DPC 21 Mk2 MAINTENANCE MANUAL

DPC- 21 (Mk2) maintenance manual
This document contains hardware description and

maintenance information for the DPC- 21 (Mk2)
Dynamic Positioning Controller.
Important notice:
The information contained in this document shall remain the

sole exclusive property of Kongsberg Simrad AS, and shall
not be disclosed by the recipient to any third party without the
written consent of the company.
163336 /B i
Document revisions
Rev Written by Checked by Approved by

Date Sign Date Sign Date Sign
A 24.03.99 EIK 26.03.99 EB 12.04.99 LKM

B 17.01.01 EIK 19.01.01 HH 02.02.01 EB
C
D
E
F
G
H
(The original signatures are recorded in the company’s logistic database)
Document history
Rev. A The first version of this document.
Rev. B Corrected according to changes in drawings and parts list. Corrected
part numbers in spare parts list. Added information on power failure
detection and spare core termination. Added names and codes for the
power units on illustrations.
ii 163336/B
DPC--21 (Mk2) maintenance manual
Contents
HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Computer and I/O--card rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Serial line interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Field interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hardware voter interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Termination of spare cores from field cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Network interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan connection and failure monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General fault finding and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Reading power LED status and measuring supply voltages . . . . . . . . . . . . . 12
The message system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fault finding flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to tighten screws in the termination blocks . . . . . . . . . . . . . . . . . . . . . . . 16
How to check connector locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
How to clean cabinets/equipment housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
How to check the fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
How to adjust voltages and currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feedback potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fail--safe currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Redundancy integrity test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preventive maintenance intervals for DPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REPLACEABLE PARTS AND CONSUMABLES . . . . . . . . . . . . . . . . . 19

Replaceable parts and recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . 20
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
163336 /B iii
HW configuration
Configuration status of documents describing the DPC--21 (Mk2) hardware for this
revision of maintenance manual:
Partslist (230 Vac): P11003, revision A

Partslist (120 Vac): P11013, revision A
General arrangement ...DPC- 21...: 796154, revision G
Cabinet layout (32ch.) ...DPC- 21..: 500188, revision C
Power distr. and wiring diagr. (32ch.) ...DPC- 21....: 797902, revision E
Power distr. and wiring diagr. (32ch.) .....DPC- 21...... (120 Vac): 500397, revision B
Power distribution, redundant 24V to termination boards: 796508, revision C
Wiring diagram TBSS card: 797491, revision A
Included product options in this manual:

P11003 (230 Vac)
P11013 (120 Vac)
iv 163336/B
Hardware description
HARDWARE DESCRIPTION
This section describes the DPC- 21 (Mk2) hardware
configuration.
163336 /B 1
Kongsberg Simrad DPC- 21 (Mk2)
Cabinet
The DPC- 21 (Mk2) comprises two identical computer systems,
each with its I/O system. The common units are doubled to
handle a single error.
The cabinet comprises two compartments (refer to Figure 1):
· termination cabinet
· process cabinet
Figure 1 Layout of a DPC- 21 (Mk2) cabinet
The redundant system hardware provides enhanced system

availability in that any single failure in the system can be handled
by backup functionality. If the master controller for any reason
stops, the slave computer takes over the controller function.
2 163336/B
The configuration uses the TBSS cards for serial line interfaces,
which provide switching of the serial line outputs from the master
to the slave computer if the master computer stops.
The master and slave computer have their separate A and B LAN
interfaces.
All the external cabling passes through the floor of the
termination cabinet where all outer shields are terminated before
the cables enter the cabinet.
For more information about shielding, see the Kongsberg Simrad
specification, Earthing, Screening and Power supply Principles.
Power distribution
The power voltage distributed to the DPC- 21 (Mk2) is
(120)230 Vac. It is usually fed from two UPSs (Uninterruptible
Power Supply). The power distribution comprises two separate
systems, one for each controller. Refer to Figure 2.
Figure 2 DPC- 21 (Mk2) cabinet equipment and interconnections
163336 /B 3
The (120)230 Vac feeds a net filter, which removes spikes and
noise, and a circuitbreaker- fuse (in the process cabinet) before the
voltage is converted to 24 Vdc. This is the distributed voltage
inside the cabinet. An AC/DC converter (in the termination
cabinet) provides the 24 Vdc. The 24 Vdc from the converter is
split in several separate power circuits each provided with a fuse.
The power circuits supply:
· the process I/O backplane, BP 407S. A Power Supply SBC
400 in the rack converts 24 Vdc to +5 Vdc & ±15 Vdc. The
+5 Vdc is used for the SBC and the I/O- cards and the
±15 Vdc is used for the analogue output I/O- cards.
· the serial line termination boards, TBSS.
· the I/O termination boards TBAI, TBDI, TBAIO DIF
(including TBAO V&C - 2) and TB VOTING.
· the DC/DC converters making ±15 Vdc (see Figure 3) and
the power status monitoring loops (see Figure 4). The
±15 Vdc is adjusted to ±10 Vdc by separate trim
potentiometers before feeding the thruster feedback
potentiometers.
Figure 3 Powering thruster- feedback potentiometers
4 163336/B
Power failure detection

