380 480450. Fax 44 (0) 2380 480451
Email m.k.woods@btinternet.com
Web site www.amimarine.com

DESIGN AND MANUFACTURE

AMI-GFV Marine Ltd,
Cefn Laboratories, Abergavenny UK,
Telephone 01873 840405. Fax 01873 840106
Email af-aditel@btinternet.com
Web site www.aditel.org.uk
Manual written by the designer Andrew Fairgrieve.
Last update 09/11/2005

DIGITAL to SYNCHRO
CONVERTOR KW960-C
DATA SHEET.
The interface receives
data by NMEA 0183 and
generates a low power
synchro, resolver (or
sine-cosine) output.
The interface will drive
typically one or two
synchro motors, or
numerous electronic
interfaces. Applications
are to generate gyro
compass or wind
instrument synchro
signals. Log speed and
GPS speed to synchro
etc is possible.
Applications include the
retro-fitting of a gyro
without a synchro
output.
The KW960 has a number of different ratios from 1:1 to 360:1. Two KW960s can be
used for a coarse and fine servo system as found on military vessels, and with
certain gyro compass transmission systems.
The adjustable voltage output is about 40 volts maximum, so it can be used for an
Anschutz repeater and others directly. For driving known coarse/fine servo systems
the KW960s standard 50v reference output is found sufficient. The synchro
frequency is that of the main power input, so for 400 Hz you need a 400 Hz power
source. For obtaining 115volt ref, 90 volt signals you a step up transformer adaptor.
This is an optional; extra, dont forget to order it.
AMI also make the KW903-SX which is a high power version of the 960 for gyro
transmission at 50/60 Hz.
SPECIFICATION
INPUT:

NMEA 0183 heading HEHDT or GPHDT or wind sentence WIMWV.

EPROM program DSC5 selects HDT if detected, rejecting sentences such as HDM.
EPROM version DSC200 for longitudinal bow water speed from VBW sentence
Scale 200 kts and 5 knots per rev.
EPROM version ROLL2 for pitch or roll. $IIXDR,A,x.x,D,A,x.x,D, etc sentence
EPROM version DSC40 for longitudinal bow water or ground speed
From VBW sentence. Scale 40 knots.

POWER:

115/230v 50 to 400 Hz at 10 VA approx. (Transformer secondary 2 x 25 volts)

OUTPUT:

SYNCHRO. Nominal 10 to 40 volts line-to-line maximum, adjustable by potentiometer.

5VA total. Virtual centre of 3-phase synchro output is at ground.

RESOLVER OPTION. Nominal 20 volts max. (EPROM specific version.)
REFERENCE OUTPUT. Nominal 25 or 50 volts, jumper selected.
(An additional transformer adapter is needed for 115v reference, 90v signals.)
Reference frequency is that of the power input. Reference output is the transformer
secondary.
ACCURACY:

+/-1 degree of synchro position. Approx 9 bits resolution.

This accuracy applies to all ratios.

NMEA INPUT OPTION: Jumper J3 = 0 = heading. J3 = 1 = Wind angle from $WIMWV input.
HEADING RATIO OPTION: Jumper J2 = 1 = 1:1 ratio. J2 = 0 = the ratio as set in EPROM location.
Available ratios 9:1, 10:1, 30:1, 36:1, 90:1, 180:1, 360:1
DUAL LOG SPEED. J2 = 1 = 200 kts/rev. J2 = 0 = 5 knots/rev.
VERSIONS: Standard bulkhead mounting enclosure 300 x 200 x 155.
For a dual (coarse/fine) system 400 x 300 x 155.

