Вы находитесь на странице: 1из 26

DPC-422 Maintenance Manual

DPC-422
Maintenance Manual

This document contains hardware description and


maintenance information for the DPC-422.

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.

177879 /A 1
DPC-422 Maintenance Manual

Document revisions

Written by Checked by Approved by


Rev Date Sign Date Sign Date Sign
A 01.06.04 EIK 16.08.04 TF 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 177879/A
DPC-422 Maintenance Manual

HW Configuration Status
(This information is for Kongsberg Maritime use only)
The configuration status of documents describing the DPC-422 hardware for this
revision of the Maintenance Manual are listed below:

Parts Lists
Parts List DPC-422 (115/230 Vac): P20190, Rev. A

Drawings
General Arrangement, DPC-422, Cabinet 600x1200x300: 1001093, Rev. B
Layout Drawing, DPC-422, 600x1200x300: 1001060, Rev. B
Power and Wiring Diagram, DPC-422, DPC w/RIO Modules: 1001141, Rev. C
Wiring Diagram, DPC-422, Net/Serial Lines: 1001142, Rev. C
Wiring Diagram, Interface Cable, RCU510 - TBSS: 1001144, Rev. C
Wiring Diagram, DPC-422, DI: 1001145, Rev. D
Wiring Diagram, DPC-422, AI 4-20mA: 1001146, Rev. B
Wiring Diagram, DPC-422, AI 0-10V: 1001147, Rev. C
Wiring Diagram, DPC-422, AI +/-10V: 1001148, Rev. C

177879 /A 3
DPC-422 Maintenance Manual

Table of contents

HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Controller configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding RIO modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Serial-line interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Data network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Field Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Field cable termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spare core termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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-422 . . . . . . . . . . . . . . . . . . . . . . . . . 20
CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing PSU1 or PSU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing Q1, Q2 or Q3 circuit-breaker (MCB) . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacing RCU510 or the fan in RCU510 module . . . . . . . . . . . . . . . . . . . . . . . 23
Replacing TBSS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REPLACEABLE PARTS AND CONSUMABLES . . . . . . . . . . . . . . . . . 25
Replaceable parts and recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . . 26
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

177879 /A 5
Hardware Description

HARDWARE DESCRIPTION
This section describes the DPC-422 hardware
configuration.

177879/A 7
Kongsberg Maritime DPC-422

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-422 cabinet is made for wall mounting. It has four
dedicated positions for RCU modules on its rear wall (see
Figure 1).
LAN connections for the RCUs are located on the lower right
wall.

LEFT WALL REAR WALL RIGHT WALL


F1 X21 F1 X31
X22 X32
X41 F1
X42

TBSS1
PSU1
U1 U3

RCU510 RCU510 TBSS2

PSU2
TBSS3

FL2 FL1
TBSS4
U2 U4
CABLE DUCT (optional)
CABLE DUCT

CABLE DUCT

CABLE DUCT
CABLE DUCT

CABLE DUCT
RCU510 RCU510
F1 X11
X12
X101 X102
F1 X13
X103
X14
SW2
X104
SW1
Q1
BUSBAR NET
Q2
A&B
Q3 MAINS
OUTLET I.E.
SOCKET

(CD3045)

Figure 1 Layout of DPC-422

Power supplies, mains filters 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.
Field cabling to DPC-422 are routed through the cabinet
bottom.

8 177879/A
Hardware Description

Block diagram
A block diagram of DPC-422 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
24 Vdc to equipment
Network outside DPC cabinet

Serial Lines
Field Cables

Serial Lines
Field Terminal Block Field Terminal Block
Field Signal Loops Field Signal Loops
Net B Net A

Network
Switches SW2 SW1 TBSS1 TBSS2 TBSS3 TBSS4

Net B to RCUs Net A to RCUs


Field Serial Lines Field Serial Lines Field Serial Lines Field Serial Lines
24 Vdc to equipment
outside DPC cabinet
Fuses

Serial Lines

Serial Lines
PSU2
Q2 FL2
115/230 Vac +24 Vdc NET A & B NET A & B
6A Filter Power RCU RCU
Supply
U3 U4
Mains Outlet
Busbar Q3 Sockets
6A

Field Terminal Block Field Terminal Block

(CD3044) Field Signal Loops Field Signal Loops

Figure 2 Block diagram of DPC-422

Controller configuration
The four RCUs are configured in two redundancy groups. The
first group comprises U1 and U3, and the second group
comprises U2 and U4 (see Figure 2). If one of the main
controllers fails, the back-up controller in that group takes over
the control.

Power supply
DPC-422 handles both 230 Vac and 115Vac as mains supply.
The block diagram in Figure 2 shows the power supply
principles of of DPC-422. Two sets of power circuitry are
provided. Each power supply supplies two RCU510s and up to
four TBSSs (serial termination boards) with 24 Vdc.
The mains voltage passes the MCBs (Q1 and Q2) before it is
filtered for noise (FL1 and FL2). The MCBs trip and break 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 and PSU2).

