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INSTALLATION & COMMISSIONING

INFORMATION
FOR THE
KH 1020 GLOBAL POSITIONING SYSTEM

PUBLICATION KH 1505

Issue 1

February 98

KELVIN HUGHES
Kelvin Hughes Ltd. is the Naval and Marine Division of Smiths Industries Aerospace
Registered Office: 765 Finchley Road, London NW11 8DS.
Incorporated in England No. 1030135

New North Road, Hainault, Ilford, Essex IG6 2UR, England


Telephone: 0181 500 1020
Telefax: 0181 559 8522
Telex: 896401
KH 1505

PUBLICATION AMENDMENT PROPOSAL


INSTRUCTIONS
1 This page is to be used to report specific errors or omissions in this publication.
2 Three copies are to be forwarded, without a covering letter, to: Kelvin Hughes Ltd., New
North Road, Hainault, Ilford, Esses 1G6 2UR England.
3 A replacement copy of this page will be forwarded to the originating source by DNLP,
with acknowledgement of the proposal.
ORIGINATING SOURCE
Originator/Ship/Establishment: Serial No.:
PROPOSED AMENDMENT
TITLE OF HANDBOOK
Volume/Section/Part: Chapter: Leaf/Page/ Paragraph/ Last
Line(s): Table/Fig: Amendment
Inserted

PROPOSAL

Date:
(Name/Rank of Proposer)
FOR NAVY OFFICE USE
Amendment is approved: YES/NO
The proposal is to be processed: *URGENTLY* *BY ROUTINE ACTION*
*DEFERRED* *FILED FOR REFERENCE*
SPONSOR’S COMMENTS

Signature: Date:

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KH 1505

WARNING

1. LETHAL VOLTAGE
2. THE EQUIPMENT DESCRIBED IN THIS PUBLICATION USES
ELECTRICAL POWER WHICH MAY BE LETHAL.
3. WHENEVER PRACTICABLE, BEFORE CARRYING OUT
MAINTENANCE OR REPAIR, PERSONNEL CONCERNED MUST:
(1) ISOLATE THE EQUIPMENT FROM THE ELECTRICAL
SUPPLY.
(2) MAKE TESTS TO VERIFY THAT THE ISOLATION IS
COMPLETE.
(3) ENSURE THAT POWER CANNOT BE ACCIDENTALLY
RECONNECTED.
4. IF IT IS ESSENTIAL TO WORK ON THE EQUIPMENT WITH POWER
CONNECTED, THE WORK MUST BE UNDERTAKEN ONLY BY
QUALIFIED PERSONNEL WHO ARE FULLY AWARE OF THE
DANGER INVOLVED AND WHO HAVE TAKEN ADEQUATE SAFETY
PRECAUTIONS TO AVOID CONTACT WITH DANGEROUS
VOLTAGES.
CAUTION
1. ELECTROSTATIC SENSITIVE DEVICES
2. The Procedures Detailed In This Manual Involve Handling Panels
Electronic Circuits (PECs) Which Carry Electrostatic Sensitive Devices
(ESSDs). The Devices Embody In Their Design A Thin Layer Of Insulation
Which May Be Damaged By Electrostatic Charge.
3. Damage Is Caused By Very Fast Discharge Times And Not By The High
Voltages Involved. Slow Discharge Paths Must Be Provided Therefore To
Avoid Damage When The PECS Are Being Handled. These Discharge Paths
Must Be Through The Maintainer, His Tools And Work Bench, To Earth.
4. All PECs Carry ESSDs And Are Factory Packed With The Connectors
Shorted Together With A Slow Discharge Foam Which Should Be Left In
Position Until The Last Possible Moment.
5. If A PEC Is Removed From The Equipment It Must Have Its Connectors
Shorted Together With The Foam At The Earliest Possible Moment.
6. Damage Resulting From Failure To Adhere To These Precautions May Not
Be Immediately Apparent But Show Up As A Component Failure After A
Period Of Time.

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KH 1505

RECORD OF AMENDMENTS
It is certified that the amendments promulagated in the undermentioned Amendment List
have been incorporated in this copy of the publication.

Amendment Chap/ * Amendment Effect Amended By Date


List Pages
Aff t d
Affected
No Date

1 11.2.99
2 21.11.00
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
* NOTE: Insert details of pages amended, inserted or cancelled.

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KH 1505

RECORD OF AMENDMENTS

Amendment Chap/ * Amendment Effect Amended By Date


List Pages
Aff t d
Affected
No Date

25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

* NOTE: Insert details of pages amended, inserted or cancelled.

Page ii Original
KH 1505

LIST OF ASSOCIATED PUBLICATIONS

KH 1503 VOL 1 PURPOSE AND PLANNING INFORMATION, OPERATING


INFORMATION AND PROGRAMME ADVANCE INFORMATION
DOCUMENTS.
KH 1504 VOL 2 TECHNICAL DESCRIPTION, MAINTENANCE PROCEDURES,
PARTS LISTS AND MODIFICATIONS.
KH 1505 VOL 3 INSTALLATION SPECIFICATION & ACCEPTANCE
PROCEDURES.

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KH 1505

TABLE OF CONTENTS

LIST OF VOLUMES
VOLUME 1 OPERATORS HANDBOOK FOR KELVIN HUGHES KH 1020 NAVAL
GPS NAVIGATION SYSTEM
VOLUME 2 TECHNICAL HANDBOOK FOR KELVIN HUGHES KH 1020 NAVAL
GPS NAVIGATION SYSTEM
VOLUME 3 INSTALLATION & COMMISSIONING HANDBOOK FOR KELVIN
HUGHES KH 1020 NAVAL GPS NAVIGATION SYSTEM

CONTENTS OF VOLUME 3
Preliminary Pages
Title and Promulgation
Publication Amendment Proposal Form
Warnings
Record of Amendments
List of Associated Publications
Table of Contents
List of Figures
List of Tables
Notes to Readers

CONTENTS
CHAPTER 1 INSTALLATION SPECIFICATION
Page No Para No
GENERAL DESCRIPTION
INTRODUCTION 1 1
BRIDGE DISPLAY EQUIPMENT 1 2
Installation kit 1 3
Power units 1 4
KH 1020--GPS equipment 1 5
FIRST FITTING ITEMS 1 6/7
DESIGN AND PLANNING INFORMATION
PHYSICAL FEATURES AND REQUIREMENTS
Positioning of Equipment 2 8/9
Shipping and Removal Route 2 10
Weights 2 11
Safety 2 12/15

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KH 1505

Page No Para No
SERVICES -- ELECTRICAL POWER
POWER SUPPLIES 3 16
Maintenance Supplies 3 17
Data Inputs 3 18
Compass Transmissions 3 19
Ships Log Transmissions 3 20
SERVICES REQUIRED DURING NON--OPERATIONAL
PERIODS 3 21
EQUIPMENT ELECTRICAL FEATURES 3 22
ON--BOARD MAINTENANCE FACILITIES AND REQUIREMENTS
SERVICING SPACE 3 23
SERVICING FACILITIES 3 24
TEST EQUIPMENT 3 25
SHIP/COMPARTMENT FACILITIES 3 26
Illumination 3 26
CONSTRUCTIONAL WORK 3 27
Site Preparation 3 27
RECEIVING AND DISMANTLING PROCEDURE
MOUNTING 4 28
DELIVERY AND INSPECTION OF STORES 4 29/31
PROTECTION OF EQUIPMENT 4 32/33
TOOLS REQUIRED 4 34
DISMANTLING 4 35
ASSEMBLY PROCEDURES
INTRODUCTION 5 36
Scope and Purpose 5 37
APPLICABLE DOCUMENTS 5 38
Government Documents 5
Manufacturing Documents 5
INSTALLATION REQUIREMENTS 6 39
General 6 39/42
Control Display Unit (CDU) 6 43
Antenna Assembly 6 44/45
Interface Wiring, Cables And Associated Hardware 6 46/48
Modifications And Ships Re--work 7 49/50
INSTALLATION PROCEDURES 7 51
Assembly 7 51/56
Electrical 7 57/60
CONTINUITY TEST 17 . . . .
INSULATION BREAKDOWN TEST 18
ANNEX E A.1
SUBMARINE CLASS OF BOAT E.1

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KH 1505

CHAPTER 2 PREPARATION FOR ACCEPTANCE


Page No Para No
INTRODUCTION 1 1
Object 1 1
References 1 2
Prerequisites 1 3
Electrical supplies 1 4
Test equipment required 1 5
Performance records 1 6/7
Time required 1 8
KH 1020 -- GPS INITIAL CHECKS
BRIDGE DISPLAY 2 9
Configuring the Modules in the Display 2 10/11
Navigation processor module -- configuration check 4 12
Interface handler module - configuration check 5 13
Display Controller Module - configura tion check 6 14
Naval interface 4 module-- configuration check 7 15
Power supply checks 7 16
REMOTE CONTROL & DISPLAY UNIT 9 17
Display controller module - configuration check 9 18
KH 1020 -- GPS BASIC EQUIPMENT CHECKS
GPS BRIDGE DISPLAY 11 19
DATA INPUT CHECKS 13 20
Interface Set--Up 13 21
RCDU DISPLAY 14 22/23
KH 1020 -- GPS FUNCTIONAL CHECKS
SENSOR INPUT CHECKS 15 24
Self Test of the System Interfaces
(refer to Annex B for interfaces fitted) 16 25
PLATFORM SET UP 17 26
POSITION INITIALISE 17 27
POSITION CHECK 17 28
ON COMPLETION 17 29
ANNEX A
PREPARATION FOR ACCEPTANCE PERFORMANCE
RECORD SHEET A.1
KH 1020 -- GPS A.1
ANNEX B
INTERFACES TO BE SET--UP/TESTED FOR EACH SHIP FIT B1