Each controller computer (SBC) continually monitors the output
voltage status signal from the corresponding power supply (PSU
x1) and power converter (PSU x2) to verify they are within their
safe limits. If one output voltage drops outside these limits, the
monitoring loop is opened and a system alarm is generated from
the SBC (see Figure 4). Which voltage failed, can be found through
measuring the voltages.
X11/21/31
24Vdc F2
DI
BP407S
PSU11/21/31
Alarm
NC
PSU12/22/32
Alarm
NC
X12/22/32
24V GND 2
(CD2792C)
Figure 4 Typical power monitoring loop
Computer and I/O--card rack

Each cardrack contains a BP 407S backplane which provides
connectors for the cards and cabling.
The Power Supply SBC 400 provides +5 Vdc and ±15 Vdc for the
racks.
The SBC (Single Board Computer), based upon the Intelâ 960
RISC processor, runs the application programs as master and
slave.
Each cardrack, see Figure 5, is normally configured with the
following I/O cards, but may differ for the pertinent vessel:
· DI 400, each providing 32 digital input channels.
· AI 400, each providing 32 analogue input channels.
· AOV 406, each providing 26 analogue input channels and 6
analogue output channels.
Note ! The BP 407S backplane limits the number of available I/O card channels
to 16. For the AOV 406 card available channels are limited to 6 analogue
out and 10 analogue in.
163336 /B 5
Figure 5 One cardrack layout (simplified)
Serial line interface

The modular serial interface unit TBSS is used with up to two
plug- in units installed in each. Each TBSS provides circuitry for
up to four serial channels. Used in a configuration with SBC the
first handles four channels and the second handles three
channels. Four TBSSs are needed to provide interface for the 14
serial lines available.
Figure 6 shows the cabling between the backplane and four TBSS
motherboards. The serial line connectors from the second BP 407S
are connected to the P2 connector of the TBSSs.
Figure 6 Principle of internal serial line cabling
6 163336/B
In the DP application the TBSS is equipped with RS232 and /or

RS422 serial line modules (depends on vessel equipment
configuration).
The Rx- line of the serial lines from the field to the two controllers
A and B are equally connected to each controller. Only the master
controller is connected to the Tx- line via a switch to the field. The
switching is made from the watch- dog- status signal from each
controller to the TBSS card as shown in Figure 7. See TBSS
Hardware Module Description for details.
Figure 7 Principle of serial line switching in TBSS
Field interface
The DPC- 21 (Mk2) provides field termination boards mounted
on the side and rear walls of the cabinet. The field cables are
connected directly to these termination boards. The termination
boards are connected to the respective I/O cards in the cardrack
via flatcables to connectors on the BP 407S. Refer to Figure 8.
The types of termination boards used are:
· TB DI ISO2, connected to DI 400.
· TB AI, connected to AI 400.
· TB AIO DIF, including TB AO V&C - 2, connected to
AOV 406.
The 24 Vdc power supplies connected to the termination boards
provide loop power for each I/O channel.
163336 /B 7
Figure 8 Field terminating board cabling
Hardware voter interface

In a dual- redundant DP system the thrusters are grouped into
two independent groups. Refer to Figure 9. The two 24 Vdc
power supplies feed the cards, and the two computers contribute
equally in controlling the cards. Each computer has two AOV 406
I/O- cards, one for each group, to contribute in making proper
analogue output signals. See TB VOTING Hardware Module
Description for details.
8 163336/B
Figure 9 Hardware voter layout
Termination of spare cores from field cables

