Manual KW991 CR Iss05 Rev02

KW991-CR
COURSE RECORDER
AMI MARINE (UK) LTD

AMI Manual KW 991-CR Doc No: AMI TM991-CR
Issue: 5 Rev02
CLASSIFICATION: Commercial In Confidence
This page is
Intentionally blank
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Issue: 5 Rev02
Document Date Modification Number (where applicable)

Issue Brief Record of Change and Reason for Change
1 15.08.02 Original Issue
2 09.03.05 Insertion of Printer Settings
3 24.07.06 Addition of 25 Pin Serial Pin ID
4 17.08.06 Addition of Connector Image
5 16.05.08 Change of address
5 Rev01 07.02.12 Removal of Gyro Types
5 Rev02 10.02.12 Addition of Installation Drawings
NOTE: All alterations must be verified by re-authorisation and approval of the

complete document.
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Issue: 5 Rev02
This page is
Intentionally blank
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Issue: 5 Rev02
HEADING REPEATER MODEL KW991
UNIVERSAL COURSE RECORDER
TECHNICAL MANUAL
CONTENTS
INTRODUCTION ........................................................................................................ 6
SPECIFICATIONS...................................................................................................... 6
INSTALLATION DRAWINGS ..................................................................................... 8
INSTALLATION NOTES ............................................................................................. 9
CONNECTING THE KW991CR ............................................................................... 10
GYRO INTERFACE WIRING ................................................................................... 11
COMMON STEPPER AND SYNCHRO INTERFACE WIRING............................. 11
OPERATOR’S GUIDE .............................................................................................. 13
NO GYRO INPUT ................................................................................................. 14
NO GPS INPUT .................................................................................................... 14
GYRO ALARM ...................................................................................................... 14
HEADING REPEATER MAINTENANCE .................................................................. 15
Printer Settings For the Epson LX300+ .................................................................... 16
BOARD LAYOUT ..................................................................................................... 17
AMI MARINE (UK) LTD
Unit 2 Tower Industrial Estate

Tower Lane
Eastleigh
Southampton
SO50 6NZ
United Kingdom
Tel No: +44 (0) 23 8048 0450

Fax No: +44 (0) 23 8065 1126
Email: technical@amimarine.net
Web: www.amimarine.net
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Issue: 5 Rev02
INTRODUCTION
A bright green vacuum fluorescent dot matrix display presents ships heading from
the gyro 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 TAPE displaying 25 degrees, DIGITAL with

GPS Information display and Large DIGITAL display.
The data output is fed to a standard low cost printer, or to a PC for recording on disk.
The information output is; time, position, gyro course, GPS ground speed, course,
and the date. Output to the printer is all on one line.
The interval between outputs varies according to the following conditions.
a) An output every 6 minutes, on a 6 minute multiple. (H+ 6,12,18 etc.)
b) An output if course changes by 2 degrees from the last output. This occurs no
faster than a 10-second interval.
c) An output on demand by pressing the " ” button.
SPECIFICATIONS
INPUT 1. NMEA 0183 valid GPS sentences.
INPUT 2. Stepper or 360:1 synchro gyro.

Or NMEA 0183 heading input
OUTPUT: Serial Data RS422 and RS232 compatible 4800 baud. (8, N, 1)
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: Nominal 24 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.
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Issue: 5 Rev02
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 will not guarantee 100% weatherproof. Units damaged by outside
use are not covered by warranty.
SITING AND INITIAL TEST
We suggest you try it first on demonstration mode, and take the Masters opinion, for
this is more than any traditional course recorder. He will probably want the instrument
sited for easy viewing and access on the watch keeping area of the bridge. The
printer may be sited where convenient.
CONNECTIONS
Remove the front of the KW991 carefully. Disconnect the ribbon cables, using the
levers on the interface board. Put it to one side for connecting up.
GYRO INPUT
The connector blocks all lift off to easy wiring up. The unit connects to most gyros.
NMEA 0183 INPUT
Connect to GPS using screened twisted pair cable. The screen should be grounded
at the GPS end. If there are too many instruments to be fed from the GPS we
suggest you use the NAVTALK distribution interface with its 10 outputs.
The GPS must output the data required. These sentences provide what is necessary.
$GPRMC, or $GPGGA + $GPVTG + GPZDA. For complete detail refer to the NMEA
0183 standard document
NMEA 0183 OUTPUT
Check if the printer's data input grounds the data common line. If so that will ground
the KW991 DC Input. If that is the case use an isolating AC-DC power supply for the
KW991. The output is 4800 baud.
RS232: A = data +. 0 = data return

