1 Technical Course Vol1

OS-500-SDP-MP5xx-BI Maintenance Manual
OS-500-SDP-MP5xx-BI
Maintenance Manual
This document contains hardware description and
maintenance information for the OS-500-SDP-MP5xx-BI.
MP5xx Computer LCD Colour Monitor
Service Keyboard Operator Panel

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.
176982 /A 1
Document revisions
Written by Checked by Approved by

Rev Date Sign Date Sign Date Sign
A 11.11.03 HHO 20.01.04 TF/GN 20.01.04 NOH
B
C
D
E
F
The original signatures are recorded on the company’s logistic data system.
Document history
Rev. A First version.
2 176982/A
HW Configuration Status
(This information is for Kongsberg Maritime use only)
The configuration status of documents describing the OS-500-SDP-MP5xx-BI hardware
for this revision of the Maintenance Manual are listed below:
Parts Lists
Parts List OS-500-SDP-BI: B56100, Rev. C
Drawings
Panel System SDP, SVC, STC, SCS, HPR, SPM, SPS: 502631, Rev. D
Power and Wiring Diagram, Complete DEsktop/Built-in
Panel System w/Mounting Plate: 503130, Rev. D
Layout Panel Plate, SDP/STC Compact Panel, Built-in: 503765, Rev. B
Mounting Plate OS 600728, Rev. B
176982 /A 3
Table of contents
HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operator interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Colour monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SDP Operator Panel, Built-in version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alphanumeric keyboard (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power supply and signal wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
The computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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 equipment housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to adjust colour monitor settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to maintain the Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to clean the colour monitor screen surface . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to clean the buttons and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to clean the trackball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preventive maintenance intervals for OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Preparation for replacement of a part in the OS-500-SDP-MP5xx-BI . . . . . . . . . . 24
Finish replacement of a part in the OS-500-SDP-MP5xx-BI . . . . . . . . . . . . . . . . . 25
Preparation for calib./test of a part in the OS-500-SDP-MP5xx-BI . . . . . . . . . . . . 25
Finish calib./test of a part in the OS-500-SDP-MP5xx-BI . . . . . . . . . . . . . . . . . . . 26
PNC 100, numeric and special function panel, and alarm and function panel
replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REPLACEABLE PARTS AND CONSUMABLES . . . . . . . . . . . . . . . . . 33
Replaceable parts and recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . . 34
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 176982/A
Hardware Description
HARDWARE DESCRIPTION
This section describes the OS-500-SDP-MP5xx-BI hardware
configuration.
176982/A 5
Kongsberg Maritime OS-500-SDP-MP5xx-BI
General
Note When reading the information below take the following into
consideration:
This document is valid for both the OS-500-SDP-MP5xx-BI as DP
System delivery and for the OS-500-SDP-MP5xx-BI as IAS
(Integrated Automation Systems) delivery. Normally the
OS-500-SDP-MP5xx-BI for IAS will be connected to network
equipment located in dedicated Network Distribution Unit (NDU).
The network hub on the mounting plate (refer to Figure 3) will then
be omitted. The NDUs are described in separate maintenance
manuals.
The OS-500-SDP-MP5xx-BI, refer to Figure 1, contains normally
the following main assemblies for installation into the customer
supplied desk/console:
· One 20.1”LCD colour monitor
· One SDP Operator Panel, Built-in version, including PSU 1,
power filters.
· One Computer
· One mounting plate including modem, patchpanel, necessary
wiring, network hub and connections
· One set interconnecting cables
6 176982/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 1 OS-500-SDP-MP5xx-BI Power Supply and Signal Wiring
176982/A 7
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.
SDP Operator Panel, Built-in version

The SDP Operator Panel, Built-in version, provides several
controls on the SDP Operator Panel. The controls 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’s

B port.
24 VDC BUILT-IN OPERATOR

CABINET
Alarm and function panel 3-axis joystic
Heading control (optional) Numeric & special functions panel Trackball
(Cd2844)
Figure 2 Layout of SDP Operator Panel, Built-in version
8 176982/A
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).
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). An automatic switch, located in the
operator panel, serve these two functions.
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 to the computer’s 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 with Autopilot
function included. The heading wheel is connected to the PNC
100.
DP/Manual switch panel (optional)

The DP/Manual panel provides the operator with possibilities to
run his vessel under Kongsberg Dynamic Positioning Control or
to run the thrusters under direct Manual Control.
Alphanumeric keyboard (optional)

A standard alphanumeric keyboard is available. It is plugged into
the back of the SDP Operator Panel, Built-in version.
The alphanumeric keyboard is for service use only.
176982/A 9
Mounting plate
Figure 3 Mounting plate layout

The OS-500-SDP-MP5xx-BI mounting plate contains the
necessary hardware for signal and power distribution to the other
OS components. The panel layout is shown in Figure 3.
Power supply and signal wiring

The 115/230Vac mains inlet is terminated on the X1 row terminals
located on the mounting plate.
The process network cabling is terminated in field termination
patch panel located on mounting plate. These connections are the
only ones required to put the OS into operation.
Two 115/230Vac circuit breakers (Q1 and Q2) are located on the
mounting plate. The circuit breakers function both as fuses and
power switches to isolate parts of the hardware.
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 for External Alarm facility) through circuit
breaker X2. All the other modules, the computer, the colour
monitor, and the network hub, require 115/230 Vac supply voltage,
which is supplied via circuit breaker Q1 (see Figure 1 for a block
diagram of power and signal wiring).
10 176982/A
A double mains outlet socket 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.
In stand-alone systems (SDP–11/21/31), up to two of the SDP
operator stations contain one 8-port hub (refer to Figure 1). The
optional hub is located on the mounting plate and is powered via
the Q1 circuit breaker.
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 1).
The computer
For detailed description of the computer refer to the Computer
Maintenance Manual.
176982/A 11
Fault Finding
FAULT FINDING
This section presents the fault finding principles for the
OS-500-SDP-MP5xx-BI.
176982/A 13
Error indicators
There are three alarm lamps in the Alarms button group on the
operator panel:
· 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.
· Alarm
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 marking and labelling specification for how to
interpret the position codes.
· Replacement procedures for replaceable modules. See the
14 176982/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.
176982/A 15
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 4 Fault finding flowchart for OS-500-SDP-MP5xx-BI
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.
16 176982/A
Preventive Maintenance
PREVENTIVE MAINTENANCE
This section presents the preventive maintenance procedures
for the OS-500-SDP-MP5xx-BI.
176982/A 17
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 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 adjust colour monitor settings

Adjust the appropriate settings in accordance with the Colour
Monitor Hardware Description Manual.
How to maintain the Computer

For preventive maintenance procedures of the Computer, refer to
the Computer Maintenance Manual.
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.
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.
18 176982/A
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-500-SDP-MP5xx-BI“.
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-500-SDP-MP5xx-BI“.
176982/A 19
Preventive maintenance intervals for OS

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

Tighten screws in the Every six month
termination blocks
Check connector locks Once a year
Clean equipment housings Once a month
Clean the Colour Monitor Once a week
Screen
Clean the Computer air Every three months
intake dust filter
Clean the trackball Every six months or when
required
Check the Computer fans Once a month
Clean the buttons and Once a month or when
panels required
Table 1 Recommended maintenance intervals OS
20 176982/A
Corrective Maintenance
CORRECTIVE MAINTENANCE
This section presents the corrective maintenance procedures
for the OS-500-SDP-MP5xx-BI.
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.
176982/A 21
General
Caution Electrostatic discharges can damage the electronic components
properly connected earthing strap while performing
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 a part in

the OS-500-SDP-MP5xx-BI
To perform replacement of of a part in the
OS-500-SDP-MP5xx-BI proceed as follows:
1 Shut down the operator station in a controlled manner.
2 Switch off the 24 Vdc circuit breakers.
3 Switch off the 115/230 Vac circuit breakers.
4 Unscrew the 8 screws fastening the Operator Panel to the
operator console.
Caution Be careful not to strain the cables or connectors.
5 Lift the Operator Panel a little up, then carefully raise the
front edge only of the Operator Panel with the rear edge in
place, so that the panel rotates approximately 90 degrees and
the underside of the bottom protective box is fully visible.
6 Disconnect the cables in the lower edge of the Operator
Panel.
7 Lift up and place the Operator Panel in the same position on
a table covered with an soft antistatic mat.
8 Unscrew the 16 screws fastening the bottom protective box
to the Operator Panel front.
9 Carefully lower the front edge of the bottom protective box
with the rear edge in place, so that the bottom box rotates
approximately 90 degrees and the interial of the Operator
Panel is fully visible.
10 Then replace the wanted part according to the specific
Hardware Module Description of the part, or according the
adequate procedure below.
22 176982/A
Finish replacement of a part in the

OS-500-SDP-MP5xx-BI
1 Carefully rise the front edge of the bottom protective box
approximately 90 degrees and the underside of the bottom
protective box of the Operator Panel is fully invisible.
2 Screw the 16 screws fastening the bottom protective box to
the Operator Panel front.
3 Lift up and place the Operator Panel in the same position on
its location on the operators console.
4 Re-connect the cables in the lower edge of the Operator
Panel.
5 Carefully lower only the front edge of the Operator Panel
with the rear edge in place, so that the panel rotates
approximately 90 degrees and the Operator Panel its normal
position in the operators console.
6 Screw the 8 screws fastening the Operator Panel to the
operator console.
7 Switch on the 24 Vdc circuit breakers.
8 Switch on the 115/230 Vac circuit breakers.
9 Verify that the replaced/calibrated unit is functioning
properly.
Preparation for calib./test of a part in the

OS-500-SDP-MP5xx-BI
To perform a calibration/test of a part in the
OS-500-SDP-MP5xx-BI proceed as follows:
1 Shut down the operator station in a controlled manner.
2 If power is not needed during calibration/test, switch off the
24 Vdc circuit breakers and the 115/230 Vac circuit breakers.
3 Unscrew the 8 screws fastening the Operator Panel to the
operator console.
4 Lift the Operator Panel a little up, then carefully raise the
front edge only of the Operator Panel with the rear edge in
place, so that the panel rotates approximately 90 degrees and
the underside of the bottom protective box is fully visible.
5 Unscrew the 16 screws fastening the bottom protective box
to the Operator Panel front.
176982/A 23
6 Carefully lower the front edge of the bottom protective box

approximately 90 degrees and the interial of the Operator
Panel is fully visible.
7 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 a part in the