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KH 1505

CHAPTER 3 HARBOUR ACCEPTANCE TRIALS

Page No Para No
INTRODUCTION 1 1
Object 1 1
References 1 2
Prerequisites 1 3
Electrical supplies 1 4
Performance records 1 5/6
Time required 1 7
Conduct of the trial 1 8
KH 1020 -- GPS TEST PROCEDURES
KH 1020 -- GPS BRIDGE DISPLAY 2 9
BRIDGE PAGE CHECKS 2 10
SENSOR CHECKS 3 11
Motion sensors 3 11
RCDU DISPLAY 3 14
ON COMPLETION 3 15
ANNEX A
HARBOUR ACCEPTANCE TRIALS RECORD SHEET A.1
KH 1020 -- GPS A.1

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KH 1505

LIST OF FIGURES
Figure No Title Page No
CHAPTER 1

1 KH 1020 GPS UE Installation - Block Diagram 8

2 Installation Layout of P37B Patrol Craft 9

3 Antenna Stub Mast 10

4 Antenna Stub Mast Mounting Base (if required) 11

5 Interconnection Diagram 12

6 Antenna Assembly 13

7 CDU Assembly 14
CHAPTER 2

1 KH 1020 bridge display - front view layout 2

2 KH 1020 bridge display -- rear view layout 3

3 KH 1020 bridge display -- module locations 3

4 Navigation processor module - link locations 5

5 Interface handler module -- link locations 6

6 Display controller module -- link locations 6

7 Naval interface 4 module - link locations 7

8 KH 1020 RCDU - front view layout 8

9 KH 1020 RCDU - rear view layout 9

10 Display controller module - link locations 10

11 Ownship screen 11

12 Self test page 17

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KH 1505

LIST OF TABLES
Table Title Page No
CHAPTER 1

1 Reference Table For KH 1020--GPS 1

2 Reference Table For Kh 1020--GPS Bridge Display 2

3 Blank 6

4 Connection List 15

5 Parts Lists 16
CHAPTER 2

1 Location Of Modules In Control Display Unit 4

2 Link Settings 5

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KH 1505

NOTES TO READERS
DISPOSAL
1 When no longer required, this Specification is to be disposed of in accordance with local
regulations for the disposal of documents.
SCOPE OF SPECIFICATION
2 This Specification describes the requirements and method of fitting the units that comprise the
KH 1020--GPS, and indicates the work to be carried out and services to be provided by the Shipbuilder,
Dockyard, Ships Staff or Contractor.
SUMMARY OF WORK AND RESPONSIBILITIES
3 The work associated with installing KH 1020--GPS comprises the preparatory work to arrive at
a ”Fit to Receive” (FTR) condition, followed by the actual equipment installation. The work to reach
a FTR condition will be performed by either Dockyards, Shipbuilders or Ships Staff and will normally
be the subject of an Alteration and Addition (A and A). The A and A guidance document should be read
in conjunction with KH 1501. The equipment installation may be carried out by any of the above or by
the equipment contractor. The Dockyard, Shipbuilder or Ships Staff is also to provide material and
articles as indicated in this Specification, other relevant specifications, and in approved Ships drawings.
A brief summary of the main items of work is as follows:
(1) Fitting and assembly of equipment.
(2) Provisioning and fitting of cable for cabling the installation and connection to the
equipment.
(3) Provisioning and fitting of support brackets etc as required.
(4) The efficient protection of the equipment from damage.
4 The above outline is for general guidance and is not exhaustive. For further information
reference is to be made to the individual paragraphs and figures of this and other relevant specifications.
GENERAL
5 The information in this Specification is of four kinds:
(1) Design and Planning information.
(2) Constructive and Electrical work.
(3) Instructions for the Assembly of the equipment.
(4) Instructions for Tests and Trials to be carried out during and on completion of various
stages of the installation process.
6 Diagrams and Schedules detailing external cabling and connections, provided in this
Specification are for guidance only, the task of installation is to be carried out in accordance with the
Approved Drawings for the ship (or class of ship), which will be based upon the information contained
herein.
DEFINITIONS
7 The following definitions are included to assist in interpretation of this Installation Specification:
(1) Naval Weapon Equipment. Weapon Equipment procured by the Navy and identified
by a Type, Outfit or System.
(2) Installation. The process by which Naval Weapon Equipment is fitted in a ship,
submarine, vehicle, establishment or site, in order that the equipment and its operators
and maintainers shall have the correct conditions and services for efficient performance
of their functions.

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KH 1505

(3) First Fitting Item (FFI). An item of Naval Weapon Equipment supplied as part of the
original fit. First Fitting Items include Special to Type Test Equipment, Tools and
Installation Aids.
(4) Responsible Authority. That authority defined as the signatory for the acceptance
certificate.
(5) Special--to--Type Test Equipment and Tools. First Fitting Items which are used by
Ship’s Staff to monitor or adjust the performance of equipment.
(6) Spare Item. An Item of Naval Weapon Equipment supplied as a potential replacement
for a defective item of equipment under an Upkeep Management Policy.
(7) On--board Spare. A Spare Item retained in the same Ship or Shore Establishment as the
equipment it supports.
(8) Associated Item. An item or combination of items from other equipment which cannot
be individually mounted nor contained within the parent equipment. An Associated Item
may comprise First Fitting Item or Spare Items.
(9) Ancillary Item. An item or combination of items essential to enable an FSI/II to be
installed, and which must be built into the complete installation. Examples of Ancillary
Items are Plinths, Brackets, Stays, Shelves, Pads, Mounts, Ferrules, Free Plugs and
Sockets, Taper Pins, Gland Nuts, Unions, Oils, Greases, Points, Nuts and Bolts etc.
(10) Installed Item (II). An assembly comprising one or more FSIs with any Associated
Items, and the Ancillary Items necessary for installation, excepting those items securing
them to the ship’s structure.
(11) Free Standing Item (FSI). A First Fitting Item or assembly of such items for a particular
ship or equipment variant which can be individually mounted and/or forms a junction or
termination for servies (eg cables, pipes, trunks etc).
CABLES, CABLE CHANGING BOXES AND JUNCTION BOXES
8 Cables shown in the Cable Schedules in this Specification are suitable for the purpose, but may
be changed at the discretion of Responsible Authority except for radio frequency cables and other cables
as indicated which may be changed only by reference to the appropriate Design Authority:
ESTABLISHMENT LIST OF STORES
9 Details of all stores comprising KH 1020--GPS are contained in Establishment List of Stores.
CATEGORIES OF SUPPLY
10 To ensure that items of equipment supplied by Space and Joint Systems Project Office are
delivered to the installation authority in the order in which they are required for use, each item is
allocated a Category of Supply thus:
(1) Category 1. Items which affect or form parts of the ship’s hull or structure (including
any Ancillary Items which may be necessary at this stage).
(2) Category 2. Items which are secured to the ship’s structure or which are required to
terminate ship’s cables (including any Ancillary Items which may be necessary at this
stage).
(3) Category 3. Items which can be installed without affecting the ship’s structure or cables.

