Os-750 Maintenance Manual

OS-750-SDP/SDPM/SPM- MP5xx (KM-04) Maintenance Manual
OS-750-SDP/SDPM/SPM-
MP5xx (KM-04)
Maintenance Manual
This document contains hardware description and
maintenance information for the
OS-750-SDP/SDPM/SPM- MP5xx (KM-04) operator
stations.
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.
177548 /A 1
Document revisions
Written by Checked by Approved by

Rev Date Sign Date Sign Date Sign
A 26.02.04 HHO 18.03.04 GN/TF 18.03.04 NOH
B
C
D
E
F
The original signatures are recorded on the company’s logistic data system.
Document history
Rev. A The first version of this document.
2 177548/A
HW Configuration Status
(This information is for Kongsberg Maritime use only)
The configuration status of documents describing the OS-750-SDP/SDPM/SPM-
MP5xx (KM-04) hardware for this revision of the Maintenance Manual are listed
below:
Parts Lists
Parts List OS-750-SDP (DP or IAS): P71000, Rev. A
Drawings
Console Complete, Assembly: 506175, Rev. A
Layout Mounting Plates, Bottom/Rear,
SDP, SVC, etc. consoles 750mm: 506192, Rev. C
Layout Panel Plate, Horizontal SDP, Console 502567, Rev. B
Net Distribution SDP 796976, Rev. A
Panel System SDP, SVC, STC, SCS, HPR, SPM, SPS 502631, Rev. D
Power and Wiring Diagram, Operator Station 505180, Rev. C
177548 /A 3
Table of contents
HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operator interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Colour monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alphanumeric keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power supply and signal wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
The computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Error indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General fault finding and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reading power LED status and measuring supply voltages . . . . . . . . . . . . . . . . 17
Fault finding flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to tighten screws in the termination blocks . . . . . . . . . . . . . . . . . . . . . . . . 20
How to check connector locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to clean console housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to adjust colour monitor settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to access the alphanumeric keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to clean the colour monitor screen surface . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to clean the buttons and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to clean the trackball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preventive maintenance intervals for OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Preparation for replacement of parts in
the OS-750-SDP/SDPM/SPM- MP5xx (KM-04) . . . . . . . . . . . . . . . . . . . . . . . . . 24
Finish replacement of parts in the
OS-750-SDP/SDPM/SPM- MP5xx (KM-04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Preparation for calib./test of parts in the
Finish calib./test of parts in the
4 177548/A
PNC 100, numeric and special function panel, and alarm and function panel
replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Trackball unit replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Trackball button board replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . 29
Joystick calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Joystick replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Joystick panel replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Heading control replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REPLACEABLE PARTS AND CONSUMABLES . . . . . . . . . . . . . . . . . 33
Replaceable parts and recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . . 34
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
177548 /A 5
Hardware Description
HARDWARE DESCRIPTION
This section contains the hardware description of the
stations.
177548/A 7
Kongsberg Maritime OS-750-SDP/SDPM/SPM- MP5xx (KM-04)
Console
Monitor Compartment
LCD Colour Monitor
Alphanumeric Keyboard Lid
Operator Panel
Operator Panel
Compartment
Computer
Compartment
Front Cover Fastening Knobs

(two of four)
Console Base
Figure 1 Operator Station
General
The OS console comprises a monitor compartment, an operator
panel compartment, a computer compartment and a console
base. The base is omitted on the Watch One (W1) type consoles.
Access to the computer compartment, where almost all
hardware modules are located, is obtained by removing the front
cover. Four fastening knobs, located one in each corner, unlock
the door to be lifted clear of the console.
Cable entries into the console goes through a cable entry plate,
MC25 EMC, located at the right hand side of the floor in the
computer compartment. To get access to this plate, the computer
must be unlocked and pulled forward on its rails, all cables
disconnected, then lifted off its rails and placed on the floor.
8 177548/A
Operator interfaces
Colour monitor
A high-resolution 20.1” LCD colour monitor provides the main
graphic display for presentation of data. The signal cable is
connected to the graphic interface, SVGA port, of the computer.
Operator panel
The operator panel provides several controls on the operator
panel. They are interfaced either to the computer or to the panel
controller (PNC 100).
The panel controller is connected via a serial line to the

computer computer’s B port.
Figure 2 Layout of operator panel
Alarm and Function Panel