RS422 or current loop. B = data +. A = data -.
PRINTER CONNECTION
If the printer is supplied from another source than AMI You must refer to the printer
handbook. RS232 input will probably need links fitting from RTS to CTS (Pins 4 to 5
on a 25 way D.) and maybe DTR to DCD to DSR (Pins 6, 8, 20.) Note: The KW991
outputs whenever power is applied or AL is pressed, and flashes "PRINTING" on
screen when giving an output.
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Issue: 5 Rev02
INSTALLATION DRAWINGS
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Issue: 5 Rev02
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 ruin 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. (See Table)
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.
OUTPUT to PRINTER
Connect A to pin 3 and 0 to pin 7 on the 25 pin ‘D’ type serial printer connector.
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.
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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Issue: 5 Rev02
CONNECTING THE KW991CR
Connector Type
HEADING
DISPLAY NMEA
I/P2
4. NMEA OUT A
6. NMEA OUT B
1. NMEA IN A
2. NMEA IN B
1. NMEA IN A
2. NMEA IN B
COMMON
3. EARTH
2. EARTH
9.EARTH
1. R1+
1. +5V
2. +5V
3. S1+
5. S2+
7. S3+
2. R2-
4. S1-
6. S2-
8. S3-
KEYPAD
1. +V
3. D1
4. D2
5. D3
3. 0V
6. 0V
5. 0
SK1
SK5
SK3
SK4
SK2
J1
Pin 5 Blue
Pin 3 Red
Serial
GPS Printer 24VDC NMEA GYRO
Other GYRO options

(6 Steps per Degree )
STEPPER -24 TO -70 VOLT KW991

HEADING GYRO I/P (SK4)
R1
R1+
R2-
S1+
S1
S1-
S2
S2+
S3
S2-
S3+
S3-
(360:1 Synchro )
KW991
SYNCHRO 360:1 AC
HEADING GYRO I/P (SK4)
R1 R1+
R2 R2-
S1 S1+
S2 S1-
S3 S2+
S2-
S3+
S3-
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Issue: 5 Rev02
GYRO INTERFACE WIRING
COMMON STEPPER AND SYNCHRO INTERFACE WIRING
Pure DC Stepper - Positive Steps
S1 to S1+
S2 to S2+
S3 to S3+
Common neg to S1-, S2-, S3- ( all linked )
Pure DC Stepper - Negative Steps
S1 to S1-
S2 to S2-
S3 to S3-
Common pos to S1+, S2+, S3+ ( all linked )
Rectified Stepper
This requires the gyro repeater drive + and - supply which is normally available for
the illumination of the repeaters. Connect it to the “reference” input.
Ref+ = R1+ Ref- = R2-
Note that you can measure raw rectified DC on the AC scale of a multimeter,
whereas pure DC should not register on the AC range. If in doubt use an
oscilloscope.
Rectified DC Stepper - Positive Steps
S1 to S1+
S2 to S2+
S3 to S3+
Common - to S1-, S2-, S3-, Ref- ( all linked )
Positive to Ref+
Rectified DC Stepper - Negative Steps
S1 to S1-
S2 to S2-
S3 to S3-
Common + to S1+, S2+, S3+, Ref+ ( all linked )
Negative to Ref-
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Issue: 5 Rev02
If Supply Line Not Available

Rectified DC Stepper - Positive Steps
S1 to S1+, and via a diode to Ref+

Common neg to S1-, S2-, S3-, Ref-
Rectified DC Stepper - Negative Steps
S1 to S1-, and via a diode to Ref-

Common + to S1+, S2+, S3+, Ref+
360:1 Synchro
R1 to Ref+
R2 to Ref-
S1 to S1+ and S3-
S2 to S2+ and S1-
S3 to S3+ and S2-
90X Contactless Transmitters
This is sometimes found on Sperry or Tokimek gyros. It looks like a synchro but has
6 connections.
R1 to Ref+ ( or Ref- )
R2 to Ref- ( or Ref+ ) ( try this if first does not follow )
S1 to S1+
S2 to S2+
S3 to S3+
N to S1-,S2-,S3-
If Output rotates in the wrong direction swap S1 and S2
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Issue: 5 Rev02
OPERATOR’S GUIDE
KEY PAD FUNCTIONS
= Press to turn off display.
= Press to turn on display.
= Increases Illumination level.
= Decreases illumination level.
= 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” message and check the gyro I/P.
Press to Print.
Hold at “Switch On” to enter demonstration mode.
= Press to change the screen functions.
1) Tape repeater at 10 pixels per degree showing > +/– 12.5 degrees.
2) Very large heading display. (Rounded to nearest degree).
3) Digital heading and GPS Information. (Degrees).
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Issue: 5 Rev02
NO GYRO INPUT
On power up if the above screen appears check the gyro input.
NMEA Heading input on SK5 will show LD2 activity.