PRINCIPLES OF GENERATING THE OUTPUT:

The input angle is read from the data input. The program rotates the synchro output to any new position,
going through all digital states towards it, not just jumping there. This is to attempt to move a synchro
smoothly, reducing the jerk caused by any sudden jump of the input. The rotation rate is adjustable by a
screwdriver switch from about 2 to 10 degrees per second.
There are 360 steps per
revolution in the 1:1 mode.
The graph shows the
relationship of the three
voltages. At 60-degree intervals
two phases become equal and
opposite with the third phase
being zero. Measured from
ground to the S1, S2, S3
outputs, add 30 degrees to the
angle first.
09/11/2005

AMI - GFV MARINE Ltd. Southampton, SO50 4NU UK

TEL 44 (0) 23 8048 0450 - FAX 44 (0) 23 8048 0451/2
Email sales@amimarine.net Web - http://www.amimarine.com

SETTING TO WORK
POWER SK6
SET THE POWER SWITCH 115/230v. The KW960C suffers massive burn out if you apply the wrong
voltage, and of course this is not covered by warranty.
The KW960 will operate from 115 or 220v 50/60 Hz and has been used on 400 Hz. On 400 Hz it gives
400 Hz synchro reference and phases output.
HEADING, WIND or PITCH AND ROLL NMEA 0183 INPUT SK2
For heading J3 = 0, For Wind J3 = 1.
For the log speed version a different EPROM is used. J3 is not used.
For pitch and roll another EPROM version is used. J3 is not used.
SYNCHRO or RESOLVER/SINE-COSINE OUTPUT SK1
The EPROM must be configured for the output.
Location 5C = 00 Hex = resolver or sin-cosine. If 5C is non-zero the output is synchro.
OUTPUT RATIO
J2 = 1 = 1:1 ratio
J2 = 0 = ratio set by location 54 Hex. Values are Hex.
00 = 360:1, 1 rev per degree, the commonest synchro transmission ratio.
FF = 180:1. 90 = 90:1. 36 = 36:1. 30 = 30:1. 10 = 10:1. 09 = 9:1
SPEED INTERFACE
Program DSC200 and later (DSC205 May 2004) provides 2 scales for a coarse-fine system.
J2 = 1 = 0 to 200 knots for 1 revolution of synchro output.
J2 = 0 = 0 to 5 knots for 1 revolution. Multiples of 5 knots act similarly; 5-10, 10-15 etc.
Zero knots is the synchro natural zero position where two phases are equal and one phase is zero volts.
It will doubtless be necessary to change the phase wires to find the right combination for the receiving
equipment. It does not matter which KW960 PCB is used for any particular ratio.
SPEED INTERFACE
Program DSC40 does 40 knots per rev, bow transducer longitudinal speed, using the VBW sentence.
J3 = 0 = water speed. J3 = 1 = ground speed.
PITCH AND ROLL INTERFACE
Program DSCROLL (May 2004) provides1:1 ratio roll and pitch synchro output. In fact it can not know
which is roll or pitch, it just uses the first or second data field in the $IIXDR data input.

$IIXDR,A,x.x,D,A,x.x,D, cr lf
J2 = 1 = use first data field
J2 = 1 = use second data field
Zero degrees is the synchro natural zero position where two phases are equal and one phase is zero
volts. It will doubtless be necessary to change the phase wires to find the right combination for the
receiving equipment. It does not matter which KW960 PCB is used for which field.
There is no NMEA 0183 sentence defined for pitch and roll. The nearest I can find is the XDR
transducer sentence and this is what is used.
SYNCHRO REFERENCE OUTPUT
J6 = F = Full reference, normally 50 volts approx
J6 = H = Half voltage, 25 volts

EXTERNAL REFERENCE INPUT SK3

This is used to input a LOW VOLTAGE excitation voltage, example 2.5 volts RMS 400 Hz. The 3
phase output signals S1, S2, S3 are then at the external reference frequency. This facility is used in
instances when an autopilot provides the excitation voltage for a real synchro transmitter. The reference
output R1-R2 are not affected, it remains at the main AC input frequency.
If you have a 400Hz AC power supply you can run the KW960 from it, and the synchro output will be at
400 Hz.

ADJUSTING FOR EXTERNAL EXCITATION VOLTAGE INPUT.

REMOVE R19 from its 8-pin socket.

