DPC-411 Maintenance Manual

DPC-411
Maintenance Manual

This document contains hardware description and

maintenance information for the DPC-411.

Important notice:

The information contained in this document shall remain

the sole exclusive property of Kongsberg Maritime AS, and
shall not be disclosed by the recipient to any third party
without the written consent of the company.

177877 /A 1
DPC-411 Maintenance Manual

Document revisions

Written by Checked by Approved by

Rev Date Sign Date Sign Date Sign
A 07.06.04 EIK 17.08.04 GKN 20.08.04 BF
B
C
D
E
F

The original signatures are recorded on the company’s logistic data system.

Document history
Rev. A First version.

2 177877/A
 DPC-411 Maintenance Manual

HW Configuration Status
(This information is for Kongsberg Maritime use only)
The configuration status of documents describing the DPC-411 hardware for this
revision of the Maintenance Manual are listed below:

Parts Lists
Parts List DPC-411 (115/230 Vac): P20130, Rev. A

Drawings
General Arrangement, DPC-411, Cabinet 600x1200x300: 1002018, Rev. A
Layout Drawing, DPC-411, 600x1200x300: 1001550, Rev. A
Power and Wiring Diagram, DPC-411, DPC w/RIO Modules: 1001548, Rev. A
Wiring Diagram, DPC-411, Net/Serial Lines: 1001549, Rev. A
Wiring Diagram, JC/DPC 401/411, Isolation Amplifiers: 1000957, Rev. A
Wiring Diagram, Interface Cable, RCU510 - TBSS: 1001144, Rev. C

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 DPC-411 Maintenance Manual

Table of contents

HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuse-status indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply (24 Vdc) monitoring and alarming . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grounding RCU modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Serial-line interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Data network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Galvanic isolation of output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Field Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Field cable termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spare core termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General fault finding and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reading power status LEDs and measuring supply voltages . . . . . . . . . . . . . . . 16
Equipment status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault finding flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to tighten screws in the termination blocks . . . . . . . . . . . . . . . . . . . . . . . . 20
How to check connector locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to clean cabinets/equipment housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preventive maintenance intervals for DPC-411 . . . . . . . . . . . . . . . . . . . . . . . . . 20
CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing PSU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing Q1 or Q2 circuit-breaker (MCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing Isolation Amplifier (ISO1 to ISO12) . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacing RCU510 or the fan in RCU510 module . . . . . . . . . . . . . . . . . . . . . . . 25
Replacing TBSS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REPLACEABLE PARTS AND CONSUMABLES . . . . . . . . . . . . . . . . . 27
Replaceable parts and recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . . 28
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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 Hardware Description

HARDWARE DESCRIPTION
This section describes the DPC-411 hardware
configuration.

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Kongsberg Maritime DPC-411

Cabinet layout
Note The layout of a delivery specific cabinet may deviate from the
standard example in Figure 1. See the vessel specific layout
drawing in the vessel’s Drawing File for the exact layout and
wiring information.
The DPC-411 cabinet is made for wall mounting. It has three
dedicated positions for RCU modules on its rear wall (see
Figure 1).
Isolation amplifiers for analog outputs are located on the lower
right of the rear wall.

LEFT WALL REAR WALL RIGHT WALL

F1 X21 F1 X31
X22 X32
X41 F1
X42

TBSS1
PSU1
U1 U3

RCU510 RCU510 TBSS2

(optional)
TBSS3

ISO 1
FL1
TBSS4
U2
CABLE DUCT
ISO 6
ISO 7
CABLE DUCT

CABLE DUCT

CABLE DUCT
CABLE DUCT

CABLE DUCT

RCU510
F1 X11
ISO 12
X12

NET
PATCH
Q1 PANEL PP1
BUSBAR
Q2
MAINS
OUTLET I.E.
SOCKET

(CD3049)

Figure 1 Layout of DPC-411

Power supply, mains filter and magnetic circuit-breakers

(MCBs) are located on the the left wall.
Up to four serial line interface boards (TBSS) are located on the
right wall together with the LAN connections for the RCUs.
Field cabling to DPC-411 are routed through the cabinet bottom.