The cabinet provides field terminals (terminal group X24 and
X25) located on the left and right side wall respectively. These
terminals are grounded to instrument earth (I.E.). All spare cores
from the field cables should be terminated on these terminals to
avoid RFI antennas inside the cabinet.
Network interface
The BP 407S backplane provides one Net A and one Net B
connection for the SBC. These connectors are by using
10- BASE- T patch cables normally connected directly to
wall- mounted twisted pair network termination boxes inside the
cabinet. From this termination boxes the network field cables are
routed to the appropriate operator stations (OSs).
163336 /B 9
Fan connection and failure monitoring

Each process I/O backplane provides connection for two fans of
which one is required for cooling the SBC. The SBC fan is
supervised from the SBC by its fan- running digital input. Both
fan- not- running and over- temperature are monitored and
alarmed through the application software.
10 163336/B
Fault finding
FAULT FINDING
This section presents the fault finding principles for the
DPC- 21 (Mk2).
163336 /B 11
General fault finding and repair

If an error situation has occurred you will need a combination of
the following information items to correct the system:
· Status information or alarm message shown on the operator
station screen. See the paragraphs relating to System
messages.
· Power LEDs and other status lamps (LEDs) on hardware
items. See the appropriate Hardware Module Description.
· Status of power voltages and fuses in the system. See the
appropriate Hardware Module Description.
· System- specific diagrams, lists and drawings. See the
Kongsberg Simrad marking and labelling specification for how to
interpret the position codes.
· Replacement procedures for replaceable modules. See the
appropriate Hardware Module Description.
Note ! Following any corrective maintenance operations that require shutdown
of the system, the Redundancy Integrity Test shall be performed as
described in the Preventive Maintenance Paragraph.
If you are not able to correct the error situation yourself, you
should contact your nearest Kongsberg Simrad service office for
advice or to request for service on board.
Reading power LED status and measuring supply

voltages
The status of the (120)230Vac to each AC/DC converter is shown
by a green LED on the front of the unit. The units are located on
the left wall inside the cabinet.
The mains voltage can be measured at the mains outlet on the
floor of the cabinet by using a multimeter with an AC- range.
Several green LEDs on the process backplane(s) display the status
of the distributed voltages on the board. See the appropriate
Hardware Module Description.
The power unit in the rack has a green LED lit when status is OK.
See the appropriate Hardware Module Description.
The message system

The system contains built- in tests that continually check for faults
while the system is running. System messages are generated to
inform you of any incorrect system operation or to bring any other
relevant information to your attention.
System messages are displayed on the screen and printed out on
the alarm printer. For detailed information concerning system
messages, refer to the appropriate Operator Manual.
12 163336/B
Fault finding
Fault finding flowcharts

This chapter contains general fault finding flowcharts.
· Figure 10 shows how to reestablish the DPC after a lost contact
with operator station.
· Figure 11 shows what to do when a system message (alarm) is
displayed on the monitor screen/printed on the alarm printer.
DPC blackout
(No response from theDPC/
lost contact with the DPC)
Check that network hub is

powered and functions by
watching its LEDs are lit.
No
Network OK?
Reestablish hub power/
change to spare port on
hub. Yes
Yes
Contact with OS
reestablished?
No
Open DPC cabinet door and

check LEDs on SBC 400
Replace hub
No
Is the RUN LED lit? Check power-ON LEDs on
Power Supply SBC 400,
Backplane BP4xx, AC/DC
Yes Converter
Restart SBC 400 by

pushing RESET
No
Is the power OK?
Reestablish power supply Yes
No
DPC response
OK?
Contact Kongsberg Simrad
Yes for recommended action
End
(ABC1028B)
Figure 10 Fault finding flowchart at DPC blackout
163336 /B 13
(The operator station displays system messages)

System Message
Use the on-line Message

Explain function to obtain more
detailed information.
No
External fault?
Yes
No
Card to be replaced?
Check external
equipment.
Yes
Search for the signal name in the as-built

I/O-list
No Find location for the card in the cabinet
Is external
equipment OK?
Find the type of card in the HW Module Description