OS-500-SDP-MP5xx-BI
1 Carefully rise the front edge of the bottom protective box
approximately 90 degrees and the underside of the bottom
protective box of the Operator Panel is fully invisible.
2 Screw the 16 screws fastening the bottom protective box to
the Operator Panel front.
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.
4 Screw the 8 screws fastening the Operator Panel to the
operator console.
5 If power has been turned off during calibration/test, switch
on the 24 Vdc and the 115/230 Vac circuit breakers.
6 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:
2 Follow the replacement of the appropriate unit in accordance
with the specific Hardware Module Description
24 176982/A
Trackball unit replacement procedures

If there is no response to the cursor on the screen when the trackball
is operated, perform the following procedure:
a part in OS-500-SDP-MP5xx-BI“. Keep the 24 Vdc and
115/230 Vac on.
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 4.
3 Shut down the operator station in a controlled manner before
turning off the power.
4 Access the OS mounting plate.
5 Switch off the 24 Vdc circuit breaker X2 and and the
115/230 Vac circuit breakers Q1 and Q2.
6 Refer to Figure 5. Disconnect the two cable connectors from
the side of the trackball unit.
176982/A 25
Figure 5 Trackball unit replacement
Note Support the trackball unit on the underside of the operator panel
while removing the screws from the topside.
7 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.
8 Remove the bezel flange from the topside of the operator
panel and the main unit from the underside. Discard the
faulty units.
9 Unpack the replacement trackball unit and remove the four
securing screws to separate the bezel flange from the main
unit.
10 Position the main unit on the underside of the operator panel
with same orientation and position as the original unit.
11 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.
12 Reconnect the two cable connectors.
26 176982/A
Trackball button board replacement procedures

If there is no response to the three buttons when choosing from
dialogue/menus on the screen, proceed as follows:
a part in OS-500-SDP-MP5xx-BI“. Access the OS mounting
plate.
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.
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:
1 Perform the procedure for “Preparation for calibration of a
part in OS-500-SDP-MP5xx-BI“. Access the OS mounting
plate.
2 Initialize 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.
176982/A 27
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
in position.
4 Perform the procedure for “Finish calibration of a part in
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:
plate.
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.
28 176982/A
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:
joystick panel.
3 Unscrew and remove the faulty joystick panel (two screws)
4 Position the replacement joystick panel (PN 37795366) onto
5 Connect the two cable connectors to TB1 and J1 on the
joystick panel.
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
plate.
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)
onto the operator panel and secure it using the same screws
that were removed in step 3.
176982/A 29
5 Connect the two cable connectors that were removed in step

2 to the heading control.
30 176982/A
Replaceable Parts and Consumables
REPLACEABLE PARTS AND CONSUMABLES

This section contains lists of replaceable parts, recommended
spare parts and consumables used in
OS-500-SDP-MP5xx-BI. Replacement procedures for the
listed parts are described in the appropriate Hardware Module
Description. No replacement procedures are supplied for the
consumeables.
176982/A 31
Replaceable parts and recommended spare parts
List Part name Recommended Part

ident. as spare part number
1 Alarm & Function Panel 600709
2 Numeric & Special Function Panel 600689
3 PNC-100 Panel Controller X 37960259
4 Heading Control (optional)
5 Joystick, 3-Axis X 47730320
6 Joystick Control Board X 37795366
7 Trackerball Unit X 47749981
8 Trackerball Button Panel 37795382
9 Alphanumeric Keyboard (optional) 700455
10 Power Supply, 100-240VAC/2A, X 47745799
24VDC/2.5A
11 Filter Schaffner, FN9222-10/06 X 700529
12 Micro Hub, 8-port Hub X (if installed) 47734496
13 Modem, Tele, Westermo, TD-33 X 700695
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, Merlin Gerin, 6A, Q1 (Mounting Plate) 47717517
2-pole
2 Fuse, Merlin Gerin, 4A, Q2 (Mounting Plate) 47718747
2-pole
Table 3 Consumables
32 176982/A
SDP/SDPM/SPM--OS (COS 200) maintenance manual
SDP/SDPM/SPM- OS (COS 200)

maintenance manual

maintenance information for the SDP/SDPM/SPM- OS
(COS 200) operator station.
Important notice:

sole exclusive property of Kongsberg Simrad AS, and shall
163394 /C i
Document revisions
Rev Written by Checked by Approved by

Date Sign Date Sign Date Sign
A 16.04.99 EIK 20.04.99 EB 20.04.99 LKM

B 02.11.99 EIK 02.11.99 EB 02.11.99 EB
C 04.08.00 EIK 31.08.00 EB 31.08.00 EB
D
E
F
G
H
(The original signatures are recorded in the company’s logistic database)
Document history
(This information is for Kongsberg Simrad use only)
Rev. A The first version of this document.

Rev. B New power supply in the computer compartment introduced.
Rev. C Corrected chapter Corrective manintenance with respect to name of cir-
cuit breakers. Added version information about COS 200. Updated
chapter Operator interfaces. Added fans and updated mains filter part
number in chapter Replaceable parts and recommended spare parts.
Corrected the Fault finding flowchart with respect to using COS 200.
Added trackball with PS/2 interface in Figure 4 and 5, and in Replaceable
parts.
ii 163394/C
SDP/SDPM/SPM- OS (COS 200) maintenance manual
Contents
HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operator interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Colour monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alphanumeric keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power supply and signal wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COS 200 computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Error indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General fault finding and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reading power LED status and measuring supply voltages . . . . . . . . . . . . . 11
Fault finding flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to tighten screws in the termination blocks . . . . . . . . . . . . . . . . . . . . . . . 14
How to check connector locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to clean cabinets/equipment housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to open the operator panel compartment . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to adjust colour monitor settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to access the alphanumeric keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
How to clean the front door dust filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
How to check the fans inside the console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
How to maintain the COS 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
How to clean the colour monitor screen surface . . . . . . . . . . . . . . . . . . . . . . . . 17
How to degauss the colour monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
How to clean the buttons and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
How to clean the trackball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preventive maintenance intervals for OS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PNC 100, numeric and special function panel, and alarm and function panel
replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Trackball unit replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Trackball button board replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . 25
Joystick calibration procedures (not SPM–OS) . . . . . . . . . . . . . . . . . . . . . . . . . 26
Joystick replacement procedures (not SPM–OS) . . . . . . . . . . . . . . . . . . . . . . . 27
Joystick panel replacement procedures (not SPM–OS) . . . . . . . . . . . . . . . . . . 28
163394 /C iii
Heading control replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Replaceable parts and recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . 32
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
iv 163394/C
HW configuration status
(This information is for Kongsberg Simrad use only)
Configuration status of documents describing the SDP/SDPM/SPM--OS (COS 200)
hardware for this revision of maintenance manual:
Partslist SDP- OS (230 Vac): P41000, revision E

Partslist SDP- OS (120 Vac): P41010, revision A
Assembly, OS Console: 779684, revision B
Mounting plate, right sidewall, OS: 779491, revision E
Power & wiring diagram, OS m/COS 200 (230Vac/120Vac): 799575, revision A
Text layout, Basic panel plate (SDP/SDPM- only): 798058, revision A
Text layout, Basic panel plate (SPM- only): 799383, revision A
Wiring Diagram Display Control OS: 779573, revision A
Wiring Diagram, Panel System SDP: 796436, revision I
163394 /C v
SDP/SDPM/SPM- OS (COS 200) hardware description
This chapter contains the hardware description of the
SDP/SDPM/SPM- OS (COS 200) operator station.
163394 /C 1
Kongsberg Simrad SDP/SDPM/SPM--OS (COS 200)
Cabinet
Figure 1 SDP/SDPM/SPM- OS (COS 200) Operator Station
The OS cabinet comprises a monitor compartment, an operator

panel compartment, a computer compartment and a cabinet base
compartment.
Access to the computer compartment, where almost all hardware
modules are located, is obtained by removing the front door. Two
door knobs, located in the top corners, unlock the door to hinge
forward, while retained at the bottom by two lugs. The door may
then be lifted clear of the cabinet.
Access to the cabinet base compartment is from the inside of the
computer compartment via two service lids, located on the floor
of the compartment. Each lid can be removed by unscrewing and
removing four screws. Access may also be obtained by removing
the front or rear external cabinet base covers.
2 163394/C
Operator interfaces
Colour monitor
A high- resolution 21” colour monitor provides the main graphic
display for presentation of data. The signal cable is connected to
the graphic interface of the COS computer.
Two fans, providing cooling to the colour monitor, are located in

the computer compartment ceiling.
Operator panel
The operator panel provides several controls on the operator
panel. They are interfaced either to the COS computer or to the
panel controller (PNC 100).
The panel controller is connected via a serial line to the COS
computer’s COM2 port.
Figure 2 Layout of SDP/SDPM/SPM- OS (COS 200) 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).
163394 /C 3
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 COS 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 to the COS computer’s
COM1 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
wheeel is connected to the PNC 100.
Alphanumeric keyboard
A standard alphanumeric keyboard is available in the operator
panel compartment. It is accessed from the front by opening two
lids, which are hinged at their bottom edge.
A switch has to be operated to select the keyboard. The Numeric

and Special Function Panel is then disabled.
The alphanumeric keyboard is for service use only.
4 163394/C
Power supply and signal wiring

The mains inlet is terminated on row terminals located in the
cabinet base and is accessible by removing the service lid. The
process network cabling is terminated in field termination box(es)
located in the upper part of the computer compartment and to the
right of the fans. These connections are the only ones required to
put the OS into operation.
Figure 3 Equipment layout inside the OS cabinet’s computer compartment