If LD2 appears to be permanently ON swap A and B on SK5-1 and 2.
If activity is seen but heading is still not displayed, check the data being input is
actually heading data. Use a suitable NMEA reader.
For Stepper input a combination of LD3, LD4 and LD5 should be illuminated. Note
there should either be 1 LD or 2 LD illuminated. If all are OFF or all are ON then
there is a fault with the gyro signal.
For Synchro the LD2, LD3, LD4 and LD5 will be illuminated so check the voltages at
SK4 input as per the gyro manufacturer’s instruction
NO GPS INPUT
If the GPS is not present all the GPS display data will show FF.
NMEA GPS input on SK2 will show LD6 activity.

If LD6 appears to be permanently ON swap A and B on SK3-1 and 2.
If activity is seen but GPS data is still not displayed, check the data being input is
actually GPS data. Use a suitable NMEA reader.
GYRO ALARM
“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 will clear the Alarm State.
“GYRO FAIL” occurs after loss of gyro signal for several seconds.
The AUDIBLE alarm (if fitted) will sound only for a heading fault and only if the alarm
has been set. To accept and mute the audio alarm press the button.
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Issue: 5 Rev02
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.
POSSIBLE “PROBLEMS”
The repeater will indicate “CHECK ALIGNMENT” if it detects errors on the gyro input
signals. 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
470Ω load resistors in the gyro stepper RTU.
WARNING!
If it is necessary to work on the display with power applied care has to be taken not
to touch the edges of the Futaba display module as it will give an unpleasant electric
shock or to short out the Futaba display module to the enclosure as this will cause an
internal fuse to rupture and then will require returning to AMI UK under non warranty.
15
Issue: 5 Rev02
Printer Settings For the Epson LX300+
The highlighted text is the required options that need changing,
Page length for tractor 12 inch

Skip over perforation Off
Auto tear off Off
Auto line feed On
Print direction Bi-D
Software ESC/P
0 slash On
High speed draft On
I/F mode Serial
Auto I/F wait time 10 seconds
Baud rate 4800BPS
Parity None
Data length 8bit
Parallel I/F bi-directional mode On
Packet mode Auto
Character table PC 437
International character set for Italic table Italic U.S.A.
Manual feed wait time 1.5 seconds
Buzzer On
Auto CR (IBM 2380 Plus) On
IBM character table Table2
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Issue: 5 Rev02
BOARD LAYOUT
17

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KW991-CR

AMI MARINE (UK) LTD

Document Date Modification Number (where applicable)

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

HEADING REPEATER MODEL KW991

UNIVERSAL COURSE RECORDER

AMI MARINE (UK) LTD

Unit 2 Tower Industrial Estate

Tel No: +44 (0) 23 8048 0450

Screen presentations of heading are TAPE displaying 25 degrees, DIGITAL with

The interval between outputs varies according to the following conditions.

a) An output every 6 minutes, on a 6 minute multiple. (H+ 6,12,18 etc.)

c) An output on demand by pressing the " ” button.

INPUT 1. NMEA 0183 valid GPS sentences.

INPUT 2. Stepper or 360:1 synchro gyro.

DISPLAY: Futaba vacuum fluorescent display 256 x 64 pixels.

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

POWER: Nominal 24 volts DC at 12 watts. (Switch on surge 3A).

HOUSING: 260 x 160 x 90 mm diecast aluminium housing.

Note: DISPLAY FOR OUTSIDE USE

SITING AND INITIAL TEST

NMEA 0183 INPUT

NMEA 0183 OUTPUT

RS232: A = data +. 0 = data return

NMEA 0183 INPUT

Use screened cable and earth from the sending end.

ALARM OUTPUT with reference to SK1-6 the 0v line

CONNECTING THE KW991CR

Other GYRO options

STEPPER -24 TO -70 VOLT KW991

GYRO INTERFACE WIRING

COMMON STEPPER AND SYNCHRO INTERFACE WIRING

Pure DC Stepper - Positive Steps

Pure DC Stepper - Negative Steps

Rectified DC Stepper - Positive Steps

Rectified DC Stepper - Negative Steps

If Supply Line Not Available

S1 to S1+, and via a diode to Ref+

Rectified DC Stepper - Negative Steps

S1 to S1-, and via a diode to Ref-

90X Contactless Transmitters

If Output rotates in the wrong direction swap S1 and S2

= Press to turn off display.

= Press to turn on display.

= Increases Illumination level.

= Decreases illumination level.

= Hold for 3 seconds to enter alignment mode.

= Press to change the screen functions.

2) Very large heading display. (Rounded to nearest degree).

3) Digital heading and GPS Information. (Degrees).

On power up if the above screen appears check the gyro input.

NMEA Heading input on SK5 will show LD2 activity.

NMEA GPS input on SK2 will show LD6 activity.

“CHECK ALIGNMENT” is given whenever a false gyro stepper or Synchro state is

HEADING REPEATER MAINTENANCE

DISPLAY MODULE SCREEN

LEDS and DATA OUTPUT

Printer Settings For the Epson LX300+

The highlighted text is the required options that need changing,