Yes Manual and read the replacement procedure.
Measure signal values on

termination board Repair external
equipment Verify if other regulations or other written
orders on-board the vessel overrule the
replacement procedure.
No
Signal values OK?
No
Can the replacement
Yes procedure be used?
Yes
Contact Kongsberg
Simrad for
recommended action.
Replace card
Perform that action.
Verify operation
No
Operation OK?
Yes
End (ABC1001E)
Figure 11 Fault finding flowchart at system alarms
14 163336/B
Preventive maintenance
PREVENTIVE MAINTENANCE
This section presents the preventive maintenance
procedures for the DPC- 21 (Mk2).
163336 /B 15
How to tighten screws in the termination blocks

Use an isolated- handle (if power is on) screwdriver, 3 mm wide
bit and tighten the screws as required.
How to check connector locks

Use a screwdriver to tighten locking screws on the D- SUB
connector houses.
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.
How to check the fans

Check that the fans below each controller rack blow properly by
listening to their sound pitch. Check that fan bearings are not
worn by listening to the sound produced.
How to adjust voltages and currents

The voltages and currents that can be adjusted, are supply
voltages for the thruster feedback potentiometers and the
fail- settings on the TB AO V&C (irrelevant for TB AO V&C - 2).
All the other voltage and current settings are factory set.
Note ! It is recommended to check supply voltages as a part of the diagnostic
work, if a system error is reported.
Feedback potentiometers
1 Use a multimeter and measure the voltages on the row
connectors with the built in potentiometers and check if
they are within specifications. See the vessel- specific
Drawing File for details.
2 Adjust the voltages to the correct values.
16 163336/B
Preventive maintenance
Fail--safe currents
The Hardware Module Description for TB AIO DIF and TB AO
V&C and Drawing File for the pertinent vessel should be at hand
when following this procedure.
1 Use a multimeter with measurement mA- range.
2 Stop the controller(s) by pressing the NMI button on the
front of SBC 400(s). The TB AIO DIF enters fail- safe mode.
3 Disconnect the positive terminal of the analogue output
loop. Connect the mA- meter in the circuit with the positive
end connected to the field wire.
4 Read fail- safe value and compare it to the values specified
in the Drawing File. Adjust value, if required, by using a
screwdriver.
5 Repeat step 3 and 4 for all outputs in use.
Figure 12 Measure output channel current
Redundancy integrity test

The redundancy integrity test is designed to verify correct
operation of the redundancy components, such as diodes, where
two or more voltages are combined.
Note ! Although primarily designed as a preventive maintenance operation,
this test should also be performed following corrective maintenance
operations involving shutdown of the system.
In the following procedure it is assumed that both computers (A
and B) are running and fully operational.
Perform the redundancy integrity test as follows:
1 Switch off circuit breaker Q1- 1 to stop computer A.
2 Verify that the system (controlled by computer B) is
operating properly by checking feedback and control
signals.
163336 /B 17
3 Switch on circuit breaker Q1- 1 and wait for approximately

one minute to allow computer A to run up.
4 Switch off circuit breaker Q2 to stop computer B.
5 Verify that the system (controlled by computer A) is
operating properly by checking feedback and control
signals.
6 Switch on circuit breaker Q2 to allow computer B to run up.
Computers A and B should now be running and the system
fully operational.
Preventive maintenance intervals for DPC

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
Check fans Every three months
Adjust voltages and currents Every six months
Redundancy integrity test Every six months
Table 1 Recommended maintenance intervals DPC
18 163336/B
Replaceable parts and consumables
REPLACEABLE PARTS AND CONSUMABLES

This section contains lists of replaceable parts,
recommended spare parts and consumables used in
DPC- 21 (Mk2). Replacement procedures for the listed
parts are described in the appropriate Hardware Module
Description. No replacement procedures are supplied
for the consumeables.
163336 /B 19
Replaceable parts and recommended spare parts
List Part name Recommended Part number

ident. as spare part
1 BP 407S 37937943
2 AI 400 * X 37970092
3 AOV 406 * X 37982675
4 DI 400 * X 37970035
5 Filter Schaffner, 47715115

FN 670--6/06
6 PMB 3.00 power 47733514

backplane
7 PMP 3.24 SIC power X 47718085

module (230Vdc)
8 PMP 3.24 SIC power X 47718812

module (120 Vdc)
9 DC/DC Converter X 47730156

24/±15 Vdc
10 Power Supply SBC 400 X 47730080
11 SBC 400H * X 37982584
12 Isolation Amplifier X 47725221