(R19 = 4 x 1K5 is used for internal reference derived from the main AC supply.)

R20 is an empty position for a 4-resistor network similar to R20.

a. R20 is selected to drop the reference voltage input to about 2.5 volts.
b. The resistor does not need to be precise because final adjustment is made using R16.
c. The following calculation is approximate. No feedback as to the accuracy of the
calculation has been received.

Calculate a value for individual resistors in R20. Select a resistor greater than that calculated.
a.

At 50/60 Hz
i. R Kilohms = ( V - 2) / 27
ii. Example. For 10 volts RMS each R in network = ( 10 2 ) / 27 = 296 ohms
iii. Use a network of four 330 ohm resistors (RS 434-3727)

b.

At 400 Hz
i. R Kilohms = ( V 2 ) / 20
ii. Example. For 26 volts RMS R = 1.2 K
iii. Use a network resistor of four 1K5. (RS 296-6855)

c.

Square wave input may be encountered from an autopilot generating its own
reference. Use the formula (b) with a voltage V = peak-to-peak / 4.
i. The KW960 will output a distorted square wave due to passing through the
transformer.

PLUG IN R20.

It is essential to follow the guidance for adjusting R16

Do not attempt to connect an external reference supply source to SK1, R1-R2.

VENTILATION
The amplifiers run warm. It is a good idea to leave off the gland plate to allow the circulation of air. This
is commonly left off to ease the passing of cables. Another idea is to remove the gasket material at the
top and bottom of the door. Do not install the KW960 in a very hot place.
STEP-UP TRANSFORMER ADAPTER

Remove the KW960C PCB.

Fit the transformer adapter in its place.
Use M3 30mm spacers to mount the KW960C above the adapter.
Wire across from Synchro output SK1 to the adapter, crossing over R1, R2
Yes, KW960C R1 to TF960 R2. KW960C R2 to TF960 R1

The UNLOADED transformer adapter will give out about 120 volts reference.
It drops on load.

DATA OUT LED LD3. DATA TEST POINT J1

LD3 flashes 1 per second in time with the data output. Regular flashing means that the microprocessor
circuit is running correctly.
Use J1 to monitor the microprocessor operation. A proprietary NMEA 0183 sentence contains in the first
field the angle the KW960 is outputting.

STATUS LED LD4

1. OFF = no power
2. STEADY RED = microprocessor not running correctly
3. FLASH RED/GREEN = Processor OK. Data input is NOT CORRECT FORMAT
4. GREEN = Processor OK. Data input is valid and being used
ROTATION SPEED SW1
Adjust this hex switch for an output rotation speed. 0 is the slowest at about 2 degrees per second and 9
the fastest at about 10 degrees per second. The exception is the 1:1 mode where rotation is fixed at
about 60 degrees per second.
The KW960 can not lose synchronisation with the input. If the output turns too rapidly some repeaters
may not keep up, and in any ratio other than 1:1 could slip out of synchronisation.
ADJUSTING FOR CORRECT PHASE CONNECTIONS
ALWAYS SWITCH OFF BEFORE DISCONNECTING ANY SYNCHRO WIRE. Disconnection can
cause a high voltage spike, which might damage the output drivers.

AT SWITCH-ON in the 1:1 RATIO MODE. This is ideal for setting up the voltage
S1-S2 = 0 volts
S2-S3 = S3-S1 = 0.86 of max phase-to-phase voltage.

The output waveform is not a pure sine wave.

The S1, S2, S3, frequency is either:

The frequency of the main supply (J4 and J5 = INT) or

a. The frequency of an external reference.

On first testing you may find the repeater turns in the wrong direction, and/or is many degrees out of
alignment. Change R1-R2 and S1, S2, S3 wires logically until the repeater indicates and turns correctly.
There are 12 possible combinations. Write them down and eventually you should find the correct
combination. If you do not, then the repeater itself needs alignment.
The natural synchro zero position with one phase measurement = 0v is always assumed to be zero
degree, see the graph on the data sheet.
TESTING THE KW960
If you have any doubt the first thing to do is to read the data output at J1. It will tell you the settings and
show the system is alive and reading the data you input. The data is an NMEA 0183 proprietary
sentence, with the angle as the first data field.
TESTING THE KW960 OUTPUT

Disconnect the load, and make sure the jumpers are set for 1:1 option.

