KW991-HR

HEADING REPEATER
AMI MARINE (UK) LTD

AMI Manual KW 991

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Document
Issue
1
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Date

Modification Number (where applicable)

Brief Record of Change and Reason for Change
15.11.02 Original Issue
14.10.05 Update of company contact details
16.05.08 Change of address

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

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AMI Manual KW 991

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HEADING REPEATER MODEL KW991

HEADING REPEATER
TECHNICAL MANUAL
CONTENTS

INTRODUCTION .................................................................................................................7
SPECIFICATIONS ...............................................................................................................7
INSTALLATION NOTES ......................................................................................................9
OFF COURSE ALARM or COMPASS COMPARATOR ALARM .......................................10
SYNCHRO TYPES.........................................................................................................10
STEPPER TYPES..........................................................................................................10
GYRO INTERFACE WIRING.............................................................................................11
KW991 OPERATORS GUIDE ..........................................................................................13
KEY PAD FUNCTIONS..................................................................................................13
ALARM LOGIC ..................................................................................................................13
COMPASS COMPARATOR ALARM .............................................................................14
TYPICAL ALARM OPERATION.....................................................................................14
HEADING REPEATER MAINTENANCE ...........................................................................15
BOARD LAYOUT...............................................................................................................16

AMI MARINE (UK) LTD

Unit 2
Tower Lane
Eastleigh
Hampshire
SO50 6NZ
United Kingdom
Tel No:
Fax No:

+44 (0) 23 8048 0450

+44 (0) 23 8065 1126

Email:

technical@amimarine.net

Web:

www.amimarine.net

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INTRODUCTION
A bright green vacuum fluorescent dot matrix display presents ships heading from the gyro
or magnetic compass. The VF display overcomes the disadvantages of other electronic
displays such as LCD, such that it can be seen in dark environments, and has a higher
contrast.
Screen presentations of heading are two TAPE displays, DIGITAL display and DIGITAL
with RATE OF TURN indicator, and OFF COURSE ALARM.
The unit connects to all standard gyro transmissions, and magnetic electronic compasses.
With two inputs, gyro and magnetic, the unit will change over to magnetic if gyro fails. As
an off course alarm it would normally receive only magnetic compass heading, but can
work from gyro or a second gyro.
An NMEA 0183 output (or proprietary data) is given so the unit is ideal as a gyro converter
for Autopilot and electronic chart systems.
SPECIFICATIONS
INPUT 1.

Stepper or 360:1 synchro gyro Sperry 90 x 400Hz transmission. (M type

and 1:1 / 36:1 synchro and raw rectified stepper tracking rate > Freq/3
degrees per second. NMEA 0183 heading input to order (i.e. 2 NMEA inputs)

INPUT 2.

NMEA 0183. All valid heading sentences, plus Cetrek and Yokogawa 4800
proprietary data.

OUTPUT 1. NMEA 0183 heading sentence.

OUTPUT 2. 5v 10mA drive.
DISPLAY:

Futaba vacuum fluorescent display 256 x 64 pixels. Viewing area 166mm x

41mm. Luminescence 540 cd/m2 typical. Protected by an anti-glare filter.

CONTROLS: Illumination, alignment and screen presentation via a waterproof pad.

POWER:

10 to 35 volts DC at 12 watts. (Switch on surge 3A).

HOUSING:

260 x 160 x 90 mm diecast aluminium housing. Provided with a trunnion

mount. Flush mount optional extra.

Note: DISPLAY FOR OUTSIDE USE

The unit is not designed to be fitted permanently in exposed positions. The main reason is
that the high-voltage fluorescent screen will not tolerate any ingress of moisture and we
cannot guarantee 100% weatherproof.
Units damaged by outside use are not covered by warranty.