(3--way)
13 TB AI 37913068
14 TB AIO DIF X (requires TB 37931623

AO V&C)
15 TB AO V&C X (install on TB 37932027

AIO DIF)
16 TB AO V&C -- 2 (new) X (install on TB 600394

AIO DIF)
17 TB VOTING X 37937588
18 TB DI ISO2 600227
19 TBSS X 37960309
20 TBSL RS232 ISO X 37767522
21 TBSL RS422 ISO X 37767563
22 Fuse, Merlin Gerin, Q1--1, Q1--2, Q2 47719828

2Amp (230 Vac)
23 Fuse, Merlin Gerin, Q1--1, Q1--2, Q2 47718747

4Amp (120 Vac)
20 163336/B
Replaceable parts and consumables
* When ordering spare cards, the revision letter/number of the

PAL/PROMs should follow the order to ensure full compatibility
of the new card.
Table 2 Replaceable parts and recommended spare parts
Consumables
List Part name Where used Part number

ident.
1 Fuse, 5x20 mm, 0.1 AF X15, F1 -- F12 47739768
2 Fuse, 5x20 mm, 1 AS X11/21, F2 and F4 43505841
3 Fuse, 5x20 mm, 2 AS X11/21, F3 43505833
4 Fuse, 5x20 mm, 4 AS X11/21, F1 43505858
5 Fuse, Pudenz BP 407S (F1) 47730726

162.6385.475, 7.5 Amp
6 Microfuse, 1.6 AF BP 407S (F2) 47703384
Table 3 Consumables
163336 /B 21

DPC 21 Mk2 MAINTENANCE MANUAL

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DPC 21 Mk2 MAINTENANCE MANUAL

Uploaded by

Copyright:

Available Formats

DPC- 21 (Mk2) maintenance manual

DPC- 21 (Mk2) maintenance manual

This document contains hardware description and

The information contained in this document shall remain the

Rev Written by Checked by Approved by

A 24.03.99 EIK 26.03.99 EB 12.04.99 LKM

REPLACEABLE PARTS AND CONSUMABLES . . . . . . . . . . . . . . . . . 19

Partslist (230 Vac): P11003, revision A

Included product options in this manual:

Figure 1 Layout of a DPC- 21 (Mk2) cabinet

The redundant system hardware provides enhanced system

Figure 2 DPC- 21 (Mk2) cabinet equipment and interconnections

Figure 3 Powering thruster- feedback potentiometers

Power failure detection

Figure 4 Typical power monitoring loop

Computer and I/O--card rack

Figure 5 One card- rack layout (simplified)

Serial line interface

Figure 6 Principle of internal serial line cabling

In the DP application the TBSS is equipped with RS232 and /or

Figure 7 Principle of serial line switching in TBSS

Figure 8 Field terminating board cabling

Hardware voter interface

Figure 9 Hardware voter layout

Termination of spare cores from field cables

Fan connection and failure monitoring

General fault finding and repair

Reading power LED status and measuring supply

The message system

Fault finding flowcharts

Check that network hub is

Open DPC cabinet door and

Restart SBC 400 by

Reestablish power supply Yes

Figure 10 Fault finding flowchart at DPC blackout

(The operator station displays system messages)

Use the on-line Message

Search for the signal name in the as-built

Find the type of card in the HW Module Description

Measure signal values on

Figure 11 Fault finding flowchart at system alarms

How to tighten screws in the termination blocks

How to check connector locks

How to clean cabinets/equipment housing

How to check the fans

How to adjust voltages and currents

Figure 12 Measure output channel current

Redundancy integrity test

3 Switch on circuit breaker Q1- 1 and wait for approximately

Preventive maintenance intervals for DPC

REPLACEABLE PARTS AND CONSUMABLES

Replaceable parts and recommended spare parts

List Part name Recommended Part number

3 AOV 406 * X 37982675

5 Filter Schaffner, 47715115

6 PMB 3.00 power 47733514

7 PMP 3.24 SIC power X 47718085

8 PMP 3.24 SIC power X 47718812

9 DC/DC Converter X 47730156

10 Power Supply SBC 400 X 47730080

11 SBC 400H * X 37982584

12 Isolation Amplifier X 47725221

14 TB AIO DIF X (requires TB 37931623

15 TB AO V&C X (install on TB 37932027