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KH 1505
Chap 1

CHAPTER 1

INSTALLATION SPECIFICATION

GENERAL DESCRIPTION
INTRODUCTION
1 KH 1020--GPS comprises an Antenna and a Control Display Unit (CDU) which provides
housing and mounting facilities for the display, processor and other navigational interfaces and
an optional Remote Control Display Unit (RCDU).
BRIDGE DISPLAY EQUIPMENT
2 The Bridge CDU essentially comprises a display, computer, interfaces and power supply.
Installation kit
3 The KH 1020--GPS is supplied with an Installation Kit whose contents are fully described
for each type of installation in Table 5.
Power units
4 The power unit is housed as follows:
(1) In the CDU which provides supplies for KH 1020--GPS Bridge CDU, RCDU and
the Antenna.
KH 1020--GPS equipment
5 The workstation equipment is as follows:
(1) Antenna.
(2) Control Display Unit.
FIRST FITTING ITEMS
6 A complete list of first fitting items is shown in Tables 1 and 2.
TABLE 1 REFERENCE TABLE FOR KH 1020--GPS

Item Weight
Stock Number Description Qty
No KG
1 Antenna Assembly 1 1.5
2 Control Display Unit (Bridge) 1 19*

* 21kg including Mounting Bracket


7 Table 2 provides a list of items located inside the Bridge CDU.

Amdt 2 (Oct 00) Page 1


KH 1505
Chap 1

TABLE 2 REFERENCE TABLE FOR KH 1020--GPS BRIDGE DISPLAY

Item Weight
Stock Number Description Qty
No KG
1 5998--66--140--3303 Interface Handler Module 1 0.5
2 5998--66--140--3302 NIF 5 Module 1 0.5
3 5998--66--140--3298 Navigation Processor Module 1 0.5
4 5998--66--140--3301 NIF 4 Module 1 0.5
5 5895--66--140--3309 Display Controller Module 1 0.5
6 5998--66--140--3300 Power Supply Unit 1 0.5
7 GPS Receiver Module 1 0.5
8 Ribbon Filter PCB (GPS A--5 only) 1 0.5

DESIGN AND PLANNING INFORMATION


PHYSICAL FEATURES AND REQUIREMENTS
Positioning of Equipment
8 The KH 1020--GPS Contol Display is sited in the Bridge Room. The RCDU is sited as
required. Refer to the A and A Guidance Document for a particular class of ship.
9 Sufficient space must be left around the Bridge Display and the RCDU to allow free
movement.
Shipping and Removal Route
10 There is no requirement for a special shipping and removal route. The individual modules
may be handled from quayside to compartment using a rope sling. All modules have been
designed to pass through a 914 mm hatchway.
Weights
11 The weights are as follows:
(1) Antenna 1.5kg
(2) Bridge Display 21kg (approximately).
(3) RCDU 13kg.
Safety
12 The Bridge Display is to be securely earthed from the earth terminal at the back of the
CDU to the deck. Ensure that a good connection to deck earth has been made and that the units
make good electrical contact with each other.
13 When ships cables are fitted ensure that all power is off, as shorting may occur when
fitting connectors into sockets. All wiring checks are to be completed before switching on the
power supplies to ensure that there is no shorting of the power cables.
14 With the power supplies connected, with fuses intact and switches on, all Modules
displaced within the display are ‘live’.
15 No radiation hazard exists.

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KH 1505
Chap 1

SERVICES - ELECTRICAL POWER


POWER SUPPLIES
16 Power Supplies are as follows:
(1) Equipment Operating Supply - 115/240V, 45--65Hz, single--phase or 24V dc.
Maintenance Supplies
17 No special servicing supplies are required other than the general requirements for 115V,
50/60Hz, 5A switch sockets for test equipment in the vicinity of the equipment.
Data Inputs
18 For details of Data Inputs from other Naval Weapon Equipment, refer to Connection
Schedules.
Compass Transmissions
19 Ship’s head data is required to be supplied as an NMEA sentence.
Ships Log Transmissions
20 Ship’s log data is required to be supplied as an NMEA sentence from the DDU.
SERVICES REQUIRED DURING NON--OPERATIONAL PERIODS
21 No special maintenance during non--operational periods is required.
EQUIPMENT ELECTRICAL FEATURES
22 Leads to associated equipments fitted in the workstation are to be fitted with the
necessary terminations.

ON--BOARD MAINTENANCE FACILITIES AND REQUIREMENTS


SERVICING SPACE
23 Space to allow the front panel to be removed.
SERVICING FACILITIES
24 Earth strap to provide the maintenance technician with electrostatic protection.
TEST EQUIPMENT
25 The normal items are used in the testing of the equipment, stowage space being allowed
for in the cupboards etc, provided for Operations Room use.
SHIP/COMPARTMENT FACILITIES
Illumination
26 The equipment is fitted with a mains on/off switch with brilliance and contrast controls.
CONSTRUCTIONAL WORK
Site Preparation
27 All cables are to be laid in position before commencing installation of the units. At least
two metres slack is to be allowed for each coaxial cable to the back entry of the unit.

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KH 1505
Chap 1

RECEIVING AND DISMANTLING PROCEDURE


MOUNTING
28 An Installation Kit is provided with the equipment.
DELIVERY AND INSPECTION OF STORES
29 KH 1020--GPS is supplied as a number of separately packed units. These units are to be
kept in the appropriate packaging until required for assembly.
30 Prior to assembly, all items, when removed from the packaging are to be inspected, and
any damage reported to the Installation Contractor.
31 The assembly of the parts into the KH 1020--GPS, and the fitting of all units is to be
carried out as a continuous process, to reduce the possibility of the introduction of foreign bodies
into the System.
PROTECTION OF EQUIPMENT
32 At all times extreme care must be taken to protect the units from damage, even after
assembly, by use of suitable covers.
33 The equipment is to be assembled in accordance with the instructions that follow.
TOOLS REQUIRED
34 The following tools are required:
(1) Normal mechanical tools, eg screwdrivers, allen keys, etc.
(2) Normal electrical tools, eg soldering iron, tapernose pliers, wirecutters, etc.
DISMANTLING
35 If necessary, all KH 1020--GPS equipment is to be removed in accordance with the
procedures detailed in the annexes to this specification, the cables detached and terminated if
necessary.

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KH 1505
Chap 1

ASSEMBLY PROCEDURES
INTRODUCTION
36 The Assembly procedure that follows describe the installation of the KH 1020 GPS UE
into a general class of surface ship.
Scope and Purpose
37 The purpose of this document is to:--
(1) Identify modifications required, equipment locations, connectors, cables and
associated hardware for installing the GPSUE in accordance with equipment
specification.
(2) Provide the Navy with sufficient information to complete Configuration Change
Proposals (CCP) and Ships Alteration Records, to reflect the installation of the
GPS UE.
APPLICABLE DOCUMENTS
38 The following documents are applicable to the installation:
Government Documents
Manufacturing Documents

Amdt 2 (Oct 00) Page 5


KH 1505
Chap 1

INSTALLATION REQUIREMENTS
General
39 The GPS UE system consists of the following sub--assemblies. See figure 1 block
diagram:--

ITEM PART No.


Control and Display Unit (CDU) P(Y) Code GPS--A2--5
Control and Display Unit (CDU) C/A Code GPS--A2--6
Remote Control and Display Unit (RCDU) - option GPS--A3
Antenna Assembly 45--910--566
Interface Wiring, Cables and associated Hardware Various

40 The installation layout is defined in figure 2, Installation Layout.


41 The locations specified for GPS sub--assemblies are the result of agreement between the
shipbuilder and the GPS Design Authority.
42 The locations represent the most suitable option that provides maximum operational
effectiveness with minimum installation cost and ease of maintenance.
Control Display Unit (CDU)
43 The KH 1020 CDU shall be located in the Wheelhouse.
Antenna Assembly
44 The GPS Antenna assembly shall be mounted on the Wheelhouse Roof.
45 The Antenna Assembly will mount on a stub mast that will attach to a bracket as shown
in figure 6, Antenna Assembly.
Interface Wiring, Cables And Associated Hardware
46 The interface wiring consists of three cables, as below, the cable type being dependant
on the installation:

50 ohm coaxial cable to antenna

Power cable

Data cable

47 The GPS antenna cable is susceptible and should be separated from other cables or routed
in conduit.
48 The GPS CDU is bonded to the ships structure via the M10 earth stud provided.

Page 6 Amdt 2 (Oct 00)


KH 1505
Chap 1

Modifications And Ships Re--work

CDU Mounting
49 The CDU is supplied with a mounting bracket and bolts. The location should be prepared
by drilling and tapping the four M10 holes using the mounting bracket as a template.

Antenna Assembly
50 The antenna assembly is designed to mount against a 50mm vertical stub mast or 50mm
horizontal yard arm. U--bolts are supplied to pass around the mast and onto the antenna bracket
which is integral with the ground plane.
NOTE

The antenna is tuned to the bracket which acts as a ground plane. It should not be
removed.
INSTALLATION PROCEDURES
Assembly

Antenna
51 Locate the antenna mast structure using Figure 2, Installation Layout.
52 Assemble the Antenna and mounting hardware as shown in Figure 6, Antenna Assembly.
53 Torque Antenna Assembly retaining bolts (11) to 20--25 Nm.

Control Display Unit


54 Assemble the CDU as follows using Figure 7, CDU Assembly.
55 Attach the KH CDU mounting bracket (2) and CDU (1) to the mounting fixture. Torque
mounting bracket bolts (3) to 32--38 Nm.
56 Adjust the viewing angle of the CDU. Tighten CDU pivot bolts (6).
Electrical

Interface Cables
57 Refer to Figure 1, Block Diagram, for cable reference designators.
58 All cables are to be routed within existing cable hangers and wire bundles wherever
practical.
59 Figure 2, Installation Layout, shows preferred cable routes. Utilise this drawing to aid
in establishing the optimum cable routes.
60 All cables should be indelibly marked with the cable reference designation and plug
number.