The most frequently-used or critical operations are available as
dedicated buttons from the Alarm and Function Panel located on
the operator panel (see Figure 2). The Alarm and Function Panel
is connected to the panel controller (PNC 100).
177548/A 9
Functions Panel
One button access to frequently used process areas are available
as dedicated buttons from the Functions Panel located on the
operator panel (see Figure 2). The Functions Panel is connected
to the panel controller (PNC 100).
Numeric and Special Function Panel

The Numeric and Special Function Panel (Keypad) contains the
function buttons (top row), the buttons for numeric entries and
buttons for navigation. These buttons are identical to the
corresponding buttons on the alphanumeric keyboard. The panel
uses the same interface on the computer as the alphanumeric
keyboard (see this topic). A rotate switch must therefore be left
in the appropriate (default) position to use this panel .
Trackball
A trackball with associated buttons is used for selecting,
viewing and operating on objects on the Windows-based
display. The trackball is connected via a serial cable, PS2, to the
computer MOUSE port.
Joystick
The operator panel provides a three-axis joystick control to
control the thrust demand in the surge, sway and yaw axes when
these axes are under manual control. The joystick is connected
to the PNC 100.
Heading wheel (optional)

The operator panel can provide a heading wheel with associated
buttons to increase or decrease the heading setpoint. The
heading wheel is connected to the PNC 100.
DP/Manual switch panel (optional)

The DP/Manual panel provides the operator with posibilities to
run his vessel under Kongsberg Dynamic Positioning Control or
to run the thrusters under direct Manual Control.
Alphanumeric keyboard
A standard alphanumeric keyboard is available inside a hinged
lid just underneath the display. It is accessed from the front by
pushing back a lid loch, making the lid open automatically. The
alphanumeric keyboard is then pulled out, and laid down on the
upper part of the operator panel.
10 177548/A
Input from the Alphanumeric Keyboard and the Numeric and

Special Function Keyboard is routed through an automatic
switch to the computer keyboard port. No manual switching
between the two keyboards is necessary.
The alphanumeric keyboard is for service use only.
Power supply and signal wiring

The 115/230Vac mains inlet is terminated on the X1 row
terminals located on the bottom mounting plate.
Note To get the best access possible to the mounting plate, the
computer can be unlocked and pulled forward on its rails (refer
to Figure 3), and then lifted off its rails.
The process network cabling is terminated in field termination

patch panel located at the left hand side of the bottom mounting
plate. These connections are the only ones required to put the
OS into operation.
Fastening Knob
Receptor (4 off)
Computer
Mounting Plate
Computer Locking Screw
CD & Floppy Drives
Computer Rails (2 off)

Modem
Hub (if installed)
24Vdc Circuit Breaker
(X2)
115/230Vac Circuit Breakers

(Q1 & Q2)
Network Patch Panel
Cable Entrance
(under the computer)
(Cd2883g)
Figure 3 Equipment layout inside the computer compartment
Two 115/230Vac circuit breakers (Q1 and Q2) are located on the
bottom mounting plate. The circuit breakers function both as
fuses and power switches to isolate parts of the hardware.
177548/A 11
The operator panel requires 24 Vdc as supply voltage and this is

supplied by the vessel/rig (to meet the requirements of the
classification societies) through circuit breaker X2. All the other
modules, the computer, the colour monitor, and the network hub
(located on the left mounting plate), require 115/230 Vac supply
voltage, which is supplied via circuit breaker Q1 (see Figure 4
for a block diagram of power and signal wiring).
A mains outlet J1 is provided for service use only. It is protected

by the circuit breaker Q2..
Caution Do not use the mains outlet for other purposes than
servicing the system. Heavy or noisy loads connected
here may damage the system.
12 177548/A
Ship's Supply:
UPS
(115/230VAC)
LCD Alphanumeric
Colour Monitor Keyboard
Q1
Q2
Power Socket
SVGA
(for Service)
KEYB
Computer Operator Panel
Numeric
MOUSE Keypad
Net C
To Adm. Hub (Adm. Net) Automatic
in NDU Switch
Network Net A
Hub* Trackerball
Net B
TB2 TB1
Back
Light
B Port Power
Mains
AC / DC
Filter 24V
Panel Controller
Patch (PNC)
Field Cables Panel
Ship's Supply: Alarm & Function

