Exercises

Theoretical, Operational and Practical

KHW019941

Project:
Product: K-Pos Maintenance Course
Location:
Synopsis:

Document number: KHW019941 Revision: A

Customer doc no: Document version:
Contract number: Number of pages: 39
Rev. Date Reason for issue Made by Checked Approved

A 03.12.14 First Issue BE/SE IVA S.E

B
C
D
E
F
G
H

©Kongsberg Maritime AS
www.kongsberg.com
 Kongsberg Maritime AS

Document history

Revision Description of Change

A First Issue

References

No Doc No Description

Copyright
The information contained in this document remains the sole property of Kongsberg
Maritime AS. No part of this document may be copied or reproduced in any form or by
any means, and the information contained within it is not to be communicated to a third
party, without the prior written consent of Kongsberg Maritime AS.

Disclaimer
Kongsberg Maritime AS endeavours to ensure that all information in this document is
correct and fairly stated, but does not accept liability for any errors or omissions.

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Table of contents
Operational – Joystick Mode (2.1) ................................................................................. 4 

Operational – Auto Position (2.2)................................................................................... 7 

Sensors and Position Reference Systems – Introduction and Theoretical (1.1) ...... 11 

Hardware – The Operator Station, Introduction (1.3) .............................................. 13 

Hardware – The Operator Station, Interconnections (1.4) ....................................... 14 

Hardware – The Operator Station, Panel and Alarm View (1.5) ............................. 16 

Hardware – The DP Cabinet, Introduction (1.6)........................................................ 19 

Hardware – The DP Cabinet, Interconnections (1.7) ................................................. 20 

Redundancy Integrity Test (3.1) .................................................................................. 22 

Network – Ping (3.2) ...................................................................................................... 23 

Network – Cable Termination (3.3) ............................................................................. 26 

Hardware – DPC, RSER Module (3.4) ........................................................................ 28 

Hardware – DPC, RMP Module (3.5) ......................................................................... 30 

cJoy – Intro and Practical (3.6) .................................................................................... 33 

System Backup and Restore (3.7)................................................................................. 37 

K-Pos System Fault Finding (3.8) ................................................................................ 38 

cJoy System Fault Finding (3.9) ................................................................................... 39 

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Operational – Joystick Mode (2.1)

______________________________________________________________________

Task:
Maneuverer the vessel around “Myrica” oil field platforms, A-B-C. Stop with the stern
between platform B and C, see sketch below. At the final position vessel to be in
AutoPos – Mode.

Learning Objectives:
Be familiar with the Joystick Mode. Demonstrate how to manoeuvre with the joystick.

Practical and Time

Individual. To be performed in the class room. Approximately 50 minutes.
______________________________________________________________________
Settings:

1.
Start with the system in Standby mode. Make sure that no position reference systems
are enabled.

2.
Select View and submenu Reset.
Click Yes to reset the Display Units to Metric Units.

3.
Go to the System (if SW rel. 8: Tools) menu and select Trainer.
In the Trainer dialog box insert these values:

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4.
Right button click in the Posplot view and select View Control.
Select the Trace and enter the same settings as shown in the figure below:

5.
Select the AutoTrack (if SW rel. 8: Setting) menu, and the submenu Editor.
This will open the AutoTrack Editor dialog box.
- Click Open, and open the File “Myrica platforms.txt”.
- Click OK in the AutoTrack Editor dialog box.

Note: This file contains a stored track with waypoints. We will in the exercise
pretend that this track is three platforms.

6.
Go to the Thruster menu and the submenu Enable. In the dialog box, enable all
thrusters, and main prop.

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Exercise/Task:

1.
Enter Joystick mode, by double-pressing the Joystick-button on the Operator Panel.
Enable also GPS 1, by clicking on the GPS 1-button on the Operator Panel.

2.
Use the joystick and move the vessel on a safe distance around the “platforms”. (Move
Counter-clockwise). Keep the speed below 3.0 m/s.

3.
Move the vessel with the stern in between the two easterly “platforms”, see sketch
below.

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Operational – Auto Position (2.2)

______________________________________________________________________

Task:
Set up the DP system in AutoPos - mode, enable Alarm limits. Move the vessel in
different directions by use of Change Position and Change Heading. Use the Capability
analysis, and record worst thinkable heading. Enable DP class 2 and verify single worst
case failure envelope.

Learning Objectives:
Be familiar with AutoPos - mode functions. Rules and regulations regarding DP class 2
and 3 – class requirements – documentations.