Amdt 2 (Oct 00) Page 7


KH 1505
Chap 1

ANTENNA
ASSEMBLY

L1

SHIPS
POWER
SK7 24V DC

C O N TR O L SK1 115/240V AC

D IS P L A Y
U N IT
PL1

RADAR
SK2 SHIP
MOTION
DATA
CD-4441

Figure 1 - KH 1020 GPS UE Installation - Block Diagram

8 Sept 97 (Amdt 1)
KH 1505
Chap 1
GPS RECEIVER/PROCESSOR

GPS
VHF BRIDGE
HF
NAVIGATION RADAR

VHF LOW

CD-1884
Figure 2 - Installation Layout of P37B Patrol Craft
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KH 1505
Chap 1

50mm.

Figure 3 - Antenna Stub Mast

10 Sept 97 (Amdt 1)
KH 1505
Chap 1

Figure 4 -- Antenna Stub Mast Mounting Base (if required)

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KH 1505
Chap 1

SK7
+24V

0V 24V DC

GROUND

115/240V AC 50/60Hz (L1)


115/240V AC
115/240v AC 50/60Hz (L2) 45-65Hz

GROUND

LOOP IN 47
BAT2 53 CD-4442

Figure 5 - Interconnection Diagram

12 Sept 97 (Amdt 1)
KH 1505
Chap 1

Figure 6 - Antenna Assembly

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KH 1505
Chap 1

Figure 7 -- CDU Assembly

14 Sept 97 (Amdt 1)
KH 1505
Chap 1

TABLE 4 CONNECTION LIST


WIRE STRIP
CRIMP POSITIONER/ INSPECTION
UNIT MATES PART NO. PINS ASSEMBLY TOOL STRIP LENGTH
TOOL TURRET HEAD GAUGE
TOOL (MM)

INSERT EXTRACT

CDU

DEPENDENT ON
CONN PL1 1 N/A N/A N/A N/A 207865
CABLE TYPE

CONN SK1 D38999/26WA98SN

BACKSHELL

CONTACT M39029/56--- 351 3 DAK95--- 20 DRK95--- 20 MH860 86--- 7 G145 4.77

CONN SK7 D38999/26WA98SA


BACKSHELL
CONTACT M39029/56--- 351 3 DAK95--- 20 DRK95--- 20 MH860 86--- 7 G145 4.77

CONN SK2 D38999/26WE35SN

BACKSHELL

CONTACT M39029/56--- 348 55 DAK95--- 22M DRK95--- 22M MH860 86--- 4 G145 3.18

CONN SK4 D38999 26WD97SN


MS27495 A20 MS27495 R20
BACKSHELL 12 MH860 86--- 7 G145 4.77
MS27495 A16 MS27495 R16
CONTENT M85049/38--- 15W

NOTE: Backshells have a part number but are normally supplied as part of the
connector.
NOTE: SK4 requires three special coaxial inserts ref. 45- 718- 5210

Amdt 2 (Oct 00) Page 15


KH 1505
Chap 1

TABLE 5 PARTS LISTS

FIGURE ITEM
DESCRIPTION PART NO. SUPPLIER QTY
NO. NO.

7 1 CONTROL DISPLAY UNIT (CDU) GPS A2-- 5 P(Y) KELVIN HUGHES 1


7 2 CDU MOUNTING BRACKET GPS-- 1022 KELVIN HUGHES 1
7 6 SCREW M10 X 25MM 25-- 262-- 1420-- 57 KELVIN HUGHES 2
7 7 WASHER PLAIN M10 25-- 281-- 3078-- 57 KELVIN HUGHES 6
7 4 WASHER SPRING M10 25-- 282-- 004 KELVIN HUGHES 6
7 3 SCREW M10 X 30MM 25-- 262-- 1421-- 57 KELVIN HUGHES 4

10 1 GPS ANTENNA ASSEMBLY 45-- 910-- 566 KELVIN HUGHES 1


PL1 TNC CONNECTOR FOR DEPENDENT ON
L1/L2 ANTENNA INSTALLATION

CONNECTORS (IF REQUIRED)


SK1 POWER AC D38999 26WA98SN CANNON 1
SK1 BACKSHELL M85049/38-- 9W CANNON 1
SK2 SERIAL DIGITAL D38999 26WE35SN CANNON 1
SK2 BACKSHELL M85049/38-- 17W CANNON 1
SK3 ANALOGUE D38999 26WC35SN CANNON 1
SK3 BACKSHELL M85049/38-- 17W CANNON 1
SK4 PTTI
NOTE: SPECIAL COAX INSERT D38999 20WD97PN CANNON 1
REQUIRED
SK4 BACKSHELL M85049/38-- 15W CANNON 1
SK7 POWER DC D38999 26WA98SA CANNON 1
SK7 BACKSHELL M85049/38-- 9SW CANNON 1

Page 16 Amdt 2 (Oct 00)


KH 1505
Chap 1

CONTINUITY TEST
This table is to be used in conjunction with the interconnection diagram for continuity testing
of cables prior to system power up.

STEP PROCEDURE YES NO


a. Ensure Power and all cables are isolated from the GPS and other
equipment.
WARNING: FAILURE TO ISOLATE ALL CABLES MAY
RESULT IN DAMAGE TO EQUIPMENT.
b. Carry out isolation tests between the following pins on cable SK1:
Pin A
Pin B
Pin C
c. Carry out continuity tests between the following points:
Pin A L1 115/240V ac
Pin B L2 115/240V ac
Pin C GROUND
d. Carry out isolation tests between the following pins on cable SK7:
Pin A
Pin B
Pin C
e. Carry out continuity tests between the following points:
Pin A +24V
Pin B 0V
Pin C Ground
f. Carry out isolation tests between the following pins on cable PL1:
Pin Centre Conductor.
Pin Screen
g. Carry out continuity tests between the following points:
Pin Centre Conductor KH 1020 to Antenna
Pin Screen KH 1020 to Antenna

Original 17
KH 1505
Chap 1

h. Carry out isolation tests between the following pins cable SK2:
Pin 17
Pin 18
Pin 10
Pin 11
Pin 4
Pin 5
Pin 6
Pin 1
Pin 2
Pin 3
Pin 19
Pin 20
Pin 12
Pin 13
Pin 7
Pin 45
Pin 52
Pin 38
Pin 46
Pin 39
Pin 47
Pin 53

INSULATION BREAKDOWN TEST


This table is to be used in conjunction with the Interconnection Diagram for insulation
testing of cables, prior to system power up.
Pins are tested then shorted to the previously tested pins through the test box. This creates a
”stack” of pins.
A each pin is tested it is added to the stack. The procedure will be as follows:
test pin 1 to shield short pin 1 and shield
test pin 2 to 1 and shield short pin 2 to 1 and shield
test pin 3 to 1, 2 and shield short pin 3 to 1, 2 and shield
test pin 4 to 1, 2, 3 and shield short....etc
To simplify the procedure, it will be written as follows:
test pin 1 to shield
2
3
4

Refer to figure 6, Interconnection Diagram for assistance.

18 Original
KH 1505
Chap 1

RESULT
STEP PROCEDURE
Y N
a. Ensure power and all cables are isolated from the junction box.
WARNING: FAILURE TO ISOLATE CABLES FROM THE
JUNCTION BOX AND SHIPS POWER MAY RESULT IN
EQUIPMENT DAMAGE OR ELECTRICAL SHOCK.
b. Disconnect SK1 from the CDU.
CAUTION: FAILURE TO DISCONNECT SK1 MAY RESULT
IN DAMAGE TO THE CDU WHEN TESTING.
c. Using a Mega--ohm Meter, carry out insulation breakdown tests
on GPS--11, SK1 as follows:
Pin A to shell
Pin B
Pin C
d Using a Mega--ohm Meter; carry out insulation breakdown tests
on GPS--11, SK7 as follows:
Pin A to shell
Pin B
Pin C
e. Does the Meter display >= 10M Ohms for each test? f e.
f. Isolate the defective wire or pin.
g. Disconnect SK2 from the CDU.
CAUTION: FAILURE TO DISCONNECT SK2 MAY RESULT
IN DAMAGE TO THE CDU WHEN TESTING.
h. Using a Mega--ohm Meter, carry out insulation breakdown tests
on GPS--12, SK2 as follows:
Pin 4 to shell
Pin 17
Pin 18
Pin 10
Pin 11
Pin 32
Pin 40
Pin 25
Pin 5
Pin 6
Pin 1
Pin 2
Pin 3

Original 19
KH 1505
Chap 1

RESULT
STEP PROCEDURE
Y N
Pin 48
Pin 54
Pin 49
Pin 41
Pin 19
Pin 20
Pin 12
Pin 13
Pin 7
Pin 14
Pin 21
Pin 8
Pin 15
Pin 9
Pin 23
Pin 31
Pin 16
Pin 24
Pin 22
Pin 36
Pin 37
Pin 28
Pin 29
Pin 30
Pin 45
Pin 52
Pin 38
Pin 46
Pin 39
Pin 50
Pin 51
Pin 43
Pin 44
Pin 55