The (120Vac) 230 Vac/24 Vdc power unit (PSU1) is located to the
left in the upper part of the computer compartment. Two different
power units have been used (see Figure 3).
Four circuit breakers are located inside the cabinet on the right
side wall. The circuit breakers function both as fuses and power
switches to isolate parts of the hardware.
The operator panel requires 24 Vdc as supply voltage and is
supplied via circuit breaker Q1. All the other modules, the COS
200, the colour monitor, the fans and the network hub, require
120/230 Vac supply voltage, which is supplied via circuit
breakers Q3 and Q4 (see Figure 4 for a block diagram of power
and signal wiring).
An additional 24 Vdc supply (backup) is connected to the
operator panel to meet the requirements of the classification
societies. This supply voltage is normally supplied by the
vessel/rig and is terminated on the connectors located in the
cabinet base. The power is supplied via circuit breaker Q2.
163394 /C 5
A mains outlet J1 is provided for service use only. It is protected

by the circuit breaker Q4, which also feeds the optional hub.
Caution ! Do not use the mains outlet for other purposes than servicing the
system. Heavy or noisy loads connected here may damage the
system.
Figure 4 Interconnections inside the single and dual SDP/SDPM/SPM- OS (COS 200)
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 on the right sidewall of the computer
compartment (see Figure 3) and powered from the Q4 circuit
breaker.
Figure 5 Network connections inside the third stand- alone SDP- OS

cabinet and in SDP/SDPM/SPM- OS (COS 200) for integrated
systems
6 163394/C
For the third SDP/SDPM/SPM- OS (COS 200) 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 COS
computer and the network termination box(es) (see Figure 5).
COS 200 computer

Caution ! Access to the inside of the COS 200 cabinet is provided for
Kongsberg Simrad-authorized service personnel only, and it is
obtained by removing eight screws on the top rim and then lift off
the lid.
The COS 200 (Common Operator Station) is a computer located
in the OS cabinet’s main compartment. It stands on shockmounts
and has all its connectors and front loads pointing towards the
right side wall of the OS.
The COS 200 contains a high- performance IntelÒ Pentium- based
graphics computer running the MicrosoftÒ Windows NTt
32- bit operating system.
The SDP/SDPM/SPM- OS (COS 200) and DPC system software
is stored on a hard disk mounted inside the COS 200 cabinet.
The communication network interface is available on the COS 200

front. Two configuration variants are available:
· COS 200 with Intel main board

Two RJ45 connectors labelled NET A and NET B (Single
network requires only NET A) for the process network on
plug- in cards and a connector named NET1 on the COS 200
main board front for the administration network (see Figure 6).
· COS 200 with SOYO main board
Three RJ45 (and AUI) connectors labelled NET A and NET B
for the process network, and ADM. NET (NET C) for the
administration network. All three are available on plug- in
cards (see Figure 7).
The air intake cover is located on the front panel of the COS 200
cabinet, and the two exhaust fans are located on the the rear wall.
The air intake cover has a dust filter that must be
cleaned/replaced regularly.
Note ! For detailed description of the COS computer refer to the COS 200
Maintenance Manual.
163394 /C 7
Figure 6 COS 200 (Intel version) computer connectors (front view)
Figure 7 COS 200 (SOYO version) computer connectors (front view)
8 163394/C
Fault finding
FAULT FINDING
This chapter presents the fault finding principles for the
SDP/SDPM/SPM- OS (COS 200).
163394 /C 9
Error indicators
There are three alarm lamps in the Alarms button group on the
operator panel:
· Computer
This lamp flashes in response to a hardware- generated alarm
indicating that the operator station computer (COS) has
stopped communicating with the operator panel controller via
the serial line. This may indicate the COS 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 COS 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.

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
· System- specific diagrams, lists and drawings. See the
Kongsberg Simrad marking and labelling specification for how to
interpret the position codes.
10 163394/C
Fault finding
Reading power LED status and measuring supply

voltages
The status of the 120/230Vac to 24 Vdc AC/DC converter (PSU1)
is shown by a green LED on the front of the unit. The unit is located
directly above the COS computer. See the appropriate Hardware
Module Description.
The mains voltage can be measured at the mains outlet on the
ceiling of the cabinet using a multimeter with AC- range.
163394 /C 11
(Black display
Start
and no lamps on
the panel can be lit)
Open front door of OS cabinet.

Check status of circuit
beakers.
Is Q3 closed? No
Close Q3 and wait for COS

Yes to come up.
Does Q3 trip again?
Yes
No
No Is PSU1 green LED
lit?
Yes
No mains voltage present.
Repair the UPS and restart
system.
No
Is the OS OK?
Repair COS and the colour

monitor as appropriate.
Yes
Is the OS OK?
Yes
No
Contact Kongsberg Simrad

for recommended action
End
(ABC1041)
Figure 8 Fault finding flowchart for SDP/SDPM/SPM- OS (COS 200)
Note ! 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.
12 163394/C
Preventive maintenance
This chapter presents the preventive maintenance
procedures for the SDP/SDPM/SPM- OS (COS 200).
163394 /C 13

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

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
How to open the operator panel compartment

To perform maintenance inside the compartment or perform
adjustments to the colour monitor settings, the operator panel
compartment is opened in the following way:
1 Loosen the eight bolts from the top (see Figure 9).
Caution ! Be careful not to strain the cables between the panels and the
compartment. Disconnect the cables if required.
2 Lift the operator panel and put it carefully aside.
14 163394/C
Figure 9 Inside the operator panel compartment
How to adjust colour monitor settings

1 Open the operator panel compartment as shown in
Figure 11 to gain access to the controls.
2 Refer to the Colour Monitor (21- inch) Hardware Module
Description for details on how to adjust the settings.
163394 /C 15
How to access the alphanumeric keyboard

Caution ! Use of the alphanumeric keyboard for maintenance purposes is
restricted to Kongsberg Simrad service personnel.
Step 1:
Step 2:
Step 3:
Figure 10 How to access the alphanumeric keyboard
16 163394/C
How to clean the front door dust filters

1 Open the front door below the operator panel compartment
by turning the left- hand knob at least three revolutions
clockwise and the right- hand knob anti- clockwise until the
front door may be hinged downwards. Lift the front door,
so that the bottom lugs clear their holes to remove the door.
2 Open the dust filter cover on the back of the front door by
turning the two quarter- turn lock handles anti- clockwise.
3 Vacuum the filter.
Note ! If the filter is very contaminated, it should be replaced.
4 Reassemble the front door by following the reverse
sequence of step 1 and 2.
How to check the fans inside the console

front door may be hinged downwards. Lift the front door so
that the bottom lugs clear their holes to remove the door.
2 Check that the two fans in the cabinet ceiling blow properly
by listening to their sound pitch.
How to maintain the COS 200

Note ! Preventive maintenance procedures for the COS 200 should be found in
the COS 200 maintenance manual.
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.
How to degauss the colour monitor

Press the Degaussing button, placed at the bottom to the right of
the screen, for a maximum of 10 seconds.
Caution ! If you have to repeat the action, wait at least 20 minutes to obtain
the maximum effect and to reduce wear of the degauss circuitry.
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.
163394 /C 17
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
properly connected earthing strap while working inside the OS or
handling the electronic components while performing
front door may be hinged downwards. Lift the front door,
so that the bottom lugs clear their holes to remove the door.
2 Shut down the operator station in a controlled manner
before turning off the power.
Note ! Refer to the operator manual for the appropriate procedure.
3 Switch off the 24Vdc circuit breakers Q1, Q2 and the
(120)230 Vac circuit breaker Q3.
4 Using a 5mm hex. wrench, unscrew and remove the eight
screws that secure the operator panel to the cabinet.
compartment.
5 Carefully raise the front edge only of the operator panel
approximately 90 degrees and the underside of operator
panel is fully visible.
6 Disconnect the connectors for the cabling.
7 Open the trackball unit by removing the four screws, one in
each corner, from below.
8 Clean the ball with a non- abrasive cloth moistened with
mild soap solution.
9 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.
10 Reinstall the clean trackball into the trackball unit and
secure the unit cover with the screws that were removed in
step 7.
11 Reinstall the operator panel properly.
12 Switch on the 24Vdc circuit breakers Q1, Q2 and the
(120)230 Vdc circuit breaker Q3.
13 Reinstall and lock the cabinet front door.
18 163394/C
Preventive maintenance intervals for OS

Note ! Local evaluations should be made to determine site- specific
Tighten screws in the Every six month
termination blocks
Clean cabinets/equipment Once a month
housing
Clean the Colour Monitor Once a week
Screen
Clean the front door dust Once every three months
filters
Clean the trackball Every six months or when
required
Check the COS 200 and OS Once a month
fans
Degauss the Colour Monitor Once a month or when
required
Clean the buttons and Once a month or when
panels required
Table 1 Recommended maintenance intervals OS
163394 /C 19
Corrective maintenance
This chapter provides the corrective maintenance
procedures for the SDP/SDPM/SPM- OS (COS 200).
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 Simrad
service personnel only.
The replaceable parts and recommended spare parts list

also indicates the recommended spare parts that should
be stored on board.
The consumables list identifies the consumable items

that should be stored on board.
163394 /C 21
PNC 100, numeric and special function panel, and

alarm and function panel replacement procedures
properly connected earthing strap while performing maintenance
procedures.
To perform replacement of the PNC 100 panel controller, numeric
and special function panel or the alarm and function panel, open
the operator cabinet as follows:
2 Switch off the 24 Vdc circuit breakers Q1, Q2 and the
bolts that secure the operator panel to the cabinet (see
Figure 11).
Caution ! Be careful not to strain the cables of the operator panel.
Disconnect the cables if required.
approximately 90 degrees and the underside of the panel is
fully visible.
5 Follow the replacement procedures of the appropriate unit
in accordance with the specific Hardware Module
Description document.
7 Switch on circuit breakers Q1, Q2 and Q3.
8 Verify that the replaced unit is functioning properly.
9 Install, close and lock the front door of the OS computer
compartment.
Trackball unit replacement procedures

replacement procedures.
If there is no response to the cursor on the screen when the
trackball is operated, perform the following procedure:
Figure 11).
22 163394/C
compartment.
approximately 90 degrees and the underside of the trackball
unit is fully visible.
Figure 11 Operator panel, shown raised
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).
3 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 in the cable to the COS 200 or
in the COS 200 computer itself, and you should report the
fault to Kongsberg Simrad and request service on board,
then reinstall the operator panel. If signals are registered,
the trackball unit is faulty; proceed to step 4.
4 Open and remove the front door of the OS computer
compartment.
163394 /C 23