Practical and Time

Individual. To be performed in the class room. Approximately 50 minutes.
______________________________________________________________________
Settings:

1.
Start with the system in Standby mode. Make sure that no position reference-systems
are enabled.

2.
Select View and submenu Reset.
Click Yes to reset the Display Units to Metric Units.

3.
Also in the View menu and Position Presentation (if SW rel. 8: Position), enable
UTM co-ordinate system, with False Easting selected.

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4.
Open the System (if SW rel. 8: Tools) menu and submenu Trainer. Set in the settings
shown in the table below:

Start Position: N 1000m 31: 500200m

Wind Speed: 10 m/s
Wind Direction: 330
Sea Current Speed: 0.5 m/s
Sea Current Direction: 320
Draught: 4.5 m
Exercise/task:

1.
Go from Standby mode to Joystick mode. Select the GPS1 and GPS2 as position-
reference system.

2.
When the lamp above the GPS1-button and GPS2-button have a steady light, double-
press the Auto Position mode-button.

3.
Insert Alarm Limits for Position, Heading, Pitch, Roll and Heave in accordance with the
settings shown below:

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4.
Change heading to 348, use Rate Of Turn; 40 deg/min.

5.
When you have automatic control of the heading, there are some alternatives to change
the vessel’s heading, explain.

……………………………………………………………………………………………

6.
Right button click in the Posplot view and select View Control.
Select the Trace and enter the same settings as shown in the figure below:

7.
Change vessel speed (Speed Setpoint) to 0.8 m/s

8.
Bring the vessel to position: N 1000m – 31: 500200m

9.
Bring the vessel 10m to starboard.

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10.
Bring the vessel 18m West.

11.
What is your position? N ………………m – 31:…………….

Trends view:

12.
There are different trend views available in the K-Pos system. Configure the trend view
so that the following trends are shown:
- Figure 1: Thr Tot Force
- Figure 2: Pow Generators
- Figure 3: DEV POS

13.
What have the maximum values been the last hour?
- Thr Resultant Force: ……………………
- Pow generators: …………..
- DEV POS - Distance: ………………..

14.
Look at the view Thruster Forces and Thruster Main, what is the load on the thrusters
now?
- Resulting Force ………..kN, Direction ………….deg

DP Capability plot and Consequence Analysis

15.
Select AutoPos and DpCap Settings (if SW rel. 8: Settings and DP capability
analysis). When simulation is possible, green light, start computing by pushing the
apply button. The result is shown in the Capability Plot view. Based on the plot, and the
EBL function, rotate the vessel starboard, to the worst thinkable heading.

16.
After the vessel has entered Present Heading, activate the DP Class 2 or 3 function-
Consequence analysis. Verify in the Alarm view that information is given, Consequence
analysis running class 2 or 3.

Does the capability plot view change, how? ___________________________

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Sensors and Position Reference

Systems – Introduction and
Theoretical (1.1)
______________________________________________________________________

Task:
Locate information for the sensors and position reference systems.

Learning Objectives:
Be able to describe purpose, function, main components and interconnections for the
sensors and position reference systems.

Practical and Time

In groups, max 3 persons. To be performed in any room. Approximately 50 minutes.
______________________________________________________________________
1.
Locate the information needed to fill in the missing information, in the sheet below.
Use e.g. the lab, technical documentation, internet and the instructor.

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Hardware – The Operator Station,

Introduction (1.3)
______________________________________________________________________

Task:
As a team, find out as much as possible about one or several main components, during
the time given. Then explain what you have found to the other team, in an informal
way.

Learning Objectives:
Learn how to identify and explain the function of the main OS components.

Practical and Time

In groups, max 3 persons. To be performed in any room. Approximately 50 minutes.
______________________________________________________________________

1.
Locate information for the highlighted bullets above, within the area which your team is
responsible for.
Use e.g. the lab, technical documentation, internet and the instructor.
2.
Explain what you have found to the other team.
Do this in a very informal way, e.g. gather around the OS in the lab. Demonstrate,
explain and discuss. The instructor will observe and guide if wanted.

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Hardware – The Operator Station,

Interconnections (1.4)
______________________________________________________________________

Task:
Fill in the interconnections for the OS and mark power and signal type for each cable.

Learning Objectives:
Learn the power and signal wiring going to/from the main components.

Practical and Time

First individual, then compare and conclude with one or two participants next to you. To
be performed in any room. Approximately 50 minutes.
______________________________________________________________________

1.
Locate the information needed to fill in the interconnections and write down the power
or signal type, from the list (next page).
Types of power levels and signals that can be used are:
 115/230VAC
 24VDC
 Analogue Input
 USB
 DVI
Use e.g. the lab, technical documentation, internet and the instructor.