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DISPLAY TRUNION MOUNT

260

90

160

4 x 13mm
CABLE
GLAND

ALLOW 350 mm

CABLE GLANDS FOR

KW 991 HEADING REPEATER
1. POWER AND NMEA I/P AND NMEA O/P
2. GYRO I/P

CABLE GLANDS FOR

KW 992 SMIDS DISPLAY
1. POWER AND NMEA I/P

DISPLAY FLUSH MOUNT

290

190

160

4 x 13mm
CABLE
GLAND

100
4 x 5mm
HOLES

CABLE GLANDS FOR

KW 991 HEADING REPEATER
1. POWER AND NMEA I/P AND NMEA O/P
2. GYRO I/P

CABLE GLANDS FOR

KW 992 SMIDS DISPLAY
1. POWER AND NMEA I/P

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INSTALLATION NOTES
SITING
Pre-planning and fore thought is essential for the practical siting of the display for best
visibility and access. It should be mounted so that it can be viewed from most positions on
the bridge, and with consideration against the bright sunlight.
Even with the anti-glare filter, direct light reflected off the screen can hinder its
performance. Adjustment of angle in its trunnion may help reduce the effect of reflections.
CONNECTIONS
Remove the lid of the unit taking care when detaching the cables from the interface board.
Use the levers to remove the ribbon cable connector.
GYRO INPUT
The interface allows connections to most as per the input specifications.
For M type transmission and 1:1 or 36:1 synchro an additional PCB has to be fitted to
order. The standard interface can connect to M type with a suitable EPROM but of
resolution to 1/3rd degree only not 1/6th.
NMEA 0183 INPUT
Use screened cable and earth from the sending end.
NMEA 0183 OUTPUT
Use A-B to drive pure opto isolated NMEA 0183 receivers. Use A-0 to drive computers and
non-standard equipment. Earth the screen at the heading repeater.
5v DRIVER OUTPUT ALARM OUTPUT with reference to SK1-6 the 0v line
D1 and D2 normally low and +5v on alarm. D3 normally +5v and 0v on alarm. The drive
capability is 10mA. It may be used to drive a low power audible alarm directly, or to drive
an external low power relay to switch a higher power alarm.
ALTERATIVE 5v OUTPUTS
These 5v outputs can be changed through the EPROM to give an output from the following
selection; 5v stepper output. Furuno clock and data output. Yokogawa data output.
Reversed heading output. Alarm output, tick output.
TESTING
If the heading turns the wrong way reverse one pair of phase wires i.e. S1 and S2.
Read the data output on a laptop PC or any other device that can read NMEA 0183. It can
give data in plain language, which is the prime source of faultfinding information.

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OFF COURSE ALARM or COMPASS COMPARATOR ALARM

The appropriate EPROM configures the unit as one or the other.
An Off Course Alarm will detect the vessel straying off the set course.
A Compass Comparator Alarm will detect a gyro failure by comparing two heading inputs
(Also this may detect you going off course).
N.B. The KW991 repeater is not your gyro alarm
VARIATIONS
Different data outputs are achieved by changing the EPROM. Please advise us of your
requirements so we can assure total satisfaction.
GYRO TRANSMISSIONS
This list is correct with information supplied from the manufacturers.
SYNCHRO TYPES
ARMA BROWN
.
AMUR CC150
.
ANSHUTZ Std 4 Std 6
GYLOT
.
.
HOKUSHIN PY76-N2
KURS 4
.
.
MICROTECHNICA .
PLATH Type 71
.
SG BROWN .
.
TOKIMEK
.
.
VEGA 1404KN
.
YOKOGAWA NAVITEC

1:1 synchro use KW910 interface

115v ref. 50/60v 500Hz sigs, synchro 360:1
50/60v ref. 20/24v 50/60Hz sigs, synchro 360:1
36:1 synchro use KW910 interface
115v ref. 90v sigs, 360:1 synchro, double-check.
110v ref. 50v 60Hz sigs, synchro 360:1, others also.
115v ref. 90v 60Hz sigs.
115v ref. 90v 60Hz sigs, double-check.
1:1 synchro use KW910 interface
1:1 synchro use KW910 interface
115v ref. 60v 60Hz sigs.
110v ref. 60v 60Hz sigs, if 24v DC on synchro treat as M-type.