7 Refer to Figure 12. Disconnect the two cable connectors
from the side of the trackball unit.
Figure 12 Trackball unit replacement
Note ! Support the trackball unit on the underside of the operator panel while
removing the screws from the topside.
8 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.
9 Remove the bezel flange from the topside of the operator
panel and the main unit from the underside. Discard the
faulty units.
10 Unpack the replacement trackball unit and remove the four
securing screws to separate the bezel flange from the main
unit.
11 Position the main unit on the underside of the operator
panel with same orientation and position as the original
unit.
24 163394/C
12 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.
13 Reconnect the two cable connectors.
16 Verify that the trackball is functioning properly.
compartment.
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:
compartment.
Figure 11).
compartment.
6 Disconnect all the necessary interconnecting cable
connectors from the panel components, so that the operator
panel may be removed from the OS cabinet completely (two
earth cables from the joystick, P1 from the PNC 100, TB2
from the trackball panel and P1 from the numeric and
special function panel).
163394 /C 25
7 Lift the operator panel off of the OS and place it upside

down on a clean, static–free and earthed work surface.
8 Disconnect the cable connector from TB1 on the trackball
button board.
9 Disconnect the two cable connectors for the trackball unit
from the connectors on the button board.
10 Unscrew and remove the faulty button board (four screws)
11 Position the replacement button board (PN 37795382) onto
12 Connect the cable connector to TB1 on the button board.
13 Connect the two cable connectors for the trackball unit to
the connectors on the button board.
14 Reinstall the operator panel properly, making sure that all
the necessary interconnecting cable connectors that were
removed in step 6 are reconnected.
16 Verify that the button board is functioning properly.
compartment.
Joystick calibration procedures (not SPM–OS)

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
Figure 11).
compartment.
approximately 90 degrees and the underside of the joystick
is fully visible.
3 Initialise analogue inputs and ensure that 24 Vdc power is
turned on to the OS.
26 163394/C
4 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
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
in position.
6 Verify that the joystick is functioning properly.
Joystick replacement procedures (not SPM–OS)

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:
compartment.
163394 /C 27

Figure 11).
compartment.
approximately 90 degrees and the underside of the joystick
is fully visible.
6 Disconnect the two earth cables from the joystick earth
terminals.
joystick panel.
8 Unscrew and remove the faulty joystick (four screws) from
the operator panel.
9 Unscrew and remove the joystick panel assembly from the
faulty joystick base and reinstall the assembly onto the
replacement joystick base.
10 Discard the faulty joystick.
11 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 8.
12 Reconnect the two cable connectors to TB1 and J1 on the
joystick panel.
13 Reconnect the two earth cables to the joystick earth
terminals.
15 Verify that the joystick functions.
16 Calibrate the joystick in accordance with step 4 of the
joystick calibration procedure.
18 Verify that the joystick is functioning properly.
compartment.
Joystick panel replacement procedures (not SPM–OS)

28 163394/C
If the joystick panel is to be replaced, perform the following

procedure:
compartment.
Figure 11).
compartment.
earth cables from the joystick, P1 from the PNC 100, TB2
from the trackball panel and P1 from the numeric & special
function panel).
joystick panel.
9 Unscrew and remove the faulty joystick panel (two screws)
10 Position the replacement joystick panel (PN 37795366) onto
11 Connect the two cable connectors to TB1 and J1 on the
joystick panel.
14 Verify that the joystick panel is functioning properly.
compartment.
163394 /C 29
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:
compartment.
Figure 11).
compartment.
earth cables, P1 from the PNC 100, TB2 from the trackball
panel and P1 from the numeric and special function panel).
8 Disconnect the two cable connectors from the heading
control.
9 Unscrew and remove the faulty heading control (four
screws) from the operator panel and discard the heading
control.
10 Position the replacement heading control (PN 37795374)
onto the operator panel and secure it using the same screws
that were removed in step 9.
11 Connect the two cable connectors that were removed in step
8 to the heading control.
30 163394/C

14 Verify that the heading control is functioning properly.
compartment.
163394 /C 31

1 Alarm & function panel 37795317
2 Alphanumeric keyboard 47733506
3 Colour monitor 21” 47744380
4 COS 200 computer see COS 200 47743778

manual
5 Function panel 37795325
6 Heading control (optional) 37795374
7 Joystick unit (not SPM–OS) 47730320
8 Joystick panel (not SPM–OS) 37795366
9 Micro hub, 8--port hub X (if installed) 47734496
10 Numeric & special 37795358

function panel
11 PNC 100 X 37960259
12 PMP 3.24 SIC AC/DC (X) 47718085

power (old type) (230 Vac)
47718812
(120 Vac)
13 Power supply X 47745799

MWS--60--24 (new type)
14 Filter Schaffner 47746748
15 Trackball unit (old type) (X) 47734108

Serial mouse conn. to
COM1 of COS 200
16 Trackball unit (new type) X 47749981

PS/2 mouse conn. to
MOUSE of COS 200
17 Trackball button panel 37795382
18 Fan, PAPST 99x6 X 47733548

(230 Vac)
47738182
(120 Vac)
32 163394/C
Consumables
List Part name Where Part
ident. used number
1 OS front door filter
2 COS Computer air intake COS 200 700038

filter
3 Fuse, Merlin Gerin, 4Amp., Q1 47718747

C6ON/C, 2--pole
4 Fuse, Merlin Gerin, 2Amp., Q2, Q4 47719828

2--pole (230 Vac)
5 Fuse, Merlin Gerin, 4Amp., Q2, Q4 47718747

2--pole (120 Vac)

2--pole (230 Vac)

2--pole (120 Vac)
8 Fuse, 5 Amp., 250V T I--042, F1, X14 44317873

Wickman 5 x 20mm.
9 Fuse, 2 Amp., 250V T I--042, F2, X14 43505833

Wickman 5 x 20mm.
10 Fuse, 0.5 Amp., 250V F F1 & F2, 43505817

I--042, Wickman 5 x 20mm. X16
Table 3 Consumables
163394 /C 33
MP5xx Hard Disk to/from CD Store/Restore
MP5xx Hard Disk to/from CD

Store/Restore Procedure
This procedure is created to help you in solving any
hard disk problem that might show up with MP5xx
Maritime computers.
178054/B 1
Procedure
Document revisions
Rev.
Date Sign. Date Sign. Date Sign.
A 06.07.04 HHO 06.07.04 NOH 06.07.04 EB
B 28.09.05 EIK 28.09.05 EB 28.09.05 EB
C
Document history
Rev. B Replaced text containing Diskette with CD.
Table of contents
1 INTRODUCTION ............................................................................................................. 3
1.1 General ......................................................................................................................... 3
1.2 Actions to be Taken .................................................................................................... 3
1.3 MP5xx Computer System Backup CD ..................................................................... 3
2 PROCEDURES ................................................................................................................... 4
2.1 Main Menu................................................................................................................... 4
2.2 How to Store the Hard Disk Content to the CD-RW Disk.................................... 5
2.3 How to Restore the Computer Hard Disk Content from the CD-RW Disk ....... 7
2 178054/B
1 INTRODUCTION
1.1 General
If the MP5xx computer hard disk needs to have its software
restored or the disk needs to be replaced, you will in both cases
need a backup of its software as it was after last time it was
updated.
Together with this procedure you should have a CD-RW drive
installed on the computer and a dedicated CD, which holds the
needed software.
1.2 Actions to be taken

The first you need to do is to create a backup of your MP5xx
computer hard disk on one or a set of CD-RW disks. Use the CD
Store procedure for this task.
If a disk error situation comes up, you should use the Hard Disk
Restore procedure to recover the data.
1.3 MP5xx Computer System Backup CD

The System Backup CD contains the necessary programs and
menus to run the procedures.
178054/B 3
Procedure
2 PROCEDURES
2.1 Main Menu

You use selection 1 (Total System Backup) on the MAIN
MENU (see below) to make a complete backup of the hard disk
to the CD-RW. You use menu selection 2 (Total System Restore)
to restore the information from the CD-RW to the hard disk.
MAIN MENU
1 Total System Backup

2 Total System Restore
3 Copy Disk1 to Disk2
g Ghost
To start select number and ENTER.
NOTE:
If this text reappear after the intended operation
is completed, then you have not removed the CD!
Please remove the CD and reboot.
4 178054/B
2.2 How to Store the Hard Disk Content to the CD-RW

Disk
The following procedure shows how to take a complete system
backup (Store) of the MP5xx computer.
1. Insert the latest System Backup CD (disk no. 1 of y) into the
computer CD-RW drive.
2. Reboot the computer by pressing the ON-OFF switch on
the computer and wait until the computer is totally shut
down. Then press the ON-OFF switch to restart.
The MAIN MENU followed by the DOS prompt Q:\> is
shown.
3. Type 1 and press Enter.
This executes the Total System Backup command in the
MAIN MENU.
4. The text :
PLEASE IGNORE GHOST’S NOTIFICATION ABOUT “DISK 2”.
THIS IS AUTOMATICALLY TAKEN CARE OF
Press any key to continue . . .