20 Original
KH 1505
Chap 1

RESULT
STEP PROCEDURE
Y N
Pin 34
Pin 42
Pin 33
Pin 26
Pin 35
Pin 27
Pin 49
i. Does the Meter display >= 10M Ohms for each test? j i.
j. Isolate the defective wire or pin.
k. Disconnect SK3 from the CDU.
CAUTION: FAILURE TO DISCONNECT SK3 MAY RESULT
IN DAMAGE TO THE CDU WHEN TESTING.
l. Using a Mega--ohm Meter, carry out insulation breakdown tests
on GPS--13, SK3 as follows:
Pin 13 to shell
Pin 14
Pin 21
Pin 1
Pin 2
Pin 15
Pin 3
Pin 4
Pin 16
Pin 5
Pin 6
Pin 10
Pin 11
Pin 19
Pin 8
Pin 9
m. Carry out insulation breakdown tests on cable GPS--13 as
follows, from the junction box end.
Gyro pitch shield to shell
Gyro roll shield
Gyro heading shield

Original 21
KH 1505
Chap 1

RESULT
STEP PROCEDURE
Y N
Gyro ref shield
Log shield
Log ref shield
n. Does the Meter display >= 10M Ohms for each test? o n.
o. Isolate the defective wide or pin.
p. Disconnect SK1 from the RCDU.
CAUTION: FAILURE TO DISCONNECT SK1 MAY RESULT
IN DAMAGE TO THE RCDU WHEN TESTING.
q. Isolate GPS--17 from the junction box.
CAUTION: FAILURE TO ISOLATE GPS--17 MAY RESULT IN
DAMAGE TO THE RCDU WHEN TESTING.
r. Using a Mega--ohm Meter, carry out insulation breakdown tests
on GPS--17, SK1 as follows:
Pin B to Pin C
Pin D
Pin E
Pin A
Pin G
s. Carry out insulation breakdown tests on cable GPS--17 as
follows, from the junction box end.
Overall shield to Tx(A)
33vac shield
t. Does the Meter display >= 10M Ohms for each test? u. t.
u. Isolate the defective wire or pin.
v. Disconnect SK5 from the CDU.
w. Disconnet P1 and P2 from the NCDS switchboard.
CAUTION: FAILURE TO ISOLATE GPS--15 MAY RESULT IN
DAMAGE TO EQUIPMENT WHEN TESTING.
x. Using a Mega--ohm Meter, carry out insulation breakdown tests
on GPS--15, SK5 as follows:
Pin 29 to 39
Pin 10
Pin 18
Pin 49
Pin 59
Pin 68

22 Original
KH 1505
Chap 1

RESULT
STEP PROCEDURE
Y N
Pin 78
Pin 27
Pin 37
Pin 8
Pin 16
Pin 47
Pin 57
Pin 25
Pin 35
Pin 11
Pin 19
Pin 37
Pin 38
Pin 69
Pin 79
Pin 48
Pin 58
Pin 9
Pin 17
Pin 26
Pin 36
Pin 67
Pin 77
Pin 46
Pin 56
Pin 71
Pin 81
Pin 51
Pin 61
Pin 50
Pin 60
Pin 70
Pin 80
Pin 3

Original 23
KH 1505
Chap 1

RESULT
STEP PROCEDURE
Y N
Pin 4
Pin 75
Pin 85
Pin 74
Pin 84
Pin 33
Pin 43
Pin 14
Pin 22
Pin 53
Pin 63
Pin 72
Pin 82
Pin 31
Pin 41
Pin 12
Pin 20
Pin 92
Pin 93
Pin 54
Pin 64
Pin 15
Pin 23
Pin 32
Pin 42
Pin 73
Pin 83
Pin 52
Pin 62
Pin 13
Pin 21
Pin 30
Pin 40
Pin 24

24 Original
KH 1505
Chap 1

RESULT
STEP PROCEDURE
Y N
Pin 34
Pin 66
Pin 76
Pin 55
Pin 65
Pin 44
Pin 45
Pin 1
Pin 2
y. At the NCDS Switchboard end, connector P2
Pin B to AS
z. At the NCDS Switchboard end, connector P1
Pin B to AS
aa. Does the Meter display >= 10M Ohms for each test? ab aa.
ab. Isolate the defective wire or pin.
ac. Disconnect PL1 and PL2 from the CDU.
ad. Disconnect P1 and P2 from the Antenna Electronics Unit.
CAUTION: FAILURE TO ISOLATE THE AEU MAY RESULT
IN DAMAGE TO EQUIPMENT WHEN TESTING.
ae. Using a Mega--ohm Meter, carry out insulation breakdown tests
on GPS--14, PL1 as follows:
Centre conductor to shell
aef Does the Meter display >= 10M Ohms for each test? ag af.
ag. Isolate the defective wire or pin.
ah. Carry out insulation breakdown test on connector PL2 using ah
steps aa.--ad.
ai. Insulation Breakdown tests complete. Replace all connectors if
disconnected during testing.
aj. Carry out Harbour acceptance tests.

Original 25
KH 1505
Chap 1

THIS PAGE INTENTIONALLY BLANK

26 Original
KH 1505
Chap 1
Annex E
ANNEX E

SUBMARINE CLASS OF BOAT

TO BE ADDED LATER
WHEN DATA AVAILABLE

Original E.1/2(Blank)
KH 1505
Chap 2

CHAPTER 2

PREPARATION FOR ACCEPTANCE


INTRODUCTION
Object
1 To prepare KH 1020 - GPS for Harbour Acceptance Trial.
References
2 The following documents associated with KH 1020 - GPS are required:
(1) KH 1503, Volume 1 -- Performance and Limitations Information, Operating
Instructions & PAIDs.
(2) KH 1504, Volume 2 -- Technical Description, Maintenance Information, Parts
Lists and Modification Leaflets.
(3) Sensor Handbooks as required.
Prerequisites
3 The following prerequisites are to be satisfied:
(1) Installation Inspection to have been satisfactorily completed and all defects
rectified.
(2) All sensors, compass and log are to be at HAT standard and to be correctly
configured for KH 1020 - GPS operation.
Electrical supplies
4 The following electrical supplies are to be available for the duration of the trial and free
from transients and breaks:
(1) 115/240V, 65--65 Hz, single--phase - Ship’s Supply or 24V dc.
Test equipment required
5 The following test equipment is required:
(1) Test Set Multimeter -- NSN 6625--99--539--4008.
Performance records
6 Results for the trial are to be recorded on the Preparation for Acceptance Performance
Record Sheet, a specimen of which is included at Annex A at the end of this chapter. The results
are to be recorded as the tests are completed. The word ‘RECORD’ in capitals in the ensuing
text signifies a test result which is to be recorded.
7 Completed Preparation for Acceptance Performance Record Sheets are to be made
available to the ship and other interested authorities in accordance with normal procedures.
Time required
8 Approximately 2 hours is required for the Preparation for Acceptance.

Amdt 2 (Oct 00) Page 1


KH 1505
Chap 2

KH 1020 - GPS INITIAL CHECKS


BRIDGE DISPLAY
WARNING
ISOLATE ALL ELECTRICAL SUPPLIES TO THE BRIDGE DISPLAY
BY REMOVING THE RELEVANT FUSES FROM THE SHIP’S SUPPLY
FUSE PANELS.
ENSURE THAT THE POWER ON/OFF SWITCH ON THE REAR OF
THE BRIDGE DISPLAY IS SET TO OFF AND THAT THE SWITCH ON
THE FRONT OF THE DISPLAY IS SET TO OFF.
9 Carry out the following Configuration and Power Supply Checks on the GPS Bridge
Display, layout diagrams of which are shown in Figures 1 and 2.

Figure 1 -- KH 1020 bridge display - front view layout


Configuring the Modules in the Display
10 The Module slots are numbered 1 to 11 with the Modules fitted as shown in Table 1 and
Figure 3 when viewed from the front.

Page 2 Amdt 2 (Oct 00)


KH 1505
Chap 2

SW1

F1

F2 F4

F3 F5

PL1 PL7

Figure 2 -- KH 1020 bridge display - rear view layout


CAUTION
Before connecting or removing cables to/from the DISPLAY, the display must
be switched OFF to prevent damage to the Modules.
Before removing any Modules, from the KH 1020, the Electrostatic Sensitive
Devices (ESD) procedure described in the Preliminary pages is to be carried
out, refer to Figure 3 for Earth/ESD stud location.
11 To remove any Module from the Display:
(1) Disconnect the test cable, if fitted, from the front of the unit.
(2) Loosen the twelve (12) captive screws and remove the front cover from the unit.
(3) Check that all Modules are located in the correct slots as shown in Table 1 and
Figure 3.
RECORD
(4) To remove a Module from the unit, free the Module by loosening the two
wedgelocks using the Spline Tool (T10).
(5) Pull the Module out from the unit by using the built--in extractor lever.

Amdt 2 (Oct 00) Page 3


KH 1505
Chap 2

1 2 3 4 5 6 7 8 9 10 11

EARTH
STUD

Figure 3 -- KH 1020 bridge display - module locations


TABLE 1 -- LOCATION OF MODULES IN CONTROL DISPLAY UNIT

SLOT MODULE DESCRIPTION


1
2
3
4 RECEIVER MODULE
5
6 INTERFACE HANDLER MODULE
7
8 NIF 5 MODULE
9 NAVIGATION PROCESSOR MODULE
10 NIF 4 MODULE
11 DISPLAY CONTROLLER MODULE

Navigation processor module - configuration check


12 With reference to Figure 3, locate the Navigation Processor Module (Slot 9). Remove
and check the configuration as follows:
(1) With reference to Figure 4, locate the links and check that the settings are as
shown in Table 2.
RECORD
(2) Refit the Module in the frame and fasten the wedgelocks.