177879/A 9
Kongsberg Maritime DPC-422

Grounding RIO modules


Each RCU module shall be grounded. FL1 fast-on terminal is
connected to PE (or to IE if specified).
See also the RIO 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 has 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
handles four channels and the second handles three channels.
See separate TBSS Hardware Module Description document for
details.
Figure 3 shows the cabling principle between two RCUs 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. A second split flat-cable is
connected between the RCU in location U3 at one end and P2
connector on TBSS 1 and P2 on TBSS 2 at the split end.
The RCU pair in location U2 and U4 are connected in the same
way to TBSS 3 and TBSS 4 as descibed above.

Serial channels
1 to 4
TBSS 1
P1/P2 (TBSS 3)

Serial channels
RCU 5 to 7
U1/U3 TBSS 2
(U2/U4) P1/P2 (TBSS 4)

(CD3014)

Figure 3 Principle of internal serial-line cabling using TBSS

The Rx-line, which carries data from the field, is equally


connected to the two RCUs in the redundancy pair (see
Figure 4). However, only the main RCU is connected at one
time to the Tx-line on the field side via a switch located on the
TBSS.

10 177879/A
Hardware Description

The switching function between the main RCU and the back-up
RCU is made from the watch-dog & application status signal
comming from each RCU and made available to the TBSS via
the flat cables.

RCU TBSS 1 and 2


U1 (TBSS 3 and 4)
(U2) P1

RCU P2
Tx
Tx (to field)
U3
(U4) Rx Rx (from field)
P3

(CD3015)

Figure 4 Principle of serial-line switching in TBSS

See also TBSS Hardware Module Description for more details.

Data network
Network field cables are terminated in the network termination
box located on lower right wall. Patch cables with RJ45
connectors at both ends are connected between the network
termination box and two 5-port unmanaged switches, one for net
A and one for net B. Patch cables are connected between each
switch and the RCUs’ A and B network connectors respectively.
The RCUs are named U1, U2, U3 and U4 (see Figure 5 below).

Net B Net B
Network
Net A Termination Net A
Field Box
Cables
Switch 1 (Net A) Switch 2 (Net B)

RCU RCU RCU RCU


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

U1 U2 U3 U4

(CD3053)

Figure 5 Network A and B connections in DPC-422

See also the separate network topology drawing in the Drawing


File for which ports on the switch are used for which RCUs.

177879/A 11
Kongsberg Maritime DPC-422

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 field terminals
(X101-X104) located on the bottom part of the rear wall. Cross
wires connect the field terminals to the termination blocks
(X1-X3) on the RCU modules.
The following illustrations show different loop typicals
implemented in DPC-422.

From the second


RCU510 in the pair

X10x RCU510

Field 1
HSD

Terminal 2
(CD3054) Block

Figure 6 Typical digital input for RCU510 redundant pair

From the second


RCU510 in the pair

RCU510
Terminal
Block

Field

430 Uin
Ohm

(CD3055)

Figure 7 Typical current input for RCU510 redundant pair

12 177879/A
Hardware Description

From the second


RCU510 in the pair

RCU510
Terminal
Block

Field

Uin

(CD3056)

Figure 8 Typical voltage input for RCU redundant pair

Note The typical shown in Figure 8 shows an externally powered field


loop.

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.

177879/A 13
Kongsberg Maritime DPC-422

Technical specifications
POWER SUPPLY REQUIREMENTS
Supply voltage 2 x 115/230 Vac
Typical power consumption 2 x 100 W
Maximum power consumption 2 x 240 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 135 W
Maximum heat dissipation 180 W
Noise level < 40 dB
Also refer to Kongsberg Maritime Environmental Specification, reg. no.:
161011

Table 1 DPC-422 technical specifications

14 177879/A
Fault Finding

FAULT FINDING
This section presents the fault finding principles for the
DPC-422.

177879/A 15
Kongsberg Maritime DPC-422

General fault finding and repair


To correct the system, if an error situation has occurred, the
flowcharts in Figure 9 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 and PSU 2 are 115/230 Vac to 24 Vdc AC/DC
converters. The status of the PSU 1 and the PSU 2, is shown by
a LED on the front of the power module. OK state corresponds
to green LED colour.
The power supply modules are located on the left sidewall
inside the cabinet. Their output voltages can be measured on
their voltage-output terminals.
The mains voltage can be measured, where appropriate, using a
multimeter with AC-range. If supply voltage is the optional
24 Vdc, a multimeter with DC-range must be used.

16 177879/A
Fault Finding

Equipment status
The RCU modules run built-in test programs that continually
check for faults while the system is running. DPC-422 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 9 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: Dual power supplies, dual LAN with net switches
1.1 One RCU module in this Defective RCU module. Replace RCU module.
DPC-422 has lost contact with
the system. Local LED is red.