5. Press a key on the keyboard. The following text is
displayed:
If You are using Boot Diskettes created by the Ghost Boot Wizard
ensure you have disk 2 (containing Ghost.exe) available when
booting from CD/DVD.
6. Remove the System Backup CD from the computer CD-RW

drive, and insert a blank CD-RW.
7. Click OK.
8. Follow the Progress Indicator dialog box.
When one CD-RW is full, the following dialog box pops
up.
178054/B 5
Procedure
New CD-R disc needed
? Insert next CD-RW disc
Cancel OK
(Vis1134a)
9. Swap the CD-RW disk with a new one and click OK to

continue.
10. Mark the CD-RW disk with CD x of y using a suitable
pen.
11. Repeat steps 8, 9 and 10 until the store is complete.
12. When the store is complete, the following message is
displayed.
Total System Backup finished!
Press any key to continue…
13. Remove the last CD-RW disk.
14. Press Enter.
The DOS prompt Q:\> is displayed.
15. Reboot the computer by turning it OFF and then ON.
16. Label the CD-RW disks with the name of the operator
station, computer serial number and date of the backup
before you store the backup in a safe place.
6 178054/B
2.3 How to Restore the Computer Hard Disk Content

from the CD-RW Disk
The following procedure shows how to Restore a complete
system backup of a computer.
1. Insert the latest System Backup CD (disk no. 1 of y) into the
computer CD-RW drive.
The MAIN MENU followed by the DOS prompt Q:\> is
shown.
3. Type 2 and press Enter.
This executes the Total System Restore command in the
MAIN MENU.
4. Follow the Progress Indicator dialog box.
When one backup CD is read, the following dialog box
pops up.
Span Volume [x] Done
! Insert next media and press enter to continue...
OK Cancel FileName?
(Vis1133)
5. Swap the CD-RW disk with the next one and click OK to
continue.
6. Repeat steps 4 and 5 until the restore is complete.
7. When the restore is complete, the following message is
displayed.
Total System Restore finished!
Press any key to continue…
8. Remove the last CD-RW disk.
9. Press Enter
The DOS prompt Q:\> is displayed.
178054/B 7
Procedure

The computer now starts the Windows XP and then the
SXX application programs as appropriate. The restore is
now completed.
11. If a dialog box is shown telling:
Device settings have been changed. Do you want to
reboot now to activate changes?
Then click No in this dialog box because the computer has
been restarted already without being able to show this
message.
8 178054/B
DPC-412 Maintenance Manual
DPC-412
Maintenance Manual

maintenance information for the DPC-412.
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.
177878 /A 1
Document revisions

A 07.06.04 EIK 16.08.04 TF 20.08.04 BF
B
C
D
E
F
Document history
2 177878/A
The configuration status of documents describing the DPC-412 hardware for this
revision of the Maintenance Manual are listed below:
Parts Lists
Parts List DPC-412 (115/230 Vac): P20150, Rev. A
Drawings
General Arrangement, DPC-412, Cabinet 600x1200x300: 1002019, Rev. A
Layout Drawing, DPC-412, 600x1200x300: 1001535, Rev. A
Power and Wiring Diagram, DPC-412, DPC w/RIO Modules: 1001533, Rev. A
Wiring Diagram, DPC-412, Net/Serial Lines: 1001534, Rev. A
Wiring Diagram, Interface Cable, RCU510 - TBSS: 1001144, Rev. C
177878 /A 3
Table of contents
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply (24 Vdc) monitoring and alarming . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding RCU modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Serial-line interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Data network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Field Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Field cable termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Spare core termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reading power status LEDs and measuring supply voltages . . . . . . . . . . . . . . . 14
Equipment status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Preventive maintenance intervals for DPC-412 . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing PSU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replacing Q1 or Q2 circuit-breaker (MCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing RCU510 or the fan in RCU510 module . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing TBSS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
177878 /A 5
This section describes the DPC-412 hardware
configuration.
177878/A 7
Kongsberg Maritime DPC-412
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-412 cabinet is made for wall mounting. It has two

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
X22
X41 F1
X42
TBSS1
PSU1
U1
RCU510 TBSS2
TBSS3
FL1
TBSS4
U2
(optional)
CABLE DUCT
CABLE DUCT
CABLE DUCT
CABLE DUCT
CABLE DUCT
CABLE DUCT
RCU510
F1 X11
X12
NET
Q1 A &B
BUSBAR PATCH PP1
Q2
MAINS PANEL
OUTLET
SOCKET I.E.
(CD3046)
Figure 1 Layout of DPC-412
Power supply, mains filter 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 together with the LAN connections for the RCUs.
Field cabling to DPC-412 are routed through the cabinet
bottom.
8 177878/A
Block diagram
A block diagram of DPC-412 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
Busbar Q3 Sockets
Serial Lines
6A
Serial Lines
To equipment outside Field Terminal Block
Field Terminal Block
DPC cabinet
Field Signal Loops Field Signal Loops
TBSS1 TBSS2 TBSS3 TBSS4
(CD3047) Field Serial Lines Field Serial Lines Field Serial Lines Field Serial Lines
Figure 2 Block diagram of DPC-412
Power supply
DPC-412 handles both 230 Vac and 115Vac as mains supply.
The block diagram in Figure 2 shows the power supply
principles of of DPC-412. The power supply supplies two
RCU510s, up to four TBSSs (serial termination boards) 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.
Power supply (24 Vdc) monitoring and

alarming
To monitor the supply voltage (24 Vdc) each RCU510 reads the
voltage with high precision at the power terminals on X1 to X4
and gives system alarm if voltage is outside predefined values.
Grounding RCU modules

Each RCU module shall be grounded. FL1 fast-on terminal is
connected to PE (or to IE if specified).
177878/A 9
See also the RCU 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 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 3 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 at one end
and connector P1 on TBSS 3 and P1 on TBSS 4 (optional) at
the split end.
Serial channels
1 to 4
TBSS 1
P1
Serial channels
5 to 7
RCU TBSS 2
P1
(CD3083)
Figure 3 Principle of internal serial-line cabling using TBSS
Data network
Network field cables are terminated on the Mini Patch Box,
PP1. Patch cables with RJ45 connectors are connected between
the RCUs’ A and B network terminals and the Patch Box
connectors.
10 177878/A
Mini Net B
Patch
Field Box
Cables
PP1
Net A
RCU RCU
Net A Net B Net A Net B
U1 U2
(CD3086)
Figure 4 Network principles in DPC-412
See separate drawing in the Drawing File for which ports on the
Patch Box are used.
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 terminal blocks on the
RCU and TBSS modules.
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.
177878/A 11
Technical specifications
POWER SUPPLY REQUIREMENTS
Supply voltage 115/230 Vac
Typical power consumption 110 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 60 W
Maximum heat dissipation 110 W
Noise level < 40 dB
Also refer to Kongsberg Maritime Environmental Specification, reg. no.:
161011
Table 1 DPC-412 technical specifications
12 177878/A
Fault Finding
FAULT FINDING
DPC-412.
177878/A 13

To correct the system, if an error situation has occurred, the
flowcharts in Figure 5 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.
appropriate Drawing File for details.
Corrective Maintenance section or the appropriate Hardware
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 is 115/230 Vac to 24 Vdc AC/DC converters. The status
of the PSU 1 is shown by a LED on the front of the power
module. OK state corresponds to green LED colour.
The power supply module is located on the left sidewall inside
the cabinet. Its output voltage can be measured on its
voltage-output terminals.
The mains voltage can be measured, where appropriate, using a
multimeter with AC-range.
14 177878/A
Fault Finding
Equipment status
The RCU modules run built-in test programs that continually
check for faults while the system is running. DPC-412 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 5 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: Single power supply, dual LAN without net switch
1.1 One RCU module in this Defective RCU module. Replace RCU module.
DPC-412 has lost contact with
the system. Local LED is red.
1.2 All RCU modules in this The power connection to the Verify presence of
DPC-412 have lost contact DPC-412 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 or X41 is Defective fuse in field terminal Replace fuse in terminal
lit block. block.
1.4 A LED in X11, X21 or X41 is Defective LED in field Replace LED terminal block.
not lit although the terminal block.
corresponding fuse has blown.
Table 2 Fault finding DPC-412

This sub-section contains .
Figure 5 shows a general fault finding flowchart telling how to
reestablish the field station after lost contact with an RCU or
blocks with I/O.
177878/A 15
Start System reports:

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

No check LED status on the
RCU module that is not
responding
Open DPC cabinet door and check
Q1, PS1 LED, fuse LEDs and RCU
LED status
Is the LED lit red?
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
Contact Kongsberg Maritime

for recommended action Yes
End
(Vis1177B)
Figure 5 Fault finding flowchart at DPC-412 error
16 177878/A
This section presents the preventive maintenance
procedures for the DPC-412.
177878/A 17

Use an isolated-handle (if power is on) screwdriver with 2 or 3
mm wide bit, as appropriate, and tighten any loose screws.

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.