Numeric & Speial
24VDC Function Panel Panel
Function Panel
X2
* Note: The Network Hub is not implemented for

the 3rd OS in a SDP-31 System nor for OSes Heading 3-Axis
in an IAS System Control Joystick
(Optional)
(Vis1139)
Figure 4 OS-750-SDP/SDPM/SPM- MP5xx (KM-04) Power Supply and Signal

Wiring
In stand-alone systems (SDP–11/21/31), up to two of the SDP

operator stations contain one 8-port hub (refer to Figure 4). The
optional hub is located at the bottom mounting plate of the
computer compartment (see Figure 3) and powered via the Q1
circuit breaker.
177548/A 13
For the third SDP in triple redundant stand-alone systems, such

as the SDP31, and for all OSs in integrated systems, they do not
have hubs installed. In these OSs the network cables are
connected directly between the computer and the network
termination box(es) (see Figure 4).
The computer
For detailed description of the computer refer to the Computer
Maintenance Manual.
14 177548/A
Fault Finding
FAULT FINDING
This section presents the fault finding principles for the
stations.
177548/A 15
Error indicators
In the Alarms button group of the Alarm and Function panel
(refer to Figure 2) there are three alarm lamps:
· Computer
This lamp flashes in response to a hardware-generated alarm
indicating that the operator station computer has stopped
communicating with the operator panel controller via the
serial line. This may indicate the computer is “dead”, or the
serial-line software has stopped executing.
Note This lamp does not indicate failures in the DP controller
computer(s). If the operator station loses contact with the DP
controller, a message is displayed in a screen dialogue:
No network response from SDP Process Unit
· Power
This lamp flashes in response to a hardware-generated alarm
indicating a power supply or UPS failure to the operator
panel controller. Two power supplies are normally supplying
this controller and if one of these fails, the alarm is activated.
· Operation
This lamp flashes in response to a software-generated alarm
or warning from the computer initiated by an operational
alarm or warning condition; for example, heading or position
deviation beyond limits or sensor error. These alarms are
generated by the DP controller and do not indicate failures in
the operator station.
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:
· 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 Maritime marking and labelling specification for
how to interpret the position codes.
· Replacement procedures for replaceable modules. See the
appropriate Hardware Module Description.
16 177548/A
Fault Finding
Reading power LED status and measuring supply

voltages
The status of the 24 Vdc supply is shown by a red LED on the
circuit breaker X2 on the mounting plate.
The mains voltage can be measured at the mains outlet circuit
breaker Q1 and Q2 on the mounting plate, using a multimeter
with AC-range.
177548/A 17
Fault finding flowchart
(Black display
Start
and no lamps on
the panel can be lit)
Check status of circuit

breakers
Is the No
circuitbreakers
closed?
Close breakers and wait
for Computer to come up
Yes
Does the
circuitbreakers trip
Yes again?
No
Is Computer Power
No LED lit ?
Yes
No mains voltage present.
Repair the UPS and restart
system.
Is the OS OK?
Repair Computer and the No
colour monitor as
appropriate.
Yes
Is the OS OK?
Yes
No
Contact Kongsberg
for recommended action
End
(Vis1036a)
Figure 5 Fault finding flowchart
Note 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 for service on board.
18 177548/A
Preventive Maintenance
PREVENTIVE MAINTENANCE
This section presents the preventive maintenance
procedures for the OS-750-SDP/SDPM/SPM- MP5xx
(KM-04) operator stations.
177548/A 19
How to tighten screws in the termination blocks

Use an isolated-handle (if power is on) screwdriver, 2 or 3mm
wide bit as required, and tighten any loose screws.
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 console 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 adjust colour monitor settings

Adjust the appropriate settings in accordance with the Colour
Monitor Hardware Description Manual.
How to access the alphanumeric keyboard

Caution Use of the alphanumeric keyboard for maintenance
purposes is restricted to Kongsberg Maritime service
personnel.
1 Open the display service lid in the display compartment.