8 177877/A
 Hardware Description

Block diagram
A block diagram of DPC-411 is shown in Figure 2.

Fuses

FL1 PSU1
Q1 NET A & B NET A & B
115/230 Vac +24 Vdc
6A Filter Power RCU RCU
Supply
U1 U2
Mains Outlet
Q3 Sockets

Serial Lines
2A

Serial Lines
ISO 1-6 ISO 7-12
To equipment outside Field Signal Loops Field Signal Loops
DPC cabinet

(optional)
TBSS1 TBSS2 TBSS3 TBSS4

Field Serial Lines Field Serial Lines Field Serial Lines Field Serial Lines

Fuses
To 3-Way Isolation
Amplifiers ISO 1-6 and ISO 7-12
NET A & B
RCU

U3
(optional)

(CD3048)

Field Signal Loops

Figure 2 Block diagram of DPC-411

Power supply
DPC-411 handles both 230 Vac and 115Vac as mains supply.
The block diagram in Figure 2 shows the power supply
principles of of DPC-411.
The power supply supplies up to three RCU510s, up to four
TBSSs (serial termination boards), several isolation amplifiers
and external equipment with 24 Vdc.
The mains voltage passes the MCB (Q1) before it is filtered for
noise (FL1). The MCB trips and breaks the circuits if the mains
current exceeds the rated MCB current.
The filtered mains voltage is converted to 24 Vdc by the AC/DC
converters (PSU1). The 24 Vdc is distributed to different
modules by fuses with rating suitable for the loads the modules
represent. The fuses can also be used to isolate the different
circuits.

Fuse-status indication
The fuses designated Fnn (F1, F2, etc.) in DPC-411, have a built-in
status LED. If a fuse is broken, the corresponding LED is lit red
because the impedance of the load forces the LED to supply
voltage ground.

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Kongsberg Maritime DPC-411

F1 - Fnn
Supply
voltage Load

R
LED
D
(CD2902)

Figure 3 Fuse status indicator circuitry

Power supply (24 Vdc) monitoring and

alarming
To monitor the supply voltage (24 Vdc) each RCU510 reads the
voltage with high precision at the power terminals on X1 to X4
and gives system alarm if voltage is outside predefined values.

Grounding RCU modules

Each RCU module shall be grounded. FL1 fast-on terminal is
connected to PE (or to IE if specified).
See also the RCU module Hardware Module Description about
details on the grounding principles.

Serial-line interface
To obtain galvanic isolation of all serial lines attached the serial
line interface TBSS module is used.
TBSS can have two plug-in adapters installed. The adapters can
be of either RS232 or RS422 type. Each adapter contains two
isolated serial channels.
A TBSS module provides circuitry for a maximum of four serial
channels. Used in a configuration with the RCU, the first TBSS
handles four channels and the second handles three channels.
See separate TBSS Hardware Module Description document for
details.
Figure 4 shows the cabling between the RCU and two TBSS
modules. A split flat-cable is connected between the RCU in
location U1 at one end and connector P1 on TBSS 1 and P1 on
TBSS 2 at the split end.
For more serial lines a second split flat-cable is connected
between RCU in location U2 and connector P1 on TBSS3 and
P1 on TBSS4 (optional) at the split end.

10 177877/A
 Hardware Description

Serial channels
1 to 4
TBSS 1
P1

Serial channels
5 to 7
RCU TBSS 2
P1

(CD3083)

Figure 4 Principle of internal serial-line cabling using TBSS

Data network
Network field cables are terminated on the Mini Patch Box,
PP1. Patch cables with RJ45 connectors are connected between
the RCUs’ A network terminals and the Patch Box connectors.

Mini
Patch
Box
Field
Cables

Net A
Net A Net A

RCU RCU RCU

Net A Net B Net A Net B Net A Net B

U1 U2 U3
(optional)

(CD3085)

Figure 5 Network principles in DPC-411

See separate drawing in the Drawing File for which ports on

the Patch Box are used.