Preventive maintenance intervals for DPC-412


Tighten screws in the Every six months
termination blocks
housing
Table 3 Recommended maintenance intervals for DPC-412
18 177878/A
This section presents the corrective maintenance
procedures for the DPC-412.

personnel only.
177878/A 19
Replacing PSU1
This procedure lists steps that should be taken to replace a
defective power supply PSU1 in DPC-412.
Note You must be allowed to turn off the power to the specific
DPC-412 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-412.
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-412.
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 RCUs modules are working OK by
watching operator station status.
11 Close the front door of DPC-412.
20 177878/A
Replacing Q1 or Q2 circuit-breaker (MCB)

defective circuit breaker (MCB) among Q1and Q2.
DPC-412 and have a spare MCB.
1 Open the front door of DPC-412.
2 For the case of your safety, turn off circuit breaker
(MCBs) that shall not be replaced.
3 Remove the busbar between the MCBs Q1 and Q2, and
remove the 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 and the wires to the MCB by using
the flat-bit screwdriver.
7 Turn on the power lines to DPC-412.
10 Verify that the RCU modules are working OK by
11 Close the front door of DPC-412.
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.
177878/A 21

This section contains lists of replaceable parts,
recommended spare parts and consumables used in
DPC-412. Replacement procedures for the listed parts are
described in the appropriate Hardware Module Description.
No replacement procedures are supplied for the
consumeables.
177878/A 23

1 Power Supply, MWS-240 47749445
115/230 Vac/24 Vdc/10 A
2 Fuse MCB, 6A, 2-pole, C-char. 701857
used at Q1 and Q2
3 RCU510 601418
4 Filter Schaffner FN 2080-6-60, 47746748
6 A
5 Telesafe Mini Patch Box, 702252
8xRJ45
6 TBSS 37960309
7 TBSL RS232 ISO 37767522
8 TBSL RS422 ISO 37767563
9 Termination Block WSI 6 LD 47753397
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.
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
3 Fuse, 5x20 mm, X11: F2-F3, F5-F8 43505817
0.50 A F
Table 5 Consumables
24 177878/A
MP530 Maintenance Manual
MP530
Maintenance Manual
This document contains the hardware description and

maintenance information for the MP530.
It covers the following variants (Kongsberg Maritime product
name and part number):
MP530 Base Model . . . . . . . . . . . 701848
MP530 w/Blue Heat . . . . . . . . . . 602816
MP530 w/CANbus . . . . . . . . . . . . 602815
MP530 w/Two-screen . . . . . . . . . 602817
Important notice:

178240 /A 1
Document revisions

A 24.08.04 EIK 26.09.04 EB 26.10.04 EB
B
C
D
E
F
Document history
2 178240/A
Table of contents
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MP530 computer cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cabinet front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cabinet rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cabinet interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MP530 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Interface cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Miniature speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power ON-OFF button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MP530 external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main-board connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Interface cards and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chassis ground connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault location/identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
How to clean the MP530 cabinet surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preventive maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to replace the CD-RW drive and floppy disk drive . . . . . . . . . . . . . . . . . . . . 22
How to replace the hard disk drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
How to replace a socket-mounted PCI card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to replace an AGP graphics card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
How to replace a RAM memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How to replace the power supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
How to replace the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
How to replace the main board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
How to replace the built-in speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
178240 /A 3

Replaceable basic parts and recommended spare parts . . . . . . . . . . . . . . . . . . . . 32
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4 178240/A
This section describes the MP530 hardware configuration.
178240/A 5
Kongsberg Maritime MP530
General description
The MP530 maritime computer is used in a wide range of
Operator Stations (OSs) produced by Kongsberg Maritime.
The computer can be installed inside operator station consoles
by using specific mounting brackets (see actual operator station
maintenance manual for details on mounting).
The OS and process station application software is stored on the
MP530 hard disk.
The MP530 is built around a high–performance CPU (central
processing unit) running the MicrosoftÒ Windows XPt or NT
4.0 operating systems.
The computer can be easily dismantled for replacing module
purposes.
MP530 accepts both 115 and 230 Vac mains input voltage by
setting the voltage switch on the rear panel correctly.
Part numbers for the different models are shown on the front
page of this document. The models differ mainly on the
combination of interface cards installed.
MP530 computer cabinet
Cabinet front
CD-RW drive and the floppy-disk drive are located adjacent to
each other. (see Figure 1). The front below the floppy-disk
drive contains microphone input, headphones output, two USB
ports, ON-OFF switch and LEDs for power and internal
hard-disk drive.
The fan-based air intake is located on the right side wall seen
from the front.
Figure 1 MP530 cabinet front
6 178240/A
Cabinet rear panel

Connectors for power, user interfaces and external equipment
are located on the rear panel (see separate section for
connections).
The layout in Figure 2 will differ between the different MP530
models (see document front page) because of different types of
AGP and PCI cards installed.
Figure 2 Typical rear panel layout
178240/A 7
Cabinet interior
Location of the main modules inside the cabinet is shown in
Figure 3. The computer is shown from above with the rear
(connector) wall pointing towards you.
The power module with its cooling fan is located to the left.
The drives assembly is the upper part shown. It can be pivoted
and supported in a tilted position.
The CPU with a fan and heat-sink block on its top is located in
the lower left corner.
CD-RW Drive
Floppy-disk Drive
Hard-disk Drive
Miniature
Speaker
Power Supply
Memory with Fan
RAM
Interface Card
AGP Socket
CPU with
Cooling Fan Interface Card
PCI Sockets
Main
Board
(CD3129)
Figure 3 MP530 internal layout
The PCI interface card assembly module (removed in Figure 3)

is located in the lower right corner. It can be pulled out (see
Figure 12) for easily mounting or removing an interface card.
8 178240/A
MP530 configuration
The following cards and components are located inside the
cabinet:
· Main board (Motherboard)
· CPU
· RAM, 512 MB
· Power supply 115/230 Vac
· Graphics card (2X or 4X) (optional)
· Network card
· Serial line cards (optional)
· CAN-bus card (optional)
· Hard-disk drive
· CD-RW drive
· Floppy-disk drive
· Miniature speaker
· Reset button (ON/OFF)
Each of the computer and interface cards, drives and power
supplies listed above are described shortly below. The
replaceable modules are described more detailed in separate
documents (Hardware Module Descriptions).
Figure 4 shows a block diagram of the MP530.
178240/A 9
The following illustration shows a block diagram of the MP530.
115/230 VAC CD-RW drive

Power fan PC power
supply
Floppy-disk drive
ATX pwr. conn. +12 VDC & +5 VDC
Rear panel
COM1 (serial) Power supply
COM2 (serial)
Mouse
Keyboard
USB1 (serial)
USB2 (serial)
USB3 (serial)
USB4 (serial)
Parallel port
Network A Hard-disk drive
Audio Out
Audio In
Mic. In
Graphics port Speaker
AGP slot
CPU
Graphics card fan Front panel
(optional) USB5 (serial)
PCI lower slot USB6 (serial)
Network card HDD. LED
(optional)
Pwr. LED
PCI upper slot
ON-OFF
Serial line card switch
(optional)
Mic. In
CANbus card Headphones
(optional) Main board Out (Vis1132B)
MP530
Figure 4 MP530 block diagram
Main board
The main board is equipped with a 2.53 GHz CPU and 512 MB
RAM.
The main board is not considered a replaceable module because
the computer has to be rebuilt from scratch and thoroughly
tested if the board is changed.
Power supply
One power module is used. It has 115 or 230 Vac as input
voltage (selectable).
10 178240/A
Note See the section Replaceable parts and consumables for module
names and and part numbers, and see the corresponding
Hardware Module Description for more technical information.
Interface cards
Standard PCI network card and optional AGP graphics card,
PCI serial line line card and PCI CAN-bus card are used in the
computer.
For details about the interface cards see the appropriate
Hardware Module Descriptions.
names and and part number.
Storage drives
Standard CD-RW drive, hard-disk drive and floppy-disk drive
are used in the computer.
For details about the storage drives see the appropriate
Hardware Module Descriptions.
names and and part numbers.
Miniature speaker
The speaker is located inside the cabinet on the left wall seen
from the front.
Cooling fans
The CPU fan is located behind the right side wall of the cabinet,
seen from the front. It provides cooling to the CPU and graphics
processor.
The power-supply module contains a fan located inside the
cabinet and blowing through this module.
Power ON-OFF button

A grey ON-OFF button is located in the centre of the cabinet
front.
Pressing the button once, the computer is turned ON or OFF,
depending on the prerequisite.
178240/A 11
MP530 external connections

The MP530 provides (included options) the necessary set of
standard PC connectors for user interfaces and the necessary set
of application-required connectors for system interfacing.
Main-board connections
This section lists the connectors available from the main board.
For more details refer to the Hardware Module Description for
the main board.
Microphone Hard-disk LED
Headphones 2 x USB ports Power LED On-Off Button

(CD3130)
Figure 5 Front connectors for external connections
Mouse Parallel port Network A

Audio
out
Audio
COM2 in
Mic.
in
Keyboard COM1 Graphics port USB1 USB3

(CD3131) USB2 USB4
Figure 6 Rear wall connectors for external connections
Mouse
This is a standard PS/2 mouse connector.
Keyboard
This is a standard PS/2 keyboard connector.
Parallel port
The Parallel port complies with the standard for PC parallel
ports.
12 178240/A
With appropriate driver software and configuration a local

printer can be connected to this port.
COM 1 and COM 2

These are standard PC serial line COM ports. COM 1 is not
used. COM 2 is connected to the PNC-100, panel controller
module in the operator panel.
Network
This is a standard ethernet network connection based on the
RJ45 connector. It is assigned to the network A in the redundant
process network.
Audio in
This is a audio line input connection based on the mini jack
connector.
Audio out
This is a audio line output connection based on the mini jack
connector.
Microphone
This is a microphone connection based on the mini jack
connector. A contact is located on the front and on the rear wall.
Headphones
This is a headphones connection based on the mini jack
connector and is located on the front.
USB
The main board provides four USB (Universal Serial Bus) roots
(ports) for attaching USB devices. Two ports are available on
the front and four on the rear panel.
Interface cards and connections

The illustration below shows the available slots for interface
cards and the standard set of cards.
· Network card (std)
· Graphics card (optional)
· RS232 serial interface card (optional)
· CAN-bus interface card (optional)
178240/A 13
Four screen graphics, CAN bus or

Serial line card (optional)
Slot for
Two-screen Mains
graphics card connector
(optional)
Mains voltage
selector
Ground
terminal
Adm. Network B
(CD3132A)
Network
Figure 7 Typical interface cards and connectors layout
Graphics cards (optional)

The two-screen card is an AGP slot card. The four-screen card is
a PCI slot card. Split cables that come with the graphics cards
are used for connecting to the colour monitors.
Note Read the numbering on the cable connectors for which monitor
they connect.
For details refer to the Hardware Module Description for the
graphics cards.
Ethernet network card (standard)

The network card is a PCI type card and provides two network
ports. The first port (the one to the left in Figure 7) is normally
connected to Network B, and the second port (to the right in
Figure 7), if required by the system, is connected to
Administration Network. The connectors are of the RJ45 type.
network card.
14 178240/A
RS232 serial interface (optional)

The card is a PCI type card and provides four RS232 serial
channels by the use of a special interface split cable. The
connector types used on the cable are four 9-pin male D-sub.
Note Read the numbering on the cable connectors for which is which
serial line.
serial line card.
CAN interface card (optional)

