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21 DPC-411 Maintenance Manual
21 DPC-411 Maintenance Manual
DPC-411
Maintenance Manual
Important notice:
177877 /A 1
DPC-411 Maintenance Manual
Document revisions
The original signatures are recorded on the company’s logistic data system.
Document history
Rev. A First version.
2 177877/A
DPC-411 Maintenance Manual
HW Configuration Status
(This information is for Kongsberg Maritime use only)
The configuration status of documents describing the DPC-411 hardware for this
revision of the Maintenance Manual are listed below:
Parts Lists
Parts List DPC-411 (115/230 Vac): P20130, Rev. A
Drawings
General Arrangement, DPC-411, Cabinet 600x1200x300: 1002018, Rev. A
Layout Drawing, DPC-411, 600x1200x300: 1001550, Rev. A
Power and Wiring Diagram, DPC-411, DPC w/RIO Modules: 1001548, Rev. A
Wiring Diagram, DPC-411, Net/Serial Lines: 1001549, Rev. A
Wiring Diagram, JC/DPC 401/411, Isolation Amplifiers: 1000957, Rev. A
Wiring Diagram, Interface Cable, RCU510 - TBSS: 1001144, Rev. C
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DPC-411 Maintenance Manual
Table of contents
HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuse-status indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply (24 Vdc) monitoring and alarming . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grounding RCU modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Serial-line interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Data network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Galvanic isolation of output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Field Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Field cable termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spare core termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General fault finding and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reading power status LEDs and measuring supply voltages . . . . . . . . . . . . . . . 16
Equipment status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault finding flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to tighten screws in the termination blocks . . . . . . . . . . . . . . . . . . . . . . . . 20
How to check connector locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to clean cabinets/equipment housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preventive maintenance intervals for DPC-411 . . . . . . . . . . . . . . . . . . . . . . . . . 20
CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing PSU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing Q1 or Q2 circuit-breaker (MCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing Isolation Amplifier (ISO1 to ISO12) . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacing RCU510 or the fan in RCU510 module . . . . . . . . . . . . . . . . . . . . . . . 25
Replacing TBSS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REPLACEABLE PARTS AND CONSUMABLES . . . . . . . . . . . . . . . . . 27
Replaceable parts and recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . . 28
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Hardware Description
HARDWARE DESCRIPTION
This section describes the DPC-411 hardware
configuration.
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Kongsberg Maritime DPC-411
Cabinet layout
Note The layout of a delivery specific cabinet may deviate from the
standard example in Figure 1. See the vessel specific layout
drawing in the vessel’s Drawing File for the exact layout and
wiring information.
The DPC-411 cabinet is made for wall mounting. It has three
dedicated positions for RCU modules on its rear wall (see
Figure 1).
Isolation amplifiers for analog outputs are located on the lower
right of the rear wall.
TBSS1
PSU1
U1 U3
(optional)
TBSS3
ISO 1
FL1
TBSS4
U2
CABLE DUCT
ISO 6
ISO 7
CABLE DUCT
CABLE DUCT
CABLE DUCT
CABLE DUCT
CABLE DUCT
RCU510
F1 X11
ISO 12
X12
NET
PATCH
Q1 PANEL PP1
BUSBAR
Q2
MAINS
OUTLET I.E.
SOCKET
(CD3049)
8 177877/A
Hardware Description
Block diagram
A block diagram of DPC-411 is shown in Figure 2.
Fuses
FL1 PSU1
Q1 NET A & B NET A & B
115/230 Vac +24 Vdc
6A Filter Power RCU RCU
Supply
U1 U2
Mains Outlet
Q3 Sockets
Serial Lines
2A
Serial Lines
ISO 1-6 ISO 7-12
To equipment outside Field Signal Loops Field Signal Loops
DPC cabinet
(optional)
TBSS1 TBSS2 TBSS3 TBSS4
Field Serial Lines Field Serial Lines Field Serial Lines Field Serial Lines
Fuses
To 3-Way Isolation
Amplifiers ISO 1-6 and ISO 7-12
NET A & B
RCU
U3
(optional)
(CD3048)
Power supply
DPC-411 handles both 230 Vac and 115Vac as mains supply.
The block diagram in Figure 2 shows the power supply
principles of of DPC-411.
The power supply supplies up to three RCU510s, up to four
TBSSs (serial termination boards), several isolation amplifiers
and external equipment with 24 Vdc.
The mains voltage passes the MCB (Q1) before it is filtered for
noise (FL1). The MCB trips and breaks the circuits if the mains
current exceeds the rated MCB current.
The filtered mains voltage is converted to 24 Vdc by the AC/DC
converters (PSU1). The 24 Vdc is distributed to different
modules by fuses with rating suitable for the loads the modules
represent. The fuses can also be used to isolate the different
circuits.
Fuse-status indication
The fuses designated Fnn (F1, F2, etc.) in DPC-411, have a built-in
status LED. If a fuse is broken, the corresponding LED is lit red
because the impedance of the load forces the LED to supply
voltage ground.
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Kongsberg Maritime DPC-411
F1 - Fnn
Supply
voltage Load
R
LED
D
(CD2902)
Serial-line interface
To obtain galvanic isolation of all serial lines attached the serial
line interface TBSS module is used.
TBSS can have two plug-in adapters installed. The adapters can
be of either RS232 or RS422 type. Each adapter contains two
isolated serial channels.