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Kongsberg Maritime DPC-411

Galvanic isolation of output signals

The output signals, mainly used to control thrusters, are normally
provided with configurable, universal isolation amplifiers
(location ISO 1 to ISO 12 in Figure 1) to obtain galvanic isolation.
Note See the vessel specific documentation for details on which
signals are provided with galvanic isolation.
The isolation amplifiers provide both voltage and current output
(see the Isolation Amplifier, 3-way, Hardware Module Description
for details).

Field Cabling

Field cable termination

The field cables’ outer shields are cut and terminated inside the
through-holes in the bottom plate of the cabinet. The signal
wires are then routed in cable ducts to the terminal blocks on the
RCU and TBSS modules.

Spare core termination

It is vessel dependent if and where to terminate the spare cores
of the field cables. Normally spare cores are terminated to IE
bar.

12 177877/A
 Hardware Description

Technical specifications
POWER SUPPLY REQUIREMENTS
Supply voltage 115/230 Vac
Typical power consumption 125 W
Maximum power consumption 285 W
MECHANICAL SPECIFICATION
Size: width x height x depth 600 x 1200 x 300 mm
Weight 65 kg
ENVIRONMENTAL REQUIREMENTS
EMC Non-shielded cabinet
IP degree IP44
Typical heat dissipation 75 W
Maximum heat dissipation 135 W
Noise level < 40 dB
Also refer to Kongsberg Maritime Environmental Specification, reg. no.:
161011

Table 1 DPC-411 technical specifications

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 Fault Finding

FAULT FINDING
This section presents the fault finding principles for the
DPC-411.

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Kongsberg Maritime DPC-411

General fault finding and repair

To correct the system, if an error situation has occurred, the
flowcharts in Figure 6 has been provided. A combination of the
following information items listed below may also be required
to locate errors and correct the system:
· Status information or alarm messages shown in the
application window on the operator station. See the
appropriate Operator Manual for more details on this topic.
· Status LEDs and lamps on hardware modules such as power
supplies and RCU modules. See the appropriate Hardware
Module Description for details.
· Values of power-output voltages and fuse state in the system.
See the appropriate Hardware Module Description for more
information.
· System-specific diagrams, lists and drawings. See the
appropriate Drawing File for details.
· Replacement procedures for replaceable modules. See the
Corrective Maintenance section or the appropriate Hardware
Module Description for details.
If you are not able to correct the error situation yourself, you
should contact your nearest Kongsberg Maritime service office
for advice or to request service on board.

Reading power status LEDs and measuring supply

voltages
PSU 1 is 115/230 Vac to 24 Vdc AC/DC converters. The status
of the PSU 1 is shown by a LED on the front of the power
module. OK state corresponds to green LED colour.
The power supply module is located on the left sidewall inside
the cabinet. Its output voltage can be measured on its
voltage-output terminals.
The mains voltage can be measured, where appropriate, using a
multimeter with AC-range.

16 177877/A
 Fault Finding

Equipment status
The RCU modules run built-in test programs that continually
check for faults while the system is running. DPC-411 related
system messages/alarms are displayed on the operator station
and/or event/alarm printer to inform/alarm the operator about
process station faults or to bring any other relevant information
to the operator’s attention. Refer to the appropriate Operator
Manual for detailed information on reading the equipment
status. Refer to Figure 6 for a general fault finding flowchart
when system messages/alarms are given.

Fault finding table

The table below lists system symptoms that can be observed
from the operator stations, what may be the cause of the
symptoms and what are recommended corrective actions.
ID SYMPTOMS PROBABLE ERROR CORRECTIVE ACTION
SOURCE
1 Configuration: Single power supply, single LAN without net switch
1.1 One RCU module in this Defective RCU module. Replace RCU module.
DPC-411 has lost contact with
the system. Local LED is red.

1.2 All RCU modules in this
DPC-411 have lost contact
with the system. No LED is lit.
The power connection to the Verify presence of
DPC-411 has been lost. 115/230 Vac supply voltage.
MCB Q1 has tripped. Close Q1.
Defective power supply PSU1. Replace PSU1 power supply.

1.3 A LED in X11, X21, X31 or Defective fuse in field terminal Replace fuse in terminal
X41 is lit block. block.

1.4 A LED in X11, X21, X31 or Defective LED in field Replace LED terminal block.
X41 is not lit although the terminal block.
corresponding fuse has blown.