The card is a PCI type card. The connectors on the CAN
interface card are 9-pin D-sub, one male and one female.
CAN interface card.
Power connection
The computer is provided with a standard three-pin apparatus
socket and fits a standard female three-hole apparatus plug.
Note The power supply’s input-voltage-selector switch must be set to
the value that match the local mains voltage (either 115 Vac or
230 Vac). A label indicates the present setting.
The correct input voltage is set using the voltage-selector
switch, which is located to the right of the apparatus socket (see
Figure 7). You should use a thin, narrow flat-blade screwdriver
to move the selector to the correct position.
Chassis ground connection

The computer is provided with a fast-on ground terminal located
at the right lower corner when the computer is seen from the
connection side (see Figure 7). This terminal must be bonded to
PE (Protection Earth) with a short ground wire having large
cross section.
178240/A 15
Voltage 115/230 Vac
Power consumtion from supply 185 W
CONFIGURATION, PERFORMANCE AND CAPACITY
CPU type and speed Intel Pentium 4
2.5 GHz
Hard-disk drive Western Digital
WD400/WD400BB-60DGA0
60 GB
CD-RW drive Hitachi GCE-84181B
Network interface card (dual port) Intel pro 100s
Memory Compaq 512MB 266MHz DDR
CL 2.5
Power Supply 115/230 Vac Compaq PDP11P/ps-7171-1cf1
Graphics card (two screen) Matrox G55MADDA32B (AGP)
(optional)
Graphics card (four screen) Matrox G450 MMS X4
Quad-display (PCI) (optional)
CAN interface iPC-I320/PCI (optional)
Serial interface Blue Heat/PCI2+2 485 (optional)
4 channels
External USB disk for History Station Maxtor Personal Storage 5000
and DP Logger DV (optional)
Size: width x depth x height 338 x 383 x 100 mm
Weight 10.1 kg
IP degree IP-21
Refer to Kongsberg Maritime Environmental Specification, reg. no.:
161011
LIFE CYCLE SPECIFICATION
MTBF calculated 108 206 hours
Table 1 MP530 technical specifications
16 178240/A
Fault Finding
FAULT FINDING
MP530.
178240/A 17
Fault location/identification
If an error situation has occurred, the fault is normally identified
from the symptoms observed. It is therefore important to record
all these observations to help the maintenance person or service
engineer. All error messages shown on the screen should be
logged for this purpose.
The fault-finding table below assumes that the problem is
caused by the MP530 computer itself and no external factors are
involved.
SOURCE
1 No visible or audible sign of External supply voltage is Check the 115/230 VAC
power present at MP530. Fans turned off or circuitbreaker power supply.
are not blowing. fuse has tripped.
Internal power supply defect Replace power supply
2 Applications are not loading Defective file system. Reinstall the software by
when booting the MP530. Only using the system backup CD.
blue screen displayed.
3 Applications are not loading Defective hard-disk drive. Replace hard disk. See
when booting after the entire procedure in section
operating system software has Corrective maintenance.
been installed on MP530. Only
4 MP530 does not respond over Network task not running. Reboot MP530
network on either channel.
5 MP530 responds over network Defective network card or Replace network card.
on only one of tree channels. network part of main board.
6 MP530 crashes or hangs Possible defective RAM. Replace RAM.
unexpectedly.
Table 2 Fault-finding tips
18 178240/A
procedures for the MP530.
Replacement procedures relating to preventive

maintenance, are described only in the Corrective
maintenance section.
178240/A 19
How to clean the MP530 cabinet surface

cleaning. Use only a moistened cloth.
Preventive maintenance intervals

Note These procedures should be performed on each MP530 in the
system. Local evaluations should be made to determine
site-specific maintenance intervals.
ACTION INTERVAL RECOMMENDED

Clean cabinet surface Each month
Check for loose connectors and Each six month
wires
Table 3 Recommended preventive maintenance intervals
20 178240/A
procedures for the MP530.

personnel only.
178240/A 21
Replacement procedures
Caution Electrostatic charges can damage components on the
cards. Notice the following precautions: Always wear a
properly connected earthing strap when handling
unpacked cards. Place unpacked cards only on a
properly connected earthing mat or a shielding bag.
Keep cards in their shielding bags when not installed.
Never store cards near electromagnetic or electrostatic
devices.
Note Replacement procedures that require power to be turned off
must be preceded by shutting down the MP530 in a controlled
manner. Refer to the system operator manual for the appropriate
procedure.
Warning To avoid the risks accompanying high voltages,
always turn off the power circuit supplying the
computer before you open the cabinet lid.
How to replace the CD-RW drive and

floppy disk drive
Disassemble
1 Disconnect all cables connected to the computer.
2 Place the cabinet on a firm surface.
3 Standing with the front of the computer away from you,
lift the lever to release the lid and pull the lid towards you
(see Figure 8 for location of the lid release lever).
Figure 8 Release lever of the cabinet lid

4 Remove the plastic front cover of the computer by pulling
the three levers marked green and move the front (see
Figure 9).
22 178240/A
Figure 9 Removing the plastic cover front
5 Disconnect the flat cable and power connector from the

drive.
6 Release the lock for CD-RW drive and floppy-disk drive
by pulling lever in position 1 shown in Figure 10 and lift
out the appropriate drive as shown in position 2.
Figure 10 Removing the CD-RW and the floppy-disk drive
Reassemble
7 Check that the new drive type is a recommended spare
part for MP530.
8 Set any mode jumpers of the new drive to the same
positions as for the replaced drive.
9 Reassemble by performing steps 1 to 6 in reverse order.
10 Verify proper drive operation.
178240/A 23
How to replace the hard disk drive
Disassemble
1 Repeat step 1 to step 4 of the How to replace the
CD-RW drive and floppy disk drive procedure
2 Pivot the drives assembly upwards by pulling the green
coloured handle indicated in position 1 in Figure 11.
3 Release the drive from the assembly by pressing the disk
lock lever in position 2 in Figure 11 and pulling the drive
out as indicated in position 3 and 4.
Figure 11 Removing the hard-disk drive
4 Mark the old drive with a label and put it aside.
Reassemble
5 Check that the new hard disk drive type is a recommended
spare part for MP530.
6 Set any mode jumpers of the new drive to the same
positions as for the replaced drive.
8 Verify proper operation. The hard disk must then be
reloaded with backup data (see this separate procedure).
24 178240/A
How to replace a socket-mounted PCI

card
Disassemble
CD-RW drive and floppy disk drive procedure.
2 Pull the PCI card assembly upwards as indicated in
position 1 in Figure 12.
Figure 12 Removing a PCI card
3 Remove the PCI card by first moving the locking lever in

the arrow direction as indicated in position 2 and then
pulling the card from the socket card.
4 Put the card aside and mark it with a label describing the
symptoms observed.
Reassemble
5 Check that the new card is a recommended spare part for
MP530.
6 Check that all jumper and DIP settings of the new card are
set correctly before starting to reassemble.
7 Reassemble by performing steps 1 to 3 in reverse.
8 If the card is a network card, you should perform the
Checking Network Cards procedure, else verify proper
operation of MP530..
178240/A 25
How to replace an AGP graphics card
Disassemble
2 Open the hinged lock that holds the AGP card in place
according to position 1 in Figure 13.
Figure 13 Removing an AGP card
3 Remove the AGP card from the main board socket by

pulling it upwards as indicated in position 2 in Figure 13.
symptoms observed.
Reassemble
MP530.
appropriate before starting to reassemble.
8 Verify that the new card works properly.
26 178240/A
How to replace a RAM memory card
Disassemble
2 Pivot the drive assembly upwards.
3 Remove the PCI interface card assembly.
4 Press the ejectors at both ends of the memory card to
release it from the socket (see Figure 14).
Memory Card Ejectors
(Cd3134)
Figure 14 Memory card sockets with ejectors
5 Put the memory module aside and mark it with a label

describing the symptoms observed.
Reassemble
6 Check that the new memory card is recommended as spare
part for MP530.
7 Reassemble by performing step 1 to 4 in reverse order.
8 Verify proper operation of MP530.
178240/A 27
How to replace the power supply module

Note An error with the power supply module should be handled by
Kongsberg Maritime Service Department only.
Disassemble
2 Pivot the drive assembly upwards (see Figure 11 step 1) to
a risen position.
3 Remove the PCI interface card assembly (see Figure 12
step 1).
4 Remove the graphics card in the AGP socket (see Figure
13)
5 Remove the three fastening screws of the rear wall (see
Figure 15) using a screwdriver with torx bit.
Fastening screws
for the rear wall
(Cd3144)
Figure 15 Removing rear wall fastening screws

6 Grip and press the release handle on the front edge of the
main board (see Figure 16), and push the main board
towards the PC front while lifting it slightly until the main
board has slid clear of the rear wall.
Figure 16 Releasing main board
28 178240/A
7 Pull the rear wall against you (see Figure 17) until its free.
Figure 17 Removing rear wall
8 Rotate the power supply module slightly to the right to get

clear of the main board connectors next to it, and then lift
the power supply module clear of the PC (see Figure 18).
Figure 18 Removing power module
9 Use a cutter to remove the strips that keep the cable

bundles together (see Figure 19).
178240/A 29
Figure 19 Removing strips before unplugging the module
10 Unplug the power module from the main board, label it

with the fault symptoms and then put it aside.
Reassemble
11 Check that the new power module is recommended as
spare part for MP530.
12 Reassemble by performing step 1 to 8 in reverse order.
How to replace the CPU

Note An error with the CPU should be handled by Kongsberg
Maritime Service Department.
How to replace the main board

Note An error with the main board should be handled by Kongsberg
Maritime Service Department.
How to replace the built-in speaker

Note An error with the built-in speaker should be handled by
Kongsberg Maritime Service Department.
30 178240/A

recommended spare parts and consumables used in MP530.
Replacement procedures for the listed parts are mainly
described in the Corrective maintenance chapter. No
replacement procedures are normally supplied for the
consumeables.
178240/A 31
Replaceable basic parts and recommended spare

parts
The table shows replaceable basic parts and recommended spare
parts.
LIST PART NAME RECOMMENDED PART NUMBER