2.
Compare and conclude with one or two participants next to you.
The instructor will observe and guide if wanted.

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Hardware – The Operator Station,

Panel and Alarm View (1.5)
______________________________________________________________________

Task:
The OS is giving alarms for the units in the OS panel. Correct the problem and verify
system ok with the mentioned procedures.

Learning Objectives:
Verify the component names and interconnections. Learn how to access and interpret
the alarm view.

Practical and Time

In groups, max 3 persons. To be performed in the lab. Approximately 50 minutes.
______________________________________________________________________

1.
Identify the faults related to the units in the OS panel (alarms for other parts of the
system might be active but should not be in focus). Use the “alarm view”. Check
“additional info” in the “alarm view”.
Press “ALARM VIEW” on the ALC panel.

2.
Read the detailed description of at least one alarm.
Right click on the alarm – choose “Help”

3.
For the units in the OS panel, locate and correct the faults. Observe how alarms change
state from “high” to “normal”.

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4.
Acknowledge the alarms.
Press “ACK” on the ALC panel.

 Can alarms in state “Normal” be acknowledged? _______________

 Can alarms in state “High” be acknowledged? _______________

5.
Fill in the table below. Three different colours correspond to three different types of
alarms.

Colour Priority

6.
When the alarms that are relevant for the OS panel units have been cleared, switch the
command to the other OS. Perform a “lamp test” and calibrate the joystick.
The instructor will guide if wanted.

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7.
Fill in the table below. Some minor variations should be expected.
Use the lab as a reference and maintenance manuals if wanted.

7
8
9
10

Name Function

10

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Hardware – The DP Cabinet,

Introduction (1.6)
______________________________________________________________________

Task:
As a team, find out as much as possible about one or several main components, during
the time given. Then explain what you have found to the other team, in an informal
way.

Learning Objectives:
Learn how to identify and explain the function of the main DPC components.

Practical and Time

In groups, max 3 persons. To be performed in any room. Approximately 50 minutes.
______________________________________________________________________

1.
Locate information for the highlighted above, bullets within the area which your team is
responsible for.
Use e.g. the lab, technical documentation, internet and the instructor.
2.
Explain what you have found to the other team.
Do this in a very informal way, e.g. gather around the DPC in the lab. Demonstrate,
explain and discuss. The instructor will observe and guide if wanted.

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Hardware – The DP Cabinet,

Interconnections (1.7)
______________________________________________________________________

Task:
Fill in the “type” of signal and which RIO module this would be connected to.

Learning Objectives:
Learn how to describe the main function of the RIO modules.

Practical and Time

First individual, then compare and conclude with one or two participants next to you. To
be performed in any room. Approximately 50 minutes.
______________________________________________________________________
1.
Individually, locate the information needed to fill in “name”, “HW”, “type” and which
RIO module this would be connected to, on the sheet available below.
Types of signals that can be handled by the RIO modules are:
 Serial
 Analogue Input (AI)
 Analogue Output (AO)
 Digital Input (DI)
 Digital Output (DO)
RIO modules are:
 RHUB
 RSER
 RMP
Use e.g. the lab, technical documentation, internet and the instructor.

2.
Compare and conclude with one or two participants next to you.
The instructor will observe and guide if wanted.

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Redundancy Integrity Test (3.1)

______________________________________________________________________

Task:
Perform a redundancy integrity test on a DPC-2.

Learning Objectives:
Identify the main DPC components, related to power. Be familiar with “redundant
stations”.

Practical and Time

In groups, max 3 persons. To be performed in the lab. Approximately 50 minutes.
______________________________________________________________________

1.
Locate the “redundancy integrity test” in the maintenance manual for the DPC-2.
Perform half of the test, for the controller A only.

2.
How often should this test be carried out according to KM recommendations?

-----------------------------------------------------------------------------------------

3.
Imagine that this test is carried out on board your vessel. You found out that the power
is not redundant, due to a faulty PSU. Where would you locate the technical
specifications needed to order a new one from Kongsberg Maritime?

-----------------------------------------------------------------------------------------

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Network – Ping (3.2)

______________________________________________________________________

Task:
One controller has been replaced, now offline, the settings need to be checked and
correct operation verified.

Learning Objectives:
To get familiar with KM network in general. Locate and use, “hosts_sbc”, “ethers” and
standard Windows network settings/tools.