Table 2 Fault finding DPC-411

Fault finding flowchart

This sub-section contains .
Figure 6 shows a general fault finding flowchart telling how to
re-establish the field station after lost contact with an RCU or
blocks with I/O.

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Kongsberg Maritime DPC-411

Start System reports:

No response from one or
more RCUs in the DPC.
Blocks of I/O have
fallen out.
Is one RCU
responding OK?
Yes

Open DPC cabinet door and

No check LED status on the
RCU module that is not
responding
Open DPC cabinet door and check
Q1, PS1 LED, fuse LEDs and RCU
LED status

Is the LED lit red?

Is power to
RCU modules OK?
Yes

Yes

No No

Repair power or
Replace RCU module replace AC/DC module
as appropriate

Is DPC
response OK?

No

Contact Kongsberg Maritime

for recommended action Yes

End
(Vis1177B)

Figure 6 Fault finding flowchart at DPC-411 error

18 177877/A
 Preventive Maintenance

PREVENTIVE MAINTENANCE
This section presents the preventive maintenance
procedures for the DPC-411.

177877/A 19
Kongsberg Maritime DPC-411

How to tighten screws in the termination blocks

Use an isolated-handle (if power is on) screwdriver with 2 or 3
mm wide bit, as appropriate, and tighten any loose screws.

How to check connector locks

Use a screwdriver to tighten locking screws on the D-SUB and
other applicable types of cable connectors.
Check if the RJ45 network connector plugs are locked by
pushing them into the connector. If the lock flip is not in lock
position, a click will be heard when pushed.
Flatcable connector locks should be checked by visual
inspection only. Ensure that the locks are in correct position.

How to clean cabinets/equipment housing

Use a lint-free, non-abrasive cloth and a neutral or mild soap
solution for best result. Do not use a dripping wet cloth when
cleaning. Use only moistened cloth.

Preventive maintenance intervals for DPC-411

Note Local evaluations should be made to determine site-specific
maintenance intervals.

Action Interval recommended

Tighten screws in the Every six months
termination blocks
Check connector locks Once a year
Clean cabinets/equipment Once a month
housing
Table 3 Recommended maintenance intervals for DPC-411

20 177877/A
 Corrective Maintenance

CORRECTIVE MAINTENANCE
This section presents the corrective maintenance
procedures for the DPC-411.

Corrective maintenance procedures not described in this

section are to be found in the appropriate hardware Module
descriptions for the part numbers referred to in the
replaceable parts and recommended spare parts list.
Corrective maintenance of parts not provided by any of the
above should be performed by Kongsberg Maritime service
personnel only.

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Kongsberg Maritime DPC-411

Replacing PSU1
This procedure lists steps that should be taken to replace a
defective power supply PSU1 in DPC-411.
Note You must be allowed to turn off the power to the specific
DPC-411 and have a spare power supply module.
Warning You should see to that the power lines to the field station are
turned off and stay turned off during this work.
1 Open the front door of DPC-411.
2 For the case of your safety, turn off circuit breaker (MCB)
Q1 for PSU1.
3 Remove wires attached to the PSU by using a flat-bit
screwdriver.
4 Remove the faulty PSU by removing the two screws
holding the clamp bracket.
5 Attach the new PSU by holding it in position and fix the
clamp bracket by fastening the two screws.
6 Re-attach the wires to the PSU by using the flat-bit
screwdriver
7 Turn on the power lines to DPC-411.
8 Turn on MCBs Q1 for PSU1.
9 Verify that the RUN LED of the RCU modules is turned
from red to green after a while.
10 Verify that the RCU modules are working OK by
watching operator station status.
11 Close the front door of DPC-411.

Replacing Q1 or Q2 circuit-breaker (MCB)

This procedure lists steps that should be taken to replace a
defective circuit breaker (MCB) among Q1and Q2.
Note You must be allowed to turn off the power to the specific
DPC-411 and have a spare MCB.
Warning You should see to that the power lines to the field station are
turned off and stay turned off during this work.
1 Open the front door of DPC-411.
2 For the case of your safety, turn off circuit breaker
(MCBs) that shall not be replaced.