A TBSS module provides circuitry for a maximum of four serial
channels. Used in a configuration with the RCU, the first TBSS
handles four channels and the second handles three channels.
See separate TBSS Hardware Module Description document for
details.
Figure 4 shows the cabling between the RCU and two TBSS
modules. A split flat-cable is connected between the RCU in
location U1 at one end and connector P1 on TBSS 1 and P1 on
TBSS 2 at the split end.
For more serial lines a second split flat-cable is connected
between RCU in location U2 and connector P1 on TBSS3 and
P1 on TBSS4 (optional) at the split end.
10 177877/A
Hardware Description
Serial channels
1 to 4
TBSS 1
P1
Serial channels
5 to 7
RCU TBSS 2
P1
(CD3083)
Data network
Network field cables are terminated on the Mini Patch Box,
PP1. Patch cables with RJ45 connectors are connected between
the RCUs’ A network terminals and the Patch Box connectors.
Mini
Patch
Box
Field
Cables
Net A
Net A Net A
U1 U2 U3
(optional)
(CD3085)
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Kongsberg Maritime DPC-411
Field Cabling
12 177877/A
Hardware Description
Technical specifications
POWER SUPPLY REQUIREMENTS
Supply voltage 115/230 Vac
Typical power consumption 125 W
Maximum power consumption 285 W
MECHANICAL SPECIFICATION
Size: width x height x depth 600 x 1200 x 300 mm
Weight 65 kg
ENVIRONMENTAL REQUIREMENTS
EMC Non-shielded cabinet
IP degree IP44
Typical heat dissipation 75 W
Maximum heat dissipation 135 W
Noise level < 40 dB
Also refer to Kongsberg Maritime Environmental Specification, reg. no.:
161011
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Fault Finding
FAULT FINDING
This section presents the fault finding principles for the
DPC-411.
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Kongsberg Maritime DPC-411
16 177877/A
Fault Finding
Equipment status
The RCU modules run built-in test programs that continually
check for faults while the system is running. DPC-411 related
system messages/alarms are displayed on the operator station
and/or event/alarm printer to inform/alarm the operator about
process station faults or to bring any other relevant information
to the operator’s attention. Refer to the appropriate Operator
Manual for detailed information on reading the equipment
status. Refer to Figure 6 for a general fault finding flowchart
when system messages/alarms are given.
1.2 All RCU modules in this The power connection to the Verify presence of
DPC-411 have lost contact DPC-411 has been lost. 115/230 Vac supply voltage.
with the system. No LED is lit.
MCB Q1 has tripped. Close Q1.
Defective power supply PSU1. Replace PSU1 power supply.
1.3 A LED in X11, X21, X31 or Defective fuse in field terminal Replace fuse in terminal
X41 is lit block. block.
1.4 A LED in X11, X21, X31 or Defective LED in field Replace LED terminal block.
X41 is not lit although the terminal block.
corresponding fuse has blown.
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Kongsberg Maritime DPC-411
Is power to
RCU modules OK?
Yes
Yes
No No
Repair power or
Replace RCU module replace AC/DC module
as appropriate
Is DPC
response OK?
No
End
(Vis1177B)
18 177877/A
Preventive Maintenance
PREVENTIVE MAINTENANCE
This section presents the preventive maintenance
procedures for the DPC-411.
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Kongsberg Maritime DPC-411
20 177877/A
Corrective Maintenance
CORRECTIVE MAINTENANCE
This section presents the corrective maintenance
procedures for the DPC-411.
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Kongsberg Maritime DPC-411
Replacing PSU1
This procedure lists steps that should be taken to replace a
defective power supply PSU1 in DPC-411.
Note You must be allowed to turn off the power to the specific
DPC-411 and have a spare power supply module.
Warning You should see to that the power lines to the field station are
turned off and stay turned off during this work.
1 Open the front door of DPC-411.
2 For the case of your safety, turn off circuit breaker (MCB)
Q1 for PSU1.
3 Remove wires attached to the PSU by using a flat-bit
screwdriver.
4 Remove the faulty PSU by removing the two screws
holding the clamp bracket.
5 Attach the new PSU by holding it in position and fix the
clamp bracket by fastening the two screws.
6 Re-attach the wires to the PSU by using the flat-bit
screwdriver
7 Turn on the power lines to DPC-411.
8 Turn on MCBs Q1 for PSU1.
9 Verify that the RUN LED of the RCU modules is turned
from red to green after a while.
10 Verify that the RCU modules are working OK by
watching operator station status.
11 Close the front door of DPC-411.
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Corrective Maintenance
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Kongsberg Maritime DPC-411
24 177877/A
Corrective Maintenance
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Replaceable Parts and Consumables
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Kongsberg Maritime DPC-411
Consumables
Note Where-used references listed in the table below are referred to
the standard product. Vessel specific DPCs can deviate from this
table. See the vessel specific drawings for actual references in
use.
List Part name Where used Part
ident. number
1 Fuse, 5x20 mm, 2 A F X11: F1, F4 43505833
X41: F1
2 Fuse, 5x20 mm, X21: F1-F2 43522218
6.3 A F X31: F1
3 Fuse, 5x20 mm, X11: F2-F3, F5-F8 43505817
0.50 A F X31: F2-F3
Table 5 Consumables
28 177877/A