Page 4 Amdt 2 (Oct 00)


KH 1505
Chap 2

TABLE 2 - LINK SETTINGS

MODULE LINK FITTED NOT FITTED STATUS


Navigation LK1 NMI Enabled NMI Disabled Fitted
Processor LK2 Watchdog Enabled Watchdog Disabled Fitted
Interface LK1 Will use Internal reset Will use External reset Not Fitted
Handler LK2 Port 0.6 Test Mode Port 0.6 Normal Mode Not Fitted
Naval LK1 24V sent to Pulse Log GPS Pulsed Log Input Application
Interface 4 Interface contacts requires External voltage Dependent
MODULE LINK Link to +5V Link to GND STATUS
Display LK1 Port 0.6 Normal Mode Port 0.6 Test Mode Fitted in Posi-
Controller tion +5V

D4 LK2 IC IC
D5 LK1 27 25
D6 SW1
IC
26

IC 32 IC 20
IC
24
IC 28

IC
19

D7
IC 12 IC 13
XTAL 1

PL 2

Fig 4 -- Navigation processor module - link locations

Interface handler module -- configuration check


13 With reference to Figure 3, locate the Interface Handler Module (Slot 6) remove it and
check the configuration as follows:

(1) With reference to Figure 5, locate the links and check the settings as shown in
Table 2.

RECORD

(2) Refit the Module in the frame and fasten the wedgelocks.
Amdt 2 (Oct 00) Page 5
KH 1505
Chap 2

LK2
LK1
IC 6 IC 7

IC 9 IC 14 X1
IC 10
IC 12 IC 13

IC 8 IC 4
IC 5
IC 1

IC 3 IC 11 IC2

Figure 5 -- Interface handler module - link locations


Display Controller Module - configuration check
14 Locate the Display Controller Module (Slot 11) and check the setting of the links as
follows:
(1) With reference to Figure 6, locate the links and check
the settings are as shown in Table 2.
RECORD

IC 4
IC 1

X2
IC 2

IC 9
IC 3
X1
LK 1
+5V GND
IC 10

IC 6 IC 5 IC 8 PL 2

PL 1 IC 7 IC 11

Figure 6 - Display controller module -- link locations


(2) Refit the Module in the frame and fasten the wedgelocks.
Page 6 Amdt 2 (Oct 00)
KH 1505
Chap 2

Naval interface 4 module-- confi guration check


15 Locate the Naval Interface 4 Mod ule (Slot 10) and check the setting of the links as
follows:
(1) With reference to Figure 7, locate the links and check the settings are as shown
in Table 2.
RECORD

PL 2

IC 4 IC 14 IC 18 IC 20

IC 9 IC 15 IC 19

IC 5 IC 3
IC 1
LK1
IC 12
IC 8
IC 13 IC 6

IC 11 IC 17 IC 10

IC 2 IC 7 IC 16

Figure 7 -- Naval interface 4 module - link locations


(2) Refit the Module in the frame and fasten the wedgelocks.
Power supply checks
16 With reference to Figure 2 carry out the following checks:
(1) Check that the three fuses, on the rear of the unit are as follows:
a. F1 -- 3.15 Amps.
b. F2 - 3.15 Amps.
c. F3 - 2 Amps.
d. F4 - 3.15 Amps
e. F5 -- 3.15 Amps
RECORD
(2) Check that the earth connection between the unit, refer to Figure 2, and the ship’s
earth stud is mechanically sound and not corroded. Check the continuity, using
a multimeter, between a good earth point and an unpainted part of the rack.
Resistance should be less than 19.
RECORD
Amdt 2 (Oct 00) Page 7
KH 1505
Chap 2

1 2 3 BRILLIANCE
KELVIN HUGHES 1020
4 5 6

7 8 9 CONTRAST

+/ - 0 .
INJ CLR

HELP F1 F2 F3 F4 F5 F6

Figure 8 - KH 1020 RCDU -- front view layout


(3) Check, using a Multimeter, that the battery voltage measured between PL2 Pin
47 and the chassis is between 3.2V and 3.8V.
RECORD
(4) Reconnect the front cable, if fitted.
(5) Restore ship’s mains to the GPS Bridge Display.
RECORD

Page 8 Amdt 2 (Oct 00)


KH 1505
Chap 2

REMOTE CONTROL & DISPLAY UNIT

WARNING

SWITCH OFF THE BRIDGE DISPLAY TO ISOLATE ALL POWER TO


THE REMOTE CONTROL & DISPLAY UNIT (RCDU).
17 Carry out the following initial checks on the GPS RCDU, a layout diagram of which is
shown in Figure 8:
(1) Remove the cover to the front of the GPS RCDU (12 screws).
(2) Check that fuse F1 on the rear of the RCDU is 2 Amps.
RECORD
(3) Check that the earth connection between the GPS RCDU, refer to Figure 9, and
the ship’s earth stud is mechanically sound and not corroded. Check the
continuity, using a multimeter, between a good earth point and an unpainted part
of the display. Resistance should be less than 1.
RECORD

EARTH STUD

Figure 9 -- KH 1020 RCDU - rear view layout

Display controller module - configuration check


18 With reference to Figure 10, locate the Display Controller Mod ule. Remove the Module
and check the configuration as follows:
(1) With reference to Figure 10, locate link LK 1 and check the setting is left:
Left(Towards Backplane): Port 0.6 Normal Mode
Right(Towards Backplane): Port 0.6 Test Mode
RECORD

Amdt 2 (Oct 00) Page 9


KH 1505
Chap 2

(2) Refit the Module.


(3) Replace the cover on the front of the GPS RCDU.

IC 4
IC 1

X2
IC 2

IC 9
IC 3
X1
LK 1
IC 10

IC 6 IC 5 IC 8 PL 2

PL 1 IC 7 IC 11

Figure 10 -- Display controller module - link locations

Page 10 Amdt 2 (Oct 00)


KH 1505
Chap 2

KH 1020 -- GPS BASIC EQUIPMENT CHECKS


GPS BRIDGE DISPLAY
19 The test procedure for the GPS Bridge Display is as follows:
(1) Switch the display power On/Off switch (SW1), located on the rear of the unit,
to ON.
NOTE
This also provides power to the RCDU.
(2) On the front of the display, rotate the brightness control clockwise (this switches
on the display) and continue until desired level of brilliance is achieved. The
contrast control may require adjusting.
(3) Check that the display momentarily shows:

WAITING FOR

NAV PROCESSOR

(4) The Ownship Screen is then displayed as shown in Figure 11, note actual values
may vary.
RECORD

11 OWNSHIP DATA

STATUS
GPS (SPS)
POSITION PFOM 2
12 30.471S

130 59.007E
FIXING
DATUM: WGS 84
3D

TIME TFOM 3
07 1230: 171K
CMG HEAD DRIFT
047.5 045.0 205
SMG KT LOG KT KT
0.00 0.00 0.0

DISPLAY ANCHOR FREEZE MAN-- OVER NIGHT MAIN


WAYPT WATCH & MARK BOARD VIEW MENU

Figure 11 - Ownship screen

Amdt 2 (Oct 00) Page 11


KH 1505
Chap 2

(5) Check that the Brilliance and Contrast controls, located on the front of the display,
function correctly.
RECORD
(6) Check that the local GPS Bridge CDU is operating correctly by carrying out the
following:
a. Press HELP and F1 keys simultaneously.
b. The following screen appears:

CDU LOCAL SELF TEST MENU

F1: RAM TEST


F2: ROM TEST
F3: VIDEO RAM TEST
F4: KEYBOARD TEST
F5: PROCESSOR TEST
F6: DISPLAY TEST

CLR: RETURN TO ON---LINE MODE


RAN GPS CDU FIRMWARE VERSION X.XX

c. Press F1 to F6 in turn and check that the following results are obtained:
i RAM TEST PASSED
ii ROM TEST PASSED
iii VIDEO RAM TEST PASSED
iv KEYBOARD TEST
Press each key on the front panel in turn and check that
the appropriate X appears in the box as shown on the
display - to exit press HELP and F1 simultaneously.
v PROCESSOR TEST PASSED
vi DISPLAY TEST
Observe the display checker patterns are ‘True’ and
‘Inverse’ for the small and large squares sequentially
displayed.
RECORD
d. Press CLR to return to the Ownship Screen.