22 177877/A
 Corrective Maintenance

3 Remove the busbar between the MCBs Q1 and Q2, and

remove the wires attached to the MCB by using a flat-bit
screwdriver.
4 Remove faulty MCB.
5 Attach the new MCB.
6 Re-attach the busbar and the wires to the MCB by using
the flat-bit screwdriver.
7 Turn on the power lines to DPC-411.
8 Turn on MCBs Q1 for PSU1.
9 Verify that the RUN LED of the RCU modules is turned
from red to green after a while.
10 Verify that the RCU modules are working OK by
watching operator station status.
11 Close the front door of DPC-411.

Replacing Isolation Amplifier (ISO1 to ISO12)

Caution Electrostatic charges can damage electronic
components. Notice the following precautions:
Always wear a properly connected earthing strap when
handling electronic components. Never store near
electromagnetic or electrostatic devices.
1 Open the front door of DPC-411.
2 Turn off power to the faulty module (X31: F2 or F3).
3 Disconnect the input and output cables from the faulty
module.
4 Remove the faulty module from the rail (see Figure 7).

Figure 7 Detachment of module from rail

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Kongsberg Maritime DPC-411

5 Ensure that the replacement module is marked (check

marks on external decals) for the correct configuration of
the appropriate part number. If not, check and configure
the module according to settings of the faulty module (see
Figure 8 how to open the module). Settings to be used are
provided in a drawing located in the Drawing File for the
vessel (for further information about this module see the
appropriate Hardware Module Description in the
Maintenance Manual).

Figure 8 Checking DIP switch settings

6 Clip the replacement module on the rail.

7 Connect the input and output cables to the appropriate
terminals on the replacement module.
8 Turn on mains power to the loop power supplies.
9 Move the label from the faulty module to the replacement
module.
10 Turn on loop power and verify that the green Power On
LED on the front of the module is lit.
11 Verify that the application is working OK by watching
operator station status.
12 Close the front door of DPC-411.

24 177877/A
 Corrective Maintenance

Replacing RCU510 or the fan in RCU510 module

Reuse power off and on steps from the PSU procedure above.
See the RCU510 Hardware Module Description for the
replacement procedure.

Replacing TBSS module

Reuse power off and on steps from the PSU procedure above
See the TBSS Hardware Module Description for the replacement
procedure.

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 Replaceable Parts and Consumables

REPLACEABLE PARTS AND CONSUMABLES

This section contains lists of replaceable parts,
recommended spare parts and consumables used in
DPC-411. Replacement procedures for the listed parts are
described in the appropriate Hardware Module Description.
No replacement procedures are supplied for the
consumeables.

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Kongsberg Maritime DPC-411

Replaceable parts and recommended spare parts

List Part name Recommended Part

ident. as spare part number
1 Power Supply, MWS-240 X 47749445
115/230 Vac/24 Vdc/10 A
2 Fuse MCB, 6A, 2-pole, C-char. 701857
used at Q1 and Q2
3 RCU510 X 601418
4 Filter Schaffner FN 2080-6-60, 47746748
6 A
5 Telesafe Mini Patch Box, 702252
8 x RJ45
6 TBSS 37960309
7 TBSL RS232 ISO 37767522
8 TBSL RS422 ISO 37767563
9 MCR-C-UI-UI-DCI-SOKS X 701567
3-Way Isolation Amplifier
10 Moxa EtherDevicet Switch X 702485
EDS-308 (optional)
11 Terminal Block WSI 6 LD 47753397

Table 4 Replaceable parts and recommended spare parts

Consumables
Note Where-used references listed in the table below are referred to
the standard product. Vessel specific DPCs can deviate from this
table. See the vessel specific drawings for actual references in
use.
List Part name Where used Part
ident. number
1 Fuse, 5x20 mm, 2 A F X11: F1, F4 43505833
X41: F1
2 Fuse, 5x20 mm, X21: F1-F2 43522218
6.3 A F X31: F1
3 Fuse, 5x20 mm, X11: F2-F3, F5-F8 43505817
0.50 A F X31: F2-F3

Table 5 Consumables

28 177877/A