2 Carefully pull the alphanumeric keyboard fully out
3 Rotate it around its upper edge, and lay it down on the
operator panel.
How to clean the colour monitor screen surface

Use a lint-free, non-abrasive cloth and a neutral cleaner based
on a non-abrasive cleaning solution or a glass cleaner for best
result.
20 177548/A
Preventive Maintenance
How to clean the buttons and panels

Use a vacuum cleaner with a soft brush to avoid damage to the
buttons and the panels. If required, clean the buttons and panel
with a non-abrasive cloth moistened with mild soap solution.
How to clean the trackball

If the trackball has been contaminated with dust particles and
grease, it should be cleaned.
Note The sign of a contaminated trackball is when the cursor does
not follow the movement of the trackball, but stops for short
periods.
Caution Electrostatic discharges can damage the electronic

components inside the operator station. Always wear
an approved and properly connected earthing strap
while working inside the OS or handling the electronic
components while performing maintenance procedures.
1 Perform the procedure for “Preparation for replacement
of a part in OS-750-SDP/SDPM/SPM- MP5xx (KM-04) “
2 Open the trackball unit by removing the four screws, one
in each corner, from below.
3 Clean the ball with a non-abrasive cloth moistened with
mild soap solution.
4 Clean the rollers. If the unit is very contaminated, it
should be replaced in accordance with the trackball
replacement procedures described in the corrective
maintenance procedures of this manual.
5 Reinstall the clean trackball into the trackball unit and
secure the unit cover with the screws that were removed in
step 2.
6 Perform the procedure for “Finish replacement of a part in
OS-750-SDP/SDPM/SPM- MP5xx (KM-04) “.
177548/A 21
Preventive maintenance intervals for OS

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

Tighten termination block screws Six months
Check connector locks Twelve months
Clean console housing One month
Clean the Colour Monitor Screen One week
Clean the trackball Six months or as required
Check the computer fans One month
Clean the buttons and panels One month or as required
Table 1 Recommended maintenance intervals OS
22 177548/A
Corrective Maintenance
CORRECTIVE MAINTENANCE
This section presents the corrective maintenance
procedures for the OS-750-SDP/SDPM/SPM- MP5xx
(KM-04) operator stations.
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.
177548/A 23
General
For unscrewing and disassembly of the Operator Panel, a set of
2 to 5mm Allen keys are needed.
Caution Electrostatic discharges can damage the electronic
components inside the operator station. Always wear
an approved and properly connected earthing strap
while performing maintenance procedures.
Caution Always be careful not to strain the cables or
connectors.
Note For shutting down an operator station, refer to the operator
manual for the appropriate procedure.
Preparation for replacement of parts in

the OS-750-SDP/SDPM/SPM- MP5xx
(KM-04)
To prepare replacement of a part in the
OS-750-SDP/SDPM/SPM- MP5xx (KM-04) proceed as
follows:
1 Shut down the operator station in a controlled manner.
2 Open the front cover of the computer compartment by
turning the four fastening knobs.
3 Turn off the 115/230Vac by switching off the circuit
breakers Q1 and Q2.
4 Turn off the 24Vdc by switching off the circuit breaker
X2.
5 Unscrew the 8 Allen screws fastening the Operator Panel
to the operator console.
6 Carefully lift the Operator Panel Assembly out of the
operator console.
Caution Be careful not to strain the cables or connectors.
7 Disconnect the cables at the rear edge of the Operator
Panel Protective Box.
8 Lift up and place the Operator Panel Assembly carefully
upside down on a table covered with an soft antistatic mat.
Rear connections pointing away.
to the Protective Box.
10 Carefully rise only the front edge of the Protective Box
with the rear edge in place, so that the panel rotates
approximately 180 degrees and the Operator Panel (with
mounted equipment) remains its position.
24 177548/A
11 Then replace the wanted part according to the specific

Hardware Module Description of the part, or according
the adequate procedure below.
Finish replacement of parts in the

OS-750-SDP/SDPM/SPM- MP5xx (KM-04)
To finish replacement of a part in the OS-750-SDP/SDPM/SPM-
MP5xx (KM-04) proceed as follows:
1 Carefully lower only the front edge of the Protective Box
approximately 180 degrees and the Operator Panel (with
mounted equipment) is covered by the Protective Box.
2 Screw the 20 Allen screws fastening the Protective Box to
the Operator Panel.
3 Lift up and place the Operator Panel Assembly on the
operator console.
4 Re-connect the cables on the rear edge of the Operator
Panel.
5 Carefully put the Operator Panel Assembly into its

original position in the operators console.
6 Screw the 8 Allen screws fastening the Operator Panel to
the operator console.
7 Turn on the 24Vdc by switching off the circuit breaker
X2.
8 Turn on the 115/230Vac by switching off the circuit
breakers Q1 and Q2.
9 Close the front cover of the computer compartment by
turning the four fastening knobs.
10 Verify that the replaced/calibrated unit is functioning
properly.
Preparation for calib./test of parts in the