(On a different ratio you must make due allowance. A 360:1 ratio means a 1 degree input
change will rotate the synchro 1 revolution back to the same position! Do not be confused.)

Switch on and measure the synchro output voltages. Adjust R16 to the voltage required.

The absolute voltage does not matter, but the ratios do.

To prove each amplifier observe LD5 LD6 LD7, the output LEDS.
o Also measure volts from ground to S1, S2 and S3. Each should be active.

Refer to the graph and the following tables. At 60-degree intervals one LED will go out.
Angle
030
090
150
210
270
330

S1-GND
LD5
1
1
0
1
1
0

S2-GND
LD6
0
1
1
0
1
1

S3-GND
LD7
1
0
1
1
0
1

Table of angle on 1:1 ratio and voltage on scale of 10 volts.

ANGLE
S1-GND
S2-GND
S3-GND
ANGLE
0 to 10v
0 to 10v
0 to 10v

000
010
020
030
040
050
060
070
080
090
100
110
120
130
140
150
160
170

4.8
6.2
7.5
8.5
9.3
9.8
10.0
9.8
9.3
8.5
7.5
6.2
4.8
3.1
1.5
0.0
1.5
3.1

4.8
3.1
1.5
0.0
1.5
3.1
4.8
6.2
7.5
8.5
9.3
9.8
10.0
9.8
9.3
8.5
7.5
6.2

10.0
9.8
9.3
8.5
7.5
6.2
4.8
3.1
1.5
0.0
1.5
3.1
4.8
6.2
7.5
8.5
9.3
9.8

180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350

TESTING WITH LOAD DIRECTLY CONNECTED (NO TRANSFORMER ADAPTER)

Switch off, connect the load, switch on

Output voltages should remain much the same. Adjust R16 slightly if necessary

Check that the heatsinks do not get very hot.

Synchro repeaters can act as a transformer and feed voltage INTO the KW960, which it
will try to sink, resulting in increased dissipation, which is not wanted.

Rotate the input again; you already KNOW the output rotates correctly.

The synchro repeater should turn.

TESTING WITH A TRANSFORMER ADAPTER

Measure the voltages at the adapter input, and output,

o and you will see them double, OFF LOAD.

The transformer has internal resistance so the output voltage must drop when on load, just
like a signal generator, which has its internal source impedance. You will therefore have to
turn the voltage output higher using R16.

Connect the load and measure the output.

The voltages output may be reduced if the receiver takes power or increased if the
receiver is feeding voltage back into the transformer adapter.

Rotate the input. The synchro repeater should turn in synchronisation.

NOTES ON DRIVING A CONTROL TRANSFORMER
CT loads are highly inductive and it is an advantage to tune it by connecting three capacitors across the
phases, for they then need less power to drive. I do know an easy method of calculating the capacitors,
but values of about 0.1 to 1 microfarad are expected at 60 Hz. The voltage will rise at resonance.
Control transformers may be used in a servo loop system, where a feedback circuit searches for a null.
Often there is a coarse (1:1) and a fine CT of maybe 36:1. The fine control transformer produces a much
more accurate null than the 1:1. Dual KW960s have been supplied for this application.
CT systems will probably work well without the transformer adapter, indeed maybe they will work better
for the low impedance source of the KW960 would be applied directly to the high impedance load.
NOTES ON DRIVING AN AUTOPILOT
Numerous KW960s have been supplied to clients who, so I was told, use them with autopilots. The
KW960 is only capable of controlling to 1 degree in the 1:1 mode but this seems to be suitable.
There has been very little feedback on how well the autopilot works, just more repeat orders for
KW960s.
Andrew Fairgrieve