Page 12 Amdt 2 (Oct 00)


KH 1505
Chap 2

DATA INPUT CHECKS


20 The following checks are designed to show that data is fed to the unit from various
sensors fitted to the system. Note that ship fits may have different sensors. All appropriate
sensors must be switched ON and be capable of sending data to the interfaces.
Interface Set--Up
21 To implement the Interface set--up:
(1) Press CLR -- Selects Owship Screen.
(2) Press F6 -- Main Menu.
(3) Press F4 - System Set--Up Menu.
(4) Press F4 - Interface Set--up Page, carry out the following from this point:
Press F1 -- Interface.
Press F1 - Next until the appropriate interface is displayed in inverse
video.
Press INJ. to enter the selection.
Press F3 - Status
Press F1 - Next to select the required condition.
Press INJ.
Press F2 - Data Exchange
Press F1 - Next until the required source is displayed
Press INJ.
Press F3 - Status.
Press F1 - Next for the required condition.
RECORD
(5) Next:
Press F6 -- More.
Press F1 - Baud Rate.
Press F1 or F2 to display 9600 in inverse video.
Press INJ.
RECORD
(6) Next:
Press F2 - Parity.
Press F1 or F2 to display None in inverse video.
Press INJ.
RECORD
(7) Next:
Press F3 - Data Bits.
Press F1 or F2 to display eight (8) in inverse video.
Press INJ.
RECORD
(8) Next Press F6 -- More, then:
Press F1 -- Interface.
Press F1 - Next to get required type
Press INJ.

RECORD
Amdt 2 (Oct 00) Page 13
KH 1505
Chap 2

(9) Next:
Press F2
Press F1 -- Next until rhe required source is displayed
Press INJ.
RECORD
(10) Next:
Press F6 -- More.
Press F1 - Baud Rate.
Press F1 - Next to seledct the required rate
Press INJ.
RECORD
(11) Next:
Press F2 - Parity.
Press F1 or F2 to display the required type.
Press INJ.
RECORD
(12) Next:
Press F3 - Data Bits.
Press F1 or F2 to display the appropriate number in inverse video.
Press INJ.
RECORD
(13) Next:
Press F6 -- More.
Press F3 - Status.
Press F2 -- To show the correct condition.
RECORD
(14) Next:
Press F1 -- Interface.
Press F1 -- Next until the required type is selected.
Press INJ.
RECORD
(15) Next:
Press F2 -- Data Exchange.
Press F1 - Next until the required source appears on the display.
Press INJ.
RECORD
(16) Next:
Press F6 -- None.
Press F1 - Baud Rate.
Press F1 - Next to choose the required rate.
Press INJ.
RECORD
Page 14 Amdt 2 (Oct 00)
KH 1505
Chap 2

(17) Next:
Press F2 - Parity.
Press F1 or F2 -- to display the correct type.
Press INJ.
RECORD
(18) Next:
Press F3 - Parity.
Press F1 or F2 - to select the correct type.
Press INJ.
RECORD
(19) Next:
Press F6 -- More.
Press F3 - Status.
Press F2 - To obtain the required condition.
RECORD
RCDU DISPLAY
22 The test procedure for the RCDU is as follows:
(1) Switch the RCDU power On/Off switch (SW1) located on the rear of the display
to ON.
(2) Check that the display shows the Ownship Screen, after displaying the same
run--up sequence as the GPS Bridge display.
RECORD
(3) Check that the Brilliance and Contrast controls, located on the front of the RCDU
panel, function correctly.
RECORD
(4) Check that the RCDU is operating correctly by carrying out the following:
a. Press HELP and F1 keys simultaneously.
b. The following screen appears:

CDU LOCAL SELF TEST MENU

F1: RAM TEST


F2: ROM TEST
F3: VIDEO RAM TEST
F4: KEYBOARD TEST
F5: PROCESSOR TEST
F6: DISPLAY TEST
CLR: RETURN TO ON---LINE MODE
RAN GPS CDU FIRMWARE VERSION X.XX

c. Press F1 to F6 in turn and check that the following results are obtained:
i RAM TEST PASSED
ii ROM TEST PASSED
iii VIDEO RAM TEST PASSED
Amdt 2 (Oct 00) Page 15
KH 1505
Chap 2

iv KEYBOARD TEST
Press each key on the front panel in turn and check that
the appropriate X appears in the box as shown on the
display - to exit press HELP and F1 simultaneously.

v PROCESSOR TEST PASSED


vi DISPLAY TEST
Observe the display checker patterns are ‘True’ and
‘Inverse’ for the small and large squares sequentially
displayed.
RECORD
d. Press CLR to return to the Ownship Screen.
RECORD

KH 1020 - GPS FUNCTIONAL CHECKS


23 The following tests and checks on KH 1020 - GPS system are designed to exercise as
many facilities of the system as possible. Ensure that all KH 1020 - GPS units and external
sensors (as available) are switched ON.
SENSOR INPUT CHECKS
24 The data input from the sensors (random readings may be received which have no
significance but confirms that data is being received) is checked by observing the values on the
Motion Data Page (12), refer to KH 1503, Volume 1, Section 2, Chapter 2.
NOTE
For Shore Establishments check that data is being received from the simulator for each
sensor, if fitted.
(1) Check the Head reading on the screen and compare with the compass output.
RECORD
(2) Check the Log data on the screen and compare with the log output.
RECORD
(3) Check the Roll on the screen and compare with the VRU output.
RECORD
(4) Check the Pitch on the screen and compare with VRU output.
RECORD
Self Test of the System Interfaces (refer to Annex B for interfaces fitted)
25 To select this test, carry out the following:
(1) Press F6 -- Main Menu.
(2) Press F5 - Fault Monitoring Menu.
(3) Press F3 -- Self Test, the screen shown in Figure 12 appears:
a. Press F1 - Nav Computer
b. Press F1 -- Confirm YES. The test interrupts normal operation of the GPS
and the operator is requested to confirm acceptability.
(4) The display indicates PASS or FAIL within 7 seconds.
RECORD
Page 16 Amdt 2 (Oct 00)
KH 1505
Chap 2

a. Press F2 -- RS422.
b. Press F1 -- Confirm YES. The test interrupts normal operation of the GPS
and the operator is requested to confirm acceptability.
(5) The display indicates PASS or FAIL within 0.5 seconds.
RECORD
a. Press F3 - Receiver Modules.
b. Press F1 -- Confirm YES. The test interrupts normal operation of the GPS
and the operator is requested to confirm acceptability.

53 SELF TEST

NAV COMP
PASS RS422
PASS
RECEIVER
PASS
SYNCHRO
PASS

NAV RS422 RECEIVER SYNCHRO


COMPUTER

Figure 12 - Self test page


(6) The display indicates PASS or FAIL within 4 minutes.
RECORD
a. Press F5 - Synchro.
b. Press F1 -- Confirm YES. The test interrupts normal operation of the GPS
and the operator is requested to confirm acceptability.
(7) The display indicates PASS or FAIL within 5 seconds.
RECORD
NOTE
This test will indicate FAIL if the Synchro Interface is not fitted.
PLATFORM SET UP
26 The platform set up is to be carried out in accordance with KH 1503, Volume 1, Section
2, Chapter 2. Note that these lever arm corrections are only applied if the receiver is being
supplied with valid heading, roll and pitch data from ship motion sensors.
RECORD
Amdt 2 (Oct 00) Page 17
KH 1505
Chap 2

POSITION INITIALISE
27 If the receiver is being set to work for the first time, has been moved more than 100Kms
when switched off or has had major maintenance on or replacement of the receiver modules or
battery, it is necessary to re--initialise the unit. This is to be carried out in accordance with
KH 1503, Volume 1, Section 2, Chapter 2.
NOTE
After initialisation wait 2 minutes for the System to stabilise.
RECORD
POSITION CHECK
28 This verifies that ship’s position may be calculated from the data input from the sensors.
Check that the position computed, with all sensors included in the calculation, is in agreement
with ship’s known position.
RECORD
ON COMPLETION
29 On completion of all PFA Checks and Tests, switch OFF GPS Bridge Display and GPS
RCDU.

Page 18 Amdt 2 (Oct 00)


KH 1502
Chap 2
Annex A
ANNEX A

PREPARATION FOR ACCEPTANCE PERFORMANCE RECORD SHEET

KH 1020 -- GPS

SHIP ...................................... ESTABLISHED ........................


DATE ....................................... REVISED ................................