To prepare a calibration/test of of a part in the
follows:
1 Shut down the operator station in a controlled manner.
177548/A 25
2 If power is not needed during calibration/test, open the

front cover of the computer compartment by turning the
four fastening knobs. Then on the Mounting Plate, turn off
115/230Vac by switching off the circuit breakers Q1 and
Q2 and the 24Vdc by switching off the circuit breaker X2
as appropriate.
to the operator console.
4 Lift the Operator Panel a little up and place an soft
antistatic mat under its rear edge (in order not to damage
the operator console).
5 Carefully raise the front edge only of the Operator Panel,
approximately 90 degrees and the underside of the
Protective Box is fully visible.
6 Unscrew the 20 Allen screws fastening the Protective Box
to the Operator Panel
7 Carefully lower the front edge of the Protective Box with
the rear edge in place, so that the Protective Box rotates
approximately 90 degrees and the internal of the Operator
Panel is fully visible.
8 Then calibrate/test the wanted part according to the
specific Hardware Module Description of the part, or
according the adequate procedure below.
Finish calib./test of parts in the

To finish a calibration/test of of a part in the
follows:
1 Carefully rise the front edge of the Protective Box with the
rear edge in place, so that the Protective Box rotates
approximately 90 degrees and the underside of the bottom
protective box of the Operator Panel is fully invisible.
2 Screw the 20 Allen screws fastening the Protective Box to
the Operator Panel.
3 Carefully lower only the front edge of the Operator Panel,
approximately 90 degrees and the Operator Panel enters
its normal position in the operators console.
26 177548/A
4 Lift the Operator Panel a little up and remove the soft

antistatic mat under its rear edge (placed there in order not
to damage the operator console).
5 Screw the 8 Allen screws fastening the Operator Panel to
the operator console.
6 If power has been turned off during calibration/test, then
on the Mounting Plate, turn on 115/230Vac by switching
on the circuit breakers Q1 and Q2 and the 24Vdc by
switching on the circuit breaker X2 as appropriate.
Thereafter close the front cover of the computer
compartment by turning the four fastening knobs.
7 Verify that the replaced/calibrated unit is functioning
properly.
PNC 100, numeric and special function panel, and

alarm and function panel replacement procedures
To perform replacement of the PNC 100 panel controller,
numeric and special function panel or the alarm and function
panel, proceed as follows:
1 Perform the procedure for “Preparation for replacement of
a part in OS-750-SDP/SDPM/SPM- MP5xx (KM-04)“.
2 Follow the replacement of the appropriate unit in
accordance with the specific Hardware Module
Description
OS-750-SDP/SDPM/SPM- MP5xx (KM-04)“.
Trackball unit replacement procedures

If there is no response to the cursor on the screen when the
trackball is operated, perform the following procedure:
1 Perform the procedure for “Preparation for test/calibration
of a part in OS-750-SDP/SDPM/SPM- MP5xx (KM-04)“.
Keep the 24Vdc and 115/230Vac switched on.
177548/A 27
Note Measurement with the multimeter shall be made with reference

to earth (the earth terminal of the multimeter connected to the
trackball panel, TB2, terminal 2).
2 Using a multimeter connected to terminal 2 (earth) and
terminal 5 (RD) of TB2 on the trackball panel, verify that
signals are registered on the multimeter when the trackball
is operated. If not, the fault is the cable to the computer or
the computer itself, and you should report the fault to
Kongsberg Maritime and request service on board, then
reinstall the operator panel. If signals are registered, the
trackball unit is faulty; proceed to step 3.
3 Switch off the 24Vdc circuit breakers X2 and and the
115/230Vac circuit breaker Q1 and Q2.
4 Refer to Figure 6. Disconnect the two cable connectors
from the side of the trackball unit.
Figure 6 Trackball unit replacement
Note Support the trackball unit on the underside of the operator panel
while removing the screws from the topside.
5 Using a 1.5mm hex. wrench, unscrew and remove the four
countersunk screws in the bezel flange that secure the
trackball unit to the operator panel.
28 177548/A
6 Remove the bezel flange from the topside of the operator

panel and the main unit from the underside. Discard the
faulty units.
7 Unpack the replacement trackball unit and remove the
four securing screws to separate the bezel flange from the
main unit.
8 Position the main unit on the underside of the operator
panel with same orientation and position as the original
unit.
9 Position the bezel flange on the topside of the operator
panel over the trackball. Insert the four screws through the
flange and panel and into the trackball unit. Tighten the
screws properly to secure the trackball unit.
10 Reconnect the two cable connectors.
11 Perform the procedure for “Finish test/calibration of a part
in OS-750-SDP/SDPM/SPM- MP5xx (KM-04)“.
Trackball button board replacement procedures