1.2 Two RCU modules, U1 & U3 MCB Q1 or Q2 has Close Q1 or Q2 as


or U2 & U4, in this DPC-422 respectively tripped. appropriate.Replace PSU1 or
have lost contact with the Defective power supply PSU1 PSU2 power supply as
system. or PSU2 respectively. appropriate.

1.3 A LED in X11, X13, X21, X31 Defective fuse in field Replace fuse in termination
or X41 is lit termination block. block.

1.4 A LED in X11, X13, X21, Defective LED in field Replace LED termination
X31, X41 is not lit although the termination block. block.
corresponding fuse has blown.

1.5 Discrepancies between input Error in the the split wiring for Verify that internal wiring is
values in a RCU redundant pair the channel. correct for the reported
of DI or AI. channel.
Channel is defective in one of Replace the defective RCU.
the RCUs in the pair.

Table 2 Fault finding DPC-422

Fault finding flowchart


Figure 9 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.

177879/A 17
Kongsberg Maritime DPC-422

Start System reports:


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

Open DPC cabinet door and


No check LED status on the
RCU(s) that is not
responding
Open DPC cabinet door and check
Q1 & Q2, PS1 & PS2 LED, fuse
LEDs, SW1& SW2, LEDs and RCU
LED status

Is the LED lit red?

Is power to
RCU modules and
net switches OK?
Yes

Yes

No No

Is network switches
Yes
working OK?

No

Replace network Repair power or


switch(es) or patch Replace RCU module(s) replace AC/DC module(s)
cables as appropriate as appropriate

Is DPC
responding OK?

No

Contact Kongsberg Maritime


for recommended action Yes

End
(Vis1179)

Figure 9 Fault finding flowchart at DPC-422 error

18 177879/A
Preventive Maintenance

PREVENTIVE MAINTENANCE
This section presents the preventive maintenance
procedures for the DPC-422.

177879/A 19
Kongsberg Maritime DPC-422

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-422


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-422

20 177879/A
Corrective Maintenance

CORRECTIVE MAINTENANCE
This section presents the corrective maintenance
procedures for the DPC-422.

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.

177879/A 21
Kongsberg Maritime DPC-422

Replacing PSU1 or PSU2


This procedure lists steps that should be taken to replace a
defective power supply PSU1 or PSU2 in DPC-422.
Note You must be allowed to turn off the power to the specific
DPC-422 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-422.
2 For the case of your safety, turn off circuit breakers
(MCBs) Q1 for PSU1 and Q2 PSU2.
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-422.
8 Turn on MCBs Q1 for PSU1 and Q2 for PSU2.
9 Verify that the RUN LED of the RCU modules is turned
from red to green after a while.
10 Verify that the RCUs modules are working OK by
watching status from the operator station.
11 Close the front door of DPC-422.

22 177879/A
Corrective Maintenance

Replacing Q1, Q2 or Q3 circuit-breaker (MCB)


This procedure lists steps that should be taken to replace a
defective circuit breaker (MCB) among Q1, Q2 and Q3.
Note You must be allowed to turn off the power to the specific
DPC-422 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-422.
2 For the case of your safety, turn off circuit breakers
(MCBs) that shall not be replaced.
3 For Q2 or Q3 remove the busbar between these two
MCBs, and remove 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, if removed, and the wires to the
MCB by using the flat-bit screwdriver.
7 Turn on the power lines to DPC-422.
8 Turn on MCBs Q1 for PSU1 and Q2 for PSU2.
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 status from the operator station.
11 Close the front door of DPC-422.

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 replacing
procedure.

Replacing TBSS module


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

177879/A 23
Replaceable Parts and Consumables

REPLACEABLE PARTS AND CONSUMABLES


This section contains lists of replaceable parts,
recommended spare parts and consumables used in
DPC-422. Replacement procedures for the listed parts are
described in the appropriate Hardware Module Description.
No replacement procedures are supplied for the
consumeables.

177879/A 25
Kongsberg Maritime DPC-422

Replaceable parts and recommended spare parts

List Part name Recommended Part


ident. as spare part number
1 Power Supply, MWS-240 47749445
115/230 Vac/24 Vdc/10 A (701149)
2 Fuse MCB, 6A, 2-pole, C-char. 701857
used at Q1, Q2 and Q3
3 RCU510 601418
4 Filter Schaffner FN 2080-6-60, 47746748
6 A
5 Moxa EtherDevice Switch 702847
EDS-205
6 TBSS 37960309
7 TBSL RS232 ISO 37767522
8 TBSL RS422 ISO 37767563
9 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 43505833
X13: F1
X41: F1, F3
2 Fuse, 5x20 mm, X21: F1-F2, 43522218
6.3 A F X31: F1-F2,
3 Fuse, 5x20 mm, X11: F2-F6 43505817
0.50 A F X13: F2-F6
X41: F2, F4

Table 5 Consumables

26 177879/A