REFERENCE ITEM CHECK AND/OR RECORD


NO

Chapter 2 KH 1020 - GPS INITIAL CHECKS


Paragraph

11(3) 1 Modules located in correct slots

12(1) 2 Nav Processor Module - links correct

13(1) 3 Interface Handler Module - links correct

14(1) 4 Display Controller Module - links correct

15(1) 5 Naval Interface 4 Module - links correct

16(1) 6 Power Supply FS1 3.15A OK


FS2 3.15A OK
FS3 2A OK
FS4 3.15A OK
FS5 3.15A OK

16(2) 7 Earth continuity less than 1 ohm

16(3) 8 Check battery within 3.2V and 3.8V

16(5) 9 Ship’s mains restored

Original A.1
KH 1502
Chap 2
Annex A

REMOTE CONTROL & DISPLAY UNIT


(Bridge Display)

17(2) 10 FS1 is 2A OK

REFERENCE ITEM CHECK AND/OR RECORD


NO

Chapter 2 REMOTE CONTROL & DISPLAY UNIT (Cont)


Paragraph (Bridge Display)

17(3) 11 Earth continuity less than 1 ohm

18(1) 12 Display Controller Module - link correct

KH 1020 - GPS BASIC EQUIPMENT CHECKS

19(4) 13 Ownship screen correct

19(5) 14 Brilliance and Contrast correct

19(6) 15 RAM Test Passed


ROM Test Passed
Video RAM Test Passed
Keyboard Test
Processor Test Passed
Display Test

DATA INPUT CHECKS Interface Set--Up

21(4) 16 Interface

21(5) 17 Baud Rate

21(6) 18 Parity

21(7) 19 Data Bits

21(8) 20 Interface

A.2 Original
KH 1502
Chap 2
Annex A

21(9) 21 Data Exchange

21(10) 22 Baud Rate

REFERENCE ITEM CHECK AND/OR RECORD


NO

Chapter 2 DATA INPUT CHECKS (Cont)


Paragraph Interface Set--Up

21(11) 23 Parity

21(12) 24 Data Bits

21(13) 25 Status

21(14) 26 Interface

21(15) 27 Data Exchange

21(16) 28 Baud Rate

21(17) 29 Parity

21(18) 30 Data

21(19) 31 Status

22(2) 40 Run Up

22(3) 41 Brilliance and Contrast correct

22(4(c)) 42 RAM Test Passed


ROM Test Passed
Video RAM Test Passed
Keyboard Test
Processor Test Passed
Display Test

Original A.3
KH 1502
Chap 2
Annex A

22(4(d)) 43 Ownship screen OK

REFERENCE ITEM CHECK AND/OR RECORD


NO

KH 1020 - GPS FUNCTIONAL CHECKS

24(1) 44 Head Reading OK

24(2) 45 Log Data OK

24(3) 46 Roll compared

24(4) 47 Pitch compared

Self Test of Interfaces

25(4) 48 Nav Computer PASS/FAIL

25(5) 49 RS422 PASS/FAIL

25(6) RECEIVER PASS/FAIL

25(7) 52 Synchro PASS/FAIL

26 53 Platform Set up OK

27 54 Position Initialisation OK

28 55 Position Check OK

Acceptance Authority

A.4 Original
KH 1502
Chap 2
Annex A
Signed ...................................

Date .....................................

Original A.5
KH 1505
Chap 2
Annex B
ANNEX B

INTERFACES TO BE SET--UP/TESTED FOR EACH SHIP FIT

Ship Name Compass Log Pitch Roll Radar


1 x x x x x
2 x x x x x
3 x x x x x
4 x x x x x
5 x x x x x
6 x x x x x
7 x x x x x
8 x x x x x

X = Interface Fitted.
N/A = Not Applicable.
TBA = To Be Added.
x(N/A)= Interface Fitted but not to be tested.

Original B.1/2(Blank)
KH 1505
Chap 3

CHAPTER 3

HARBOUR ACCEPTANCE TRIALS


INTRODUCTION
Object
1 The object of the Harbour Acceptance Trial for KH 1020 - GPS is to check that the system
performs to an acceptable standard and that it is in all respects ready for sea.
References
2 The following documents associated with KH 1020 - GPS are required:
(1) KH 1503, Volume 1 -- Performance and Limitations Information & Operating
Instructions.
Prerequisites
3 Ensure that the following prerequisites have been met:
(1) Installation Inspection and Preparation For Acceptance (PFA) to have been satisfactorily
completed and all outstanding defects have been rectified and PFA records available.
(2) All Navigation sensors, compass, log to be at HAT standard and to be correctly
configured for KH 1020 - GPS operation.
Electrical supplies
4 The following electrical supplies are to be available for the duration of the trial and are to be free
from transients and breaks:
(1) 115V, 60 Hz, 1 Phase - Ship’s Supply or 24V dc supply.
Performance records
5 Results for the trial are to be recorded on the Harbour Acceptance Trial Performance Record
Sheet, a specimen of which is included at Annex A at the end of this chapter. The results are to be
recorded as the tests are completed. The word ‘RECORD’ in capitals in the ensuing text signifies a test
result which is to be recorded. The Interface Tests are to be carried out in accordance with the matrix
in Chapter 2, Annex B.
6 Completed Harbour Acceptance Performance Trial Record Sheets are to be distributed to the
ship and other interested authorities iaw normal procedures.
Time required
7 Approximately 1 man day is required to carry out the Harbour Acceptance Trial.
Conduct of the trial
8 The HAT is conducted in two sections, one for the KH 1020 - GPS Bridge equipment and one
for the Remote Control Display Unit (RCDU) equipment if fitted. The HAT is based on the tests and
checks carried out in the Factory Acceptance Test (FAT).

Original 1
KH 1505
Chap 3

KH 1020 -- GPS TEST PROCEDURES


KH 1020 -- GPS BRIDGE DISPLAY
9 The procedure to test KH 1020 - GPS Bridge display is as follows:
(1) Switch the display power On/Off switch (SW1) located on the rear of the display to ON.
(2) Rotate the Brilliance Control to switch on the display and set the correct level of
brilliance.
(3) Check that the display provides a similar initialisation sequence as the following, before
entering the Ownship page:

WAITING FOR

NAV PROCESSOR

RECORD
BRIDGE PAGE CHECKS
10 Check for the correct display of the following pages:
(1) Ownship (11). Check position, time and time zone and determine if appropriate for ship
location. The position is to be within 10km and the time within 20 seconds.
NOTE
Correct information allows the Receiver to carry out a warm start without initial position
information. Incorrect information requires that the Receiver Set- up procedure is carried out,
refer to Chapter 2.
RECORD
(2) Satellite Data Page (31). After 90 seconds select this page and check that at least four
channels have Status C&C (Code & Carrier). This indicates that the Receiver is
collecting Satellite data.
RECORD
(3) Ownship (11). Select this page and check that the position is appropriate to the location.
RECORD
(4) Crypto Set Up Page (45). Using the KYK--13 Fill Gun key the Receiver. Select this page
and ensure that the key has been correctly loaded and verified.
RECORD

2 Original
KH 1505
Chap 3

SENSOR CHECKS
NOTE
Only carry out the Sensor checks as appropriate to those fitted, refer to Chapter 2, Annex B -
Interfaces to be Set- up/Tested for each Ship Fit.
Motion sensors
11 Check that data from the Motion sensors is being received on the Motion Data Page (12) as
shown below:

Log Data Check


12 To check Log Data:
(1) Confirm that the log set--up of the GPS Receiver is appropriate to the Interface on the
ship.
(2) Adjust the log input to read from - ve full scale to +ve full scale in steps of 10kts or less
and check the values received by the GPS.
NOTE
It may be possible to manually set the Log Synchro or Pulse Output to a particular speed for
this test. If no manual adjustment is possible the current under the vessel provides some Log
data against which the sense and magnitude of the motion data may be read.
(3) Set any fixed Log Offset into the Log Error parameter.
RECORD

Compass Data Check


13 To check Compass Data:
(1) Confirm the Compass (Head) set--up of the GPS.
(2) Adjust the Compass input to read from 0° to 360° in increments of 45° and check the
value received by the GPS.
(3) Set any fixed Compass transmission error into the Gyro Error parameter.
RECORD
RCDU DISPLAY
14 The procedure to test the RCDU functions is as follows:
(1) Switch the display power On/Off switch (SW1) located on the rear of the display to ON.
(2) Rotate the Brilliance Control to switch on the display and set the correct level of
brilliance.
(3) Check that the display shows the Ownship Page, after displaying the same start--up
sequence as shown on the Bridge display.
RECORD
(4) Select CLR on the RCDU and confirm that Ownship Page displays Position, Time,
Course and Speed appropriate to the location of the vessel.
RECORD
ON COMPLETION
15 On completion of all test/checks, switch OFF the GPS Bridge Display and RCDU.

Original 3
KH 1505
Chap 3
Annex A
ANNEX A

HARBOUR ACCEPTANCE TRIALS RECORD SHEET

KH 1020 -- GPS

SHIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . ESTABLISHED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
DATE . . . . . . . . . . . . . . . . . . . . . . . REVISED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFERENCE ITEM CHECK AND/OR RECORD


NO

Chapter 3 KH 1020 -- TEST PROCEDURE


Paragraph GPS BRIDGE DISPLAY

9(3) 1 Ownship screen correct

BRIDGE PAGE CHECKS

10(1) 2 Position and Time correct

10(2) 3 Status C & C Channel 1


Channel 2
Channel 3
Channel 4

10(3) 4 Ownship Position correct

10(4) 5 Key correctly loaded

SENSOR CHECKS
Motion Sensors

12 6 Log Data correct

13 7 Compass Data correct

Original A.1
KH 1505
Chap 3
Annex A

REFERENCE ITEM CHECK AND/OR RECORD


NO

RCDU Display

14(3) 12 Ownship Display correct

14(4) 13 Position,, Time and Course & Speed correct

Acceptance Authority
Signed . . . . . . . . . . . . . . . . . . . . . . . . . .
Date ..........................

A.2 Original