If there is no response to the three buttons when choosing from
dialogue/menus on the screen, perform the following procedure:
2 Disconnect the cable connector from TB1 on the trackball
button board.
3 Disconnect the two cable connectors for the trackball unit
from the connectors on the button board.
4 Unscrew and remove the faulty button board (four screws)
from the operator panel and discard the button board.
5 Position the replacement button board (PN 37795382)
onto the operator panel and secure it using the same
screws that were removed in step 4.
6 Connect the cable connector to TB1 on the button board.
7 Connect the two cable connectors for the trackball unit to
the connectors on the button board.
8 Perform the procedure for “Finish replacement of a part
Joystick calibration procedures

If the thrusters do not provide neutral pitch/minimum thrust
while the joystick is in the zero position in the x–axis
(forward/reverse) or the y–axis (port/starboard), perform the
following procedure:
177548/A 29
1 Perform the procedure for “Preparation for

test/calibration of a part in OS-750-SDP/SDPM/SPM-
MP5xx (KM-04)“.
2 Initiate analogue inputs and ensure that 24 Vdc power is
turned on to the OS.
3 Using a multimeter, calibrate the joystick as follows:
Note The joystick rotate controller (z–axis) is calibrated at the factory
and cannot be reset.
Note During joystick calibration, all measurements with the
multimeter shall be made with reference to earth (the earth
terminal of the multimeter connected to the joystick panel, TB1,
terminal 3).
a Move the joystick to the zero position in the x–axis
(forward/reverse) and measure the voltage at the
joystick panel, TB1, terminal 5. The measured voltage
shall be 2.5 V ¦0.05 V.
b If not, loosen the two screws slightly that secure the
x–axis potentiometer to the base of the joystick. Rotate
the potentiometer until the correct voltage is measured.
Then tighten the two screws to secure the potentiometer
in position.
c Move the joystick to the zero position in the y–axis
(port/starboard) and measure the voltage at the joystick
panel, TB1, terminal 6. The measured voltage shall be
2.5 V ¦0.05 V.
d If not, loosen the two screws slightly that secure the
y–axis potentiometer to the base of the joystick. Rotate
the potentiometer until the correct voltage is measured.
Then tighten the two screws to secure the potentiometer
in position.
4 Perform the procedure for “Finish test/calibration of a part
Joystick replacement procedures

If the thrusters do not provide neutral pitch/minimum thrust
while the joystick is in the zero position in the z–axis (rotate), or
minor adjustments to the joystick in x–axis or y–axis result in
disproportionate or erratic adjustment of the thrusters, perform
the following procedure:
30 177548/A
2 Disconnect the two earth cables from the joystick earth

terminals.
3 Disconnect the two cable connectors from TB1 and J1 on
the joystick panel.
4 Unscrew and remove the faulty joystick (four screws)
from the operator panel.
5 Unscrew and remove the joystick panel assembly from
the faulty joystick base and reinstall the assembly onto the
replacement joystick base.
6 Discard the faulty joystick.
7 Insert the replacement joystick (PN 47730320) handle
through the operator panel and secure the base to the
underside of the panel using the same screws that were
removed in step 4.
8 Reconnect the two cable connectors to TB1 and J1 on the
joystick panel.
9 Reconnect the two earth cables to the joystick earth
terminals.
11 Calibrate the joystick in accordance with the joystick
calibration procedure.
Joystick panel replacement procedures

If the joystick panel is to be replaced, perform the following
procedure:
2 Disconnect the two cable connectors from TB1 and J1 on
the joystick panel.
3 Unscrew and remove the faulty joystick panel (two
screws) from the operator panel and discard the button
board.
4 Position the replacement joystick panel (PN 37795366)
5 Connect the two cable connectors to TB1 and J1 on the
joystick panel (that was removed in step 2).
177548/A 31
Heading control replacement procedures