STEPPER TYPES
ADMIRALTY M TYPE
24v M-type (EPROM option)
ANSHUTZ Std 20 .
24v steps. NMEA 0183 or Anshutz private format.
ARMA BROWN Mk1
+steps.
ARMA BROWN Mk10
steps.
SG BROWN 1000 .
steps.
PLATH NAVIGAT 7,8
steps. Also 48step/degree bipolar.
ROBERTSON SKR80
+ and steps. Both encountered please check.
ROBERTSON SKR82
NMEA 0183 9600 baud.
SPERRY Mk 20
.
Unsmoothed rectified or +steps. Check for both.
SPERRY Mk 37
.
Unsmoothed rectified 35v steps.
SPERRY SR120, 130,140 35v steps.
SPERRY VT6
.
steps. NMEA 0183 $HEHDT, xxx,xxxx,T
TOKIMEK
.
.
400Hz contactless transmitter (90x)
TOKIMEK
.
.
35v steps.
YOKOGAWA CMZ250/300x
35v steps. YOKOGAWA proprietary data.
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GYRO INTERFACE WIRING

FINAL PHASING ADJUSTMENT
If heading turns the wrong way reverse one pair of wires, S1 and S2.
PURE DC STEPPER NEGATIVE STEPS
S1
to
S1
S2
to
S2
S3
to
S3
Common + to
S1+, S2+, S3+ (Most common stepper system)
PURE DC STEPPER POSITIVE STEPS
S1
to
S1+
S2
to
S2+
S3
to
S3+
Common to
S1, S2, S3
UNSMOOTHED RECTIFIED STEPPER
This is raw rectified. You can measure using a scope. On a multimeter you can measure a
voltage on AC range where as with pure DC you should not measure a voltage. This
connection uses the gyro repeater + and supply which is normally provided for
illumination, and is the source for the stepper signals. This is called the Common + and .
UNSMOOTHED RECTIFIED STEPPER NEGATIVE STEPS
S1
to
S1
S2
to
S2
S3
to
S3
Common + to
R1+, S1+, S2+, S3+
Common to
R2
UNSMOOTHED RECTIFIED STEPPER POSITIVE STEPS
S1
to
S1+
S2
to
S2+
S3
to
S3+
Common + to
R1+
Common to
R2, S1, S2, S3
UNSMOOTHED RECTIFIED STEPPER NEGATIVE STEPS. Neg. line not available
S1
to
S1 and via a diode to R2
S2
to
S2 and via a diode to R2
S3
to
S3 and via a diode to R2
Common + to
R1+, S1+, S2+, S3+
UNSMOOTHED RECTIFIED STEPPER POSITIVE STEPS. Pos. line not available
S1
to
S1+ and via a diode to R1+
S2
to
S2+ and via a diode to R1+
S3
to
S3+ and via a diode to R1+
Common to
R2, S1, S2, S3
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M-TYPE STEPPER (Requires EPROM option)

S1
to
S1+ and S3
S2
to
S2+ and S1
S3
to
S3+ and S2
SYNCHRO 1 REV PER DEGREE. (N.B. DC SYNCHRO DO NOT CONNECT R1 AND
R2)
S1
to
S1+ and S3
S2
to
S2+ and S1
S3
to
S3+ and S2
R1
to
R1+
R2
to
R2
CONNECTION FOR 90x CONTACTLESS TRANSMITTER or SYNCHRO
This is found as the basic transmitting device in some Sperry and Tokimek gyros. It looks
like a synchro but has 6 connections instead of 5. The reference is fed with 115v 400Hz.
S1
to
S1+
S2
to
S2+
S3
to
S3+
R1
to
R1+
R2
to
R2
N
to
S1, S2, S3.
If this does not work reverse R1 and R2.
The 2 NMEA input version does not allow connection to stepper or synchro.

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KW991 OPERATORS GUIDE

KEY PAD FUNCTIONS
{

Switch off Display illumination.

Switch on Display illumination.

Increase illumination. Increase OCA or CCA window.
Decrease illumination. Decrease OCA or CCA window.
Hold for 3 seconds to enter alignment mode. Keep holding then use INC and
DEC to align heading. Heading MUST be aligned or the wrong course will be
displayed! Heading from an NMEA 0183 source can not be changed here;
you must change it at its source.
Press to accept a CHECK ALIGNMENT error message and CHECK IT.
Press to save or clear Course to Steer.
Hold at Switch On to enter demonstration mode.
Press to change the screen functions.
1) Tape repeater at 8 pixels per degree showing > +/ 30 degrees.
2) Tape repeater at 10 pixels per degree showing > +/ 25 degrees.
3) Digital heading and rate of turn indicator. (Degrees per minute).
4) Very large heading display. (Rounded to nearest degree).
5) Off Course or Compass Comparator Alarm.