Practical and Time

In groups, max 3 persons. To be performed in the lab. Approximately 50 minutes.
______________________________________________________________________

1.
One controller is not communicating with the system. Verify the IP address in the file
“hosts_sbc”.
Fill in the table below, using the “hosts_sbc” file.

IP Address DpPs (e.g. DpPs31)

Main-DP controller A

Main-DP controller B

(Ctrl+Shift+Esc – New Task – write “explorer” – locate “c:\DPxxxxx” – search for

“hosts_sbc” – open with “notepad”)

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2.
Try to “ping” the controller that is offline.
(Ctrl+Shift+Esc – New Task – write “cmd” – write “ping xxx.xx.x.x”, please see
example below)

To see how the ping result should look like when successful, ping the neighbour
Operator Station, both net A and net B. Verify its IP address with the command
“ipconfig /all” in cmd.
The instructor will guide if wanted.

3.
Verify the corresponding MAC address in file “ethers”.
Fill in the table below, using the “ethers” file.

The last three digits in the MAC address

Main-DP controller A

Main-DP controller B

(Ctrl+Shift+Esc – New Task – write “explorer” – locate “c:\DPxxxxx” – search for

“ethers” – open with “notepad”)

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4.
With the information you now have, control the address wheels on both of the
controllers.

5.
Verify ok operation for the corrected controller, with the checklist below.

Ok / Not Ok

Ping response

LED status on the RCU is green

No “lost packages” to any nodes/equipment

(System – Equipment – Net Status – observe “Lost messages”)

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Network – Cable Termination (3.3)

______________________________________________________________________

Task:
Terminate a network STP Cat.7 cable in a KM standard patch panel.

Learning Objectives:
Recognise a proper KM standard network installation. Be aware of what effects an
improper installation can result in.

Practical and Time

In groups, max 3 persons. To be performed in any room. Approximately 50 minutes.
______________________________________________________________________
1.
Create a permanent link, including two separate patch panels and STP Cat.7 cable.
Terminate according to the KM Network Installation Manual, each group member
should do at least one cable termination.

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2.
Verify the permanent link with a cable tester.

Straight cable or fail

Cable length

3.
Discuss and write down at least three things that you believe is important with the
termination you have just done, and why.

Important things when terminating STP Why?

4.
Discuss and write down your own experience from fault finding networks.

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Hardware – DPC, RSER Module (3.4)

______________________________________________________________________

Task:
Connect minimum one wind sensor and one gyro sensor to the DPC. Verify input and
enable the sensor.

Learning Objectives:
Identify and explain the function of the RIO modules. Demonstrate where and how to
connect a serial line.

Practical and Time

In groups, max 3 persons. To be performed in the lab. Approximately 50 minutes.
______________________________________________________________________

1.
Fill in the table below, relevant for the wind sensor. You can choose any one of the
available wind sensors.

Which channel (e.g. 104)

Where to terminate on RIO module (e.g. X4: 5,6)

Baud rate set for this channel, in the IO-Manager

Use vessel documentation and technical reference material.

System – Equipment – right click on DpPsXX – station explorer – IO Manager - ComAs
The instructor will guide if wanted.

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2.
Connect the sensor and verify the input with the “logger” function in IO-Manager.
Right-click on the channel in IO-Manager to access the logging feature.
The instructor will guide if wanted.

Sometimes a serial line port can “hang”, a SW or a HW reset will fix the problem.
SW reset can be done in “comAs”. If needed, a HW reset is done by tilting the RIO
module down so that the power goes down.

3.
Enable the sensor on the DP operator panel. Also, verify the signal with the LEDs on
the RIO module.

4.
Do the same thing with a gyro sensor.

Which channel (e.g. 104)

Where to terminate on RIO module (e.g. X4: 5,6)

Baud rate set for this channel, in the IO-Manager

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Hardware – DPC, RMP Module (3.5)

______________________________________________________________________

Task:
There have been reported problems with a thruster interface. After some initial fault
finding you suspect the RIO module. Next step is to verify the DPC components.

Learning Objectives:
Identify and explain the function of the RIO modules. Demonstrate where and how to
connect a DI and AI.

Practical and Time

In groups, max 3 persons. To be performed in the lab. Approximately 50 minutes.
______________________________________________________________________

1.
Fill in the table below, relevant for one DI that you choose. It can be anyone of the
available interfaces.

Name of the DI signal (e.g. Thr. 3 Ready)

Which module type and address (e.g. RSER 31)

Where to terminate on RIO module (e.g. X4: 5,6)

Use vessel documentation and technical reference material.