If a heading control has been installed and there is no change to
the vessel’s heading displayed on the screen when using it,
perform the following procedure:
2 Disconnect the two cable connectors from the heading
control.
3 Unscrew and remove the faulty heading control (four
screws) from the operator panel and discard the heading
control.
4 Position the replacement heading control (PN 37795374)
5 Connect the two cable connectors that were removed in
step 2 to the heading control.
32 177548/A
Replaceable Parts and Consumables
REPLACEABLE PARTS AND CONSUMABLES

This section contains lists of replaceable parts,
recommended spare parts and consumables used in
stations. Replacement procedures for the listed parts are
described in the appropriate Hardware Module Description.
No replacement procedures are supplied for the
consumeables.
177548/A 33
Replaceable parts and recommended spare parts
List Part name Recommended as Part

ident. spare part number
1 Alarm & function panel 600687
2 Function panel 600688
3 Heading control (optional) 600711
4 Joystick unit (not SPM–OS) 47730320
5 Joystick control board (not SPM–OS) 37795366
6 Micro hub, 8-port hub X (if installed) 47734496
7 Numeric & special 600689
function panel
8 Trackball Unit. 47749981
9 Trackball button panel 37795382
10 PNC 100 X 37960259
11 Power supply MWS-60-24 X 47745799
(new type)
12 Filter Schaffner 700529
13 Westermo Modem TD-32B 702048
DC
Table 2 Replaceable parts and recommended spare parts
For information on replaceable parts and recommended spare

parts for the Computer, refer to the Maintenance Manual for the
Computer.
For information on replaceable parts and recommended spare
parts for the Monitor, refer to the Maintenance Manual for the
Monitor.
Consumables
List Part name Where used Part
ident. number
1 Fuse, 1930K, 125V, TR3-F PNC-100 47742150
(micro fuse) panel
2 Fuse, Merlin Gerin, 6A, Q1 (Mounting Plate) 47717517
2-pole
3 Fuse, Merlin Gerin, 4A, Q2 (Mounting Plate) 47718747
2-pole
Table 3 Consumables
34 177548/A

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OS-750-SDP/SDPM/SPM- MP5xx (KM-04) Maintenance Manual

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LCD Colour Monitor

Alphanumeric Keyboard Lid

Front Cover Fastening Knobs

Figure 1 Operator Station

The panel controller is connected via a serial line to the

Figure 2 Layout of operator panel

Alarm and Function Panel

Numeric and Special Function Panel

Heading wheel (optional)

DP/Manual switch panel (optional)

Input from the Alphanumeric Keyboard and the Numeric and

The alphanumeric keyboard is for service use only.

Power supply and signal wiring

The process network cabling is terminated in field termination

CD & Floppy Drives

Computer Rails (2 off)

115/230Vac Circuit Breakers

Network Patch Panel

Figure 3 Equipment layout inside the computer compartment

The operator panel requires 24 Vdc as supply voltage and this is

A mains outlet J1 is provided for service use only. It is protected

Ship's Supply: Alarm & Function

* Note: The Network Hub is not implemented for

Figure 4 OS-750-SDP/SDPM/SPM- MP5xx (KM-04) Power Supply and Signal

In stand-alone systems (SDP–11/21/31), up to two of the SDP

For the third SDP in triple redundant stand-alone systems, such

General fault finding and repair

Reading power LED status and measuring supply

Fault finding flowchart

Check status of circuit

Figure 5 Fault finding flowchart

How to tighten screws in the termination blocks

How to check connector locks

How to clean console housing

How to adjust colour monitor settings

How to access the alphanumeric keyboard

1 Open the display service lid in the display compartment.

How to clean the colour monitor screen surface

How to clean the buttons and panels

How to clean the trackball

Caution Electrostatic discharges can damage the electronic

Preventive maintenance intervals for OS

Action Interval recommended

Corrective maintenance procedures not described in this

Preparation for replacement of parts in

11 Then replace the wanted part according to the specific

Finish replacement of parts in the

5 Carefully put the Operator Panel Assembly into its

Preparation for calib./test of parts in the

2 If power is not needed during calibration/test, open the

Finish calib./test of parts in the

Caution Be careful not to strain the cables or connectors.

4 Lift the Operator Panel a little up and remove the soft

PNC 100, numeric and special function panel, and

Trackball unit replacement procedures

Note Measurement with the multimeter shall be made with reference

Figure 6 Trackball unit replacement

6 Remove the bezel flange from the topside of the operator

Trackball button board replacement procedures

Joystick calibration procedures

1 Perform the procedure for “Preparation for