ALARM LOGIC
GYRO (OR MAGNETIC COMPASS) ALARMS
CHECK ALIGNMENT is given whenever a false gyro stepper or synchro state is detected
even if briefly. If this message is persistent it indicates a gyro transmission fault NOT a
fault with the Heading Repeater. Pressing AL will clear the Alarm State.
GYRO FAIL occurs after loss of gyro signal for several seconds.
The AUDIBLE alarm (if fitted) will sound on a heading fault ONLY if an alarm has been set.
To accept and cancel the audio alarm press the AL button.
OFF COURSE ALARM
The alarm is OFF when there no Course to Steer and / or the off course limit window is set
to zero. The display and audio alarms become active when both CTS and window are set.
(By toggling the AL button)

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TYPICAL OCA OPERATION

When the ship is on passage select the OCA screen and open the window by using INC.
(DEC to decrease it). Press AL to save your present heading as CTS. You will see the bar
indicate the deviation from the CTS. The alarm will be raised if the bar passes the window
limit lines. (You only need to come back to this screen to alter the window limit lines).
The Off Course Alarm will remain active with whatever screen you now select. Thus you
can now use it as a heading repeater on a tape display.
When you are going to change to a new course you can disable the alarm by pressing AL
to clear CTS. (You do not need to go back to the OCA screen). Bring the ship steady on
the new course and press AL again to save the new course and reactivate the OCA.
For harbour entry go to the OCA screen and set to zero. The CTS function can then be
used to save steady as she goes heading.
CAUTION
1.
The Off Course Alarm is really an OFF HEADING ALARM! It can not monitor your
actual course made good.
2.
An OCA should take its heading from a source separate to that used for steering.
i.e. Autopilot from gyro OCA from magnetic compass.
COMPASS COMPARATOR ALARM
The alarm is OFF when disabled or the limit window is set to zero. The display and audio
alarms become active by toggling the AL button. The comparator alarm compares the two
heading inputs and ideally they should always stay the same. If one input failed and the
two diverged by more than the window setting, the alarm will be raised.
If the second input is TRUE (Gyro or SMIDS) the difference between the two is used and
displayed. If the second input is magnetic there could be a substantial fixed difference
between the two so the CCA allows for this and stores a correction to make them equal at
the time the alarm is enabled. (In effect applying correction for variation and deviation at
the time of pressing AL.
TYPICAL ALARM OPERATION
When the ship is on passage select the ALARM screen and open the window limits by
using INC. (DEC to decrease it). Press AL to set the alarm. You will see the bar indicate
the divergence of the two headings. The alarm will be raised if the bar passes the window
limit lines. (You only need to come back to this screen to alter the window limit lines).
The Compass Comparator Alarm will remain active with whatever screen you now select.
Thus you can now use it as a heading repeater on a tape display.
When you are going to change to a new course you do not disable the alarm, for both
inputs should stay synchronised. In a perfect world you need not switch the alarm off!
Unfortunately electronic magnetic compasses are prone to show errors as you change
course and location or pass close to large steel structures.
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HEADING REPEATER MAINTENANCE

DISPLAY MODULE SCREEN
Clean the screen using Anti-static cleaning pads or lint free cloth and glass polish.
DO NOT use abrasive cleaners or scouring pads, as the filter material is soft and will
scratch easily.
LEDS and DATA OUTPUT
Self-explanatory LEDs on the PCB give confidence in the operation of the unit. The NMEA
data output can be read on a PC and is a further source of test data.
The NMEA 0183 output can be used to drive other instruments.
POSSIBLE PROBLEMS
The repeater will indicate CHECK ALIGNMENT if it detects errors on the gyro signals
input. In that case investigate possible problems with the gyro Retransmission Unit. It is
common for lightly loaded stepper drivers to produce errors. In that case then fit 470 load
resistors in the gyro stepper RTU.

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BOARD LAYOUT

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