2.
Use a jumper (a short length of conductor) to verify the channel. Observe the change in
IO-Manager and “Thr Main” view in the application.
The instructor will guide if wanted.

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3.
What happens if you change physical position with the RMP module next to the one
you are working with? Any alarms? Does it work?
The modules are “hot-swap”

-----------------------------------------------------------------------------------------

4.
What happens if you change address with the RMP module next to the one you are
working with? Any alarms? Does it work?

-----------------------------------------------------------------------------------------

5.
Fill in the table below, relevant for one AI that you choose. It can be anyone of the
available interfaces.

Name of the AI signal (e.g. Thr. 2 Pitch FB)

Which module type and address (e.g. RSER 31)

Where to terminate on RIO module (e.g. X4: 5,6)

Use vessel documentation and technical reference material.

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6.
Use the calibrator/process meter to simulate values on the chosen AI. Monitor the
values in the IO Manager.
Fill in the table below.

Current (mA) Sensor Value Engineering Value

12

16

20

7.
What is the difference between “sensor value” and “engineering value”?

-----------------------------------------------------------------------------------------

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cJoy – Intro and Practical (3.6)

______________________________________________________________________

Task:
Complete the interconnections, start up the system and complete the task described
below.

Learning Objectives:
Identify and explain the function of the main cJoy components.

Practical and Time

In groups, max 3 persons. To be performed in the lab. Approximately 50 minutes.
______________________________________________________________________

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1.

Complete the interconnections and mark signal type.

(Two types, CAN and LAN)

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2.
From where are the Junction Boxes powered? Note down the answer, which unit,
voltage level and terminals, on the previous page. Add the interconnections on the
layout.

3.
Start up the complete cJoy system, OT and cC-1.
The instructor will guide if wanted.

4.
Without using keyboard or mouse, change Rate of Turn to 20 deg/min
Use the operator manual, if needed

5.
Without using keyboard or mouse, restart only the cJoy OT

6.
On the cJoy JB, what is the correct value to be set on the Panel-ID code?
Test and note down what happens if there is an incorrect value. The OT needs to be
rebooted for the change to take effect.

7.
On the cJoy JB, what is the correct value to be set on the Panel-orientation code?
Test and note down what happens when different settings. The OT needs to be rebooted
for the change to take effect.

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8.
Which of the three main sensors for DP systems is related to “environmental
compensation”?

-----------------------------------------------------------------------------------------

9.
Move the command between cJoy OT and cWing OT (if cWing is available)

10.
Using the IO-specification for the system (provided by the instructor), simulate at least
two ready signals for thrusters, with HW. Verify on the OT

11.
Simulate two AO to AI signals for thrusters, with HW. Choose the same thrusters as in
the previous exercise

12.
Enable the two (or more) thrusters and use the joystick to see activity on command and
feedback.

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System Backup and Restore (3.7)

______________________________________________________________________

Task:
Perform a system backup. System restore is optional.

Learning Objectives:
Demonstrate a system backup and joystick calibration.

Practical and Time

All participants, together with instructor. Approximately 50 minutes.
______________________________________________________________________
1.
For the backup program “paragon”, locate “how to use an alternative backup procedure”
in the backup and restore procedure, MP8200/MP8300. Perform a backup on one of the
OS.
Alternatively, the instructor will guide if decided to use the backup program “ghost”.
2.
When should a backup be done, and who does it?

-----------------------------------------------------------------------------------------
3.
When should a restore be done, and who does it?

-----------------------------------------------------------------------------------------
4.
When a restore have been done, the joystick will need to be calibrated. Why?

-----------------------------------------------------------------------------------------

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K-Pos System Fault Finding (3.8)

______________________________________________________________________

Task:
Locate and correct faults and errors.

Learning Objectives:
Be able to identify the main components, use alarm view, analyse and diagnose
symptoms and faults.

Practical and Time

In groups, max 3 persons. To be performed in the lab. Approximately 50 minutes.
______________________________________________________________________
1.
Start up the system and verify ok operation. Write down possible faults in the list below.

Symptom Fault

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cJoy System Fault Finding (3.9)

______________________________________________________________________

Task:
Locate and correct faults and errors.

Learning Objectives:
Be able to identify the main components, use alarm view, analyse and diagnose
symptoms and faults.

Practical and Time

In groups, max 3 persons. To be performed in the lab. Approximately 50 minutes.
______________________________________________________________________
1.
Start up the system and verify ok operation. Write down possible faults in the list below.

Symptom Fault

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