ICE 3015: CONTROL SYSTEM

COMPONENTS

Class 10: Zeroing Synchros

Dr. S. Meenatchisundaram
Email: meenasundar@gmail.com

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 TX-TDX-TR System Operation
(Addition):
• Frequently it is necessary to set up a TX-TDX-TR system for
addition.
• This is done by reversing the S1 and S3 leads between the TX and
the TDX, and the R1 and R3 leads between the TDX and the TR.
• With these connections, the system behaves as illustrated in figure.
• When the TX rotor is turned to 75º, while the TDX is set at 0º view
A. In the TX, with the rotor at 75º, increased coupling between the
rotor and S1 increases the current in, and consequently the
magnetic field around, that coil.
• At the same time, the field strengths of S2 and S3 decrease
proportionately. This causes the resultant field of the TX stator to
rotate counter clockwise and align itself with its rotor field.

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
TX-TDX-TR System Operation
(Addition):

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
TX-TDX-TR System Operation
(Addition):

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Zeroing Synchros:
• If synchros are to work properly in a system, they must be
connected and aligned correctly with respect to each other and to
the other devices with which they are used.
• The reference point for alignment of all synchro units is
ELECTRICAL ZERO.
• The mechanical reference point for the units connected to the
synchros depends upon the particular application of the synchro
system.
• Whatever the application, the electrical and mechanical reference
points must be aligned with each other.
• The mechanical position is usually set first, and then the synchro
device is aligned to electrical zero.

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Zeroing Synchros:
• There are various methods for zeroing synchros. Some of the more
common zeroing methods are
• the voltmeter,
• the electrical-lock, and
• the synchro-tester methods
• The method used depends upon the facilities and tools available
and how the synchros are connected in the system.
• Also, the method for zeroing a unit whose rotor or stator is not free
to turn may differ from the procedure for zeroing a similar unit whose
rotor or stator is free to turn.

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Zeroing Synchros:
• Regardless of the synchro to be zeroed, there are two major steps in
each procedure.
• The first step is the coarse or approximate setting.
• The second step is the fine setting.
• The coarse setting ensures the device is zeroed on the 0º position
rather than the 180º position.
• Many synchro units are marked in such a manner that the coarse
setting may be approximated physically by aligning two marks on
the synchro.
• On standard synchros, this setting is indicated by an arrow stamped
on the frame and a line marked on the shaft, as shown in figure.
• The fine setting is where the synchro is precisely set on 0º.

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
Zeroing Synchros:

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Zeroing Transmitters and
Receivers:
1. Deenergize the synchro circuit and disconnect the stator leads.
NOTE: Many synchro systems are energized by individual
switches. Therefore, be sure that the synchro power is off before
working on the connections. Set the voltmeter to its 0- to 250-volt
scale and connect it into the circuit as shown in view A of figure.

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Zeroing Transmitters and
Receivers:
2. Energize the synchro circuit and turn the stator until the meter
reads about 37 volts (15 volts for a 26-volt synchro). Should the
voltmeter read approximately 193 volts (115 volts + 78 volts = 193
volts), the rotor is at 180º. Turn it through a half revolution to bring it
back to 0º. If you cannot obtain the desired 37 (or 15) volts, use the
lowest reading you can take with the meter. This is the coarse
setting and places the synchro approximately on electrical zero.
3. Deenergize the synchro circuit and connect the meter as shown in
view B. Start with a high scale on the meter and work down to the
0- to 5-volt scale to protect the meter movement.
4. Reenergize the synchro circuit and adjust the stator for a zero or
minimum voltage reading. This is the fine electrical zero position of
the synchro.

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
Zeroing Transmitters and
Receivers:

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Zeroing Differential Synchros:
1. Carefully and accurately set the unit whose position the CDX or TDX
transmits on zero or on its reference position. In the case of the TDR,
deenergize the circuit and disconnect all leads before setting its rotor
to 0º or to its reference position. You may need to secure the rotor in
this position; taping the dial to the frame is usually sufficient.
2. Deenergize the circuit and disconnect all leads on the differential
except leads S2 and S3 when you use the 78-volt (10.2 volts for 26-
volt units) supply from the transmitting unit to zero the differential. Set
the voltmeter to its 0- to 250-volt scale and connect it as shown in
view A of figure. If the 78-volts is not available from the transmitter or
from an auto transformer, you may use a 115-volt source instead. If
you use 115 volts instead of 78 volts, do not leave the synchro
connected for more than 2 minutes or it will overheat and may
become permanently damaged.
Control System Components (ICE 3015)
Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
Zeroing Differential Synchros:

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Electric Lock Method:
• The electrical lock method, although not as accurate as the voltmeter
method, is perhaps tile fastest method of zeroing synchros.
• However, this method can be used only if the rotors of the units to be
zeroed are free to turn and the lead connections are accessible.
• For this reason, this method is usually used on the TR because,
unlike transmitters, the TR shaft is free to turn.
• To zero a synchro by the electrical lock method, deenergize the unit,
connect the leads as shown in figure, and apply power.
• The synchro rotor will then quickly snap to the electrical zero position
and lock.
• If the indicating device connected to the synchro shaft does not point
to zero, loosen the synchro in its mounting and rotate it until the zero
position of the indicator corresponds with the electrical zero.
Control System Components (ICE 3015)
Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
Electric Lock Method:

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Synchro Tester:
• Two types of synchro testers are shown in figure, view (A) and view
(B).
• Each is nothing more than a synchro receiver on which a calibrated
dial is mounted.

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 Synchro Tester:

• Turn the stator of the synchro being zeroed until the synchro tester
dial reads 0º. The synchro is now approximately on electrically zero.
• Momentarily short S1 to S3 as shown. If the synchro tester dial
moves when S1 is shorted to S3, the synchro is not zeroed. Check
the tester dial to ensure it has not slipped. If the tester dial has not
slipped, move the synchro stator until there is no movement when S1
and S3 are shorted. This is the electrical zero position of the synchro
being aligned.
Control System Components (ICE 3015)
Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017
 References:

• Navy Electricity and Electronics Training Series (NEETS)

Module 15—Principles of Synchros, Servos, and Gyros
http://www.rfcafe.com/references/electrical/NEETS-
Modules/NEETS-Module-15-1-1-1-10.htm

Control System Components (ICE 3015)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2017