IDENT. AS SPARE PART
1 Hard-disk drive X 702810
Seagate Disk Barracuda 7200.7, 286692-001
2 CD-RW drive 702805
Liteon LTR-48246S, 295475-M30
3 Floppy-disk drive, 3.5” 702806
Citizen ZIDE-64A, 176137-232
4 Network interface card (dual port) 702795
Intel pro 1000s Dual Port Server Adapter
5 Memory 702809
HP Memory 256MB DDR 400, cl3, 326667-041
6 Power Supply 115/230 Vac 702808
Compaq PDP124P, 308439-001
7 Mainboard 702807
HP P45I P6B5, 323991-001
8 Graphics card (two screen) 701789
Matrox G55MADDA32B (AGP) (optional)
9 Graphics card (four screen) 701865
Matrox G450 MMS X4 Quad-display (PCI)
(optional)
10 CAN interface 700783
iPC-I320/PCI (optional)
11 Serial interface 701058
Blue Heat/PCI2+2 485 (optional)
12 External USB disk for History Station and DP 701710
Logger
Maxtor Personal Storage 5000 DV (optional)
Table 4 Replaceable parts and recommended spare parts for the computer
Consumables
1 System Backup CD MP530 X 702794
32 178240/A
MP510
Maintenance Manual
This document contains the hardware description and

maintenance information for the MP510.
It covers the following variants (Kongsberg product name and part
number):
MP510 Base Model . . . . . . . . . . . 701707
MP510 w/Blue Heat . . . . . . . . . . 701708
MP510 w/CANbus . . . . . . . . . . . . 701709
MP510 w/Two-screen . . . . . . . . . 701720
Important notice:

sole exclusive property of Kongsberg Maritime AS, and shall
176429 /A 1
Document revisions

A 07.07.03 EIK 03.12.03 EB 03.12.03 EB
B
C
D
E
F
Document history
2 176429/A
Table of contents
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MP510 computer cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cabinet front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cabinet back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cabinet interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MP510 configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Interface cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Miniature speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power ON-OFF button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MP510 external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main-board connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Interface cards and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault location/identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
How to clean the MP510 cabinet surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to replace the air-inlet dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preventive maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to replace the hard-disk drive, CD-RW drive and floppy drive . . . . . . . . . . . 22
How to replace a socket-mounted PCI card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
How to replace an AGP graphics card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
How to replace the power supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
176429 /A 3
This section describes the MP510 hardware configuration.
176429/A 5
Kongsberg MP510
General description
The MP510 maritime computer is used in a wide range of Operator
Stations (OSs) produced by Kongsberg Maritime.
The computer can be installed inside operator station consoles by
using specific mounting brackets (see actual operator station
maintenance manual for details on mounting).
The OS and process station application software is stored on the
MP510 hard disk.
The MP510 is built around a high–performance CPU (central
processing unit) running the MicrosoftÒ Windows XPt
operating system.
The computer can be easily dismantled for replacing module
purposes.
MP510 accepts 115/230 Vac mains input voltage.
Part numbers for the different models are shown on the front page
of this document. The models differ mainly on the combination of
interface cards installed.
MP510 computer cabinet
Cabinet front
CD-RW drive and the floppy-disk drive are located above each
other to the left, and the air intake is located to the right (see
Figure 1). The lower rim of the front contains microphone input,
headphones output, USB ports, ON-OFF switch and LEDs for
power and internal hard-disk drive.
Figure 1 MP510 cabinet front
6 176429/A
Cabinet back
Connectors for power, user interfaces and external equipment are
located on the rear panel (see separate section for connections).
Figure 2 Typical rear panel layout
176429/A 7
Kongsberg MP510
Cabinet interior
Location of the main modules inside the cabinet are shown in
Figure 3. The front is facing to the right.
The interface card assembly moduel is shown in the upper left
corner. It can be pulled out.
The power module with its cooling fan is located in the lower left
corner. The module can be pivoted and supported in a tilted
position.
The drives assambly is seen to the right. It can be pivoted and
supported in a tilted position.
The CPU with a fan and heat-sink block on its top is located in the
upper middel part.
Interface Cards CPU with Cooling Fan

Memory
Hard-disk Drive
CD-RW Drive
Power Supply CD-RW Drive

(CD3002)
Figure 3 MP510 internal layout
8 176429/A
MP510 configuration
The following cards and components are located inside the
cabinet:
· Main board (Motherboard)
· CPU
· RAM, 512 MB
· Power supply 115/230 Vac
· Graphics card (2X or 4X) (optional)
· Network card
· Serial line cards (optional)
· CANbus card (optional)
· Hard-disk drive
· CD-RW drive
· Floppy-disk drive
· Miniature speaker
· Reset button (ON/OFF)
Each of the computer and interface cards, drives and power
supplies listed above are described shortly below. The replaceable
modules are described more detailed in separate documents
(Hardware Module Descriptions).
Figure 4 shows a block diagram of the MP510.
176429/A 9
Kongsberg MP510
The following illustration shows a block diagram of the MP510.
115/230 VAC CD-RW drive

Power fan PC power
supply
Floppy-disk drive
ATX pwr. conn. +12 VDC & +5 VDC
Rear panel Power supply

Mouse
Keyboard
COM1 (serial)
COM2 (serial)
USB1 (serial)
USB2 (serial)
Parallel port
Network A Hard-disk drive
Audio Out
Audio In
Graphics port
Spkr
AGP slot
CPU
Graphics card fan Front panel
(optional) USB3 (serial)
PCI lower slot USB4 (serial)
Network card HDD.LED
(standard)
Pwr.LED
PCI upper slot
ON-OFF
Serial line card switch
(optional)
Mic. In
CANbus card Headphones
(optional) Main board Out
(Vis1132)
Figure 4 MP510 block diagram
Main board
The main board is equipped with a 2.53 GHz CPU and 512 MB
RAM.
The main board is not considered a replaceable module because the
computer has to be rebuilt from scratch and thoroughly tested if the
board is changed.
10 176429/A
Power supply
One power module is available: 115/230 Vac input.
names and and part numbers, and see the corresponding
Hardware Module Description for more technical information.
Interface cards
Standard network card and optional graphics card, serial line line
card and CANbus card are used in the computer.
For details about the interface cards see the appropriate Hardware
Module Descriptions.
names and and part number.
Storage drives
Standard CD-RW drive, hard-disk drive and floppy-disk drive are
used in the computer.
For details about the storage drives see the appropriate Hardware
Module Descriptions.
names and and part numbers.
Miniature speaker
The speaker is located inside the cabinet on the left wall seen from
the front.
Cooling fans
One fan is located behind the front of the cabinet. It provides
cooling to the CPU.
The power-supply module contains a fan located inside the cabinet
and blowing through this module.
Power ON-OFF button

A green ON-OFF button is located in the centre of the lower rim
of the cabinet front.
Pressing the button once, the computer is turned ON or OFF,
depending on the prerequisite.
176429/A 11
Kongsberg MP510
MP510 external connections

The MP510 provides (included options) the necessary set of
standard PC connectors for user interfaces and the necessary set of
application-required connectors for system interfacing.
Power connection
The computer is provided with a standard apparatus socket and fits
a standard female apparatus plug.
Main-board connections
This section lists the connectors available from the main board. For
more details refer to the Hardware Module Description for the
main board.
Microphone Power LED Hard-disk LED
Headphones 2 x USB ports On-off Switch (CD3001)
Figure 5 Front connectors for external connections
Parallel port Net A

USB1
Mouse USB2
Keyboard
Line Line
COM1 Graphics port COM2 out in
(Cd2990)
Figure 6 Rear wall connectors for external connections
Mouse
This is a standard PS/2 mouse connector.
Keyboard
This is a standard PS/2 keyboard connector.
Parallel port
The Parallel port complies with the standard for PC parallel ports.
12 176429/A
With appropriate driver software and configuration a local printer

can be connected to this port.
COM 1 and COM 2

These are standard PC serial line COM ports. COM 1 is not used.
COM 2 is connected to the PNC-100, panel controller module in
the operator panel.
Network
This is a standard network connection based on the RJ45
connector. It is assigned to the A network in the redundant process
network.
Line in
This is a audio line input connection based on the mini jack
connector.
Line out
This is a audio line output connection based on the mini jack
connector.
Microphone
This is a microphone connection based on the mini jack connector
and is located on the front.
Headphones
This is a headphones connection based on the mini jack connector
and is located on the front.
USB
The main board provides four USB (Universal Serial Bus) roots
(ports) for attaching USB devices. Two ports are available on the
front and two on the rear panel.
Interface cards and connections

The illustration below shows the available slots for interface cards
and the standard set of cards.
· Network card (std)
· Graphics card (optional)
· RS232 serial interface card (optional)
· CANbus interface card (optional)
176429/A 13
Kongsberg MP510
Serial line card

connector
Network card
connectors
Two-screen
graphics card
connector
(CD2983)
Figure 7 Typical interface cards and connectors layout
Graphics cards (optional)

The two-screen card is an AGP slot card. The four-screen card is
a PCI slot card. Split cables that come with the graphics cards are
used for connecting the monitors.
Note Read the numbering on the cable connectors for which monitor
they connect.
graphics cards.
Network card (standard)

The network card provides two network ports. The first port (the
one to the left in Figure 7) is normally connected to the B network,
and the second port (to the right), if required by the system, is
connected to the C (administration) network. The connectors are
of the RJ45 type.
network card.
RS232 serial interface (optional)

The card provides four RS232 serial channels by the use of a
special interface split cable. The connector types used on the cable
are four 9-pin male D-sub.
Note Read the numbering on the cable connectors for which is which
serial line.
14 176429/A
For details refer to the Hardware Module Description for the serial
line card.
CAN interface card (optional)

The connector types on the CAN interface card are 9-pin D-sub,
one male and one female.
For details refer to the Hardware Module Description for the CAN
interface card.
176429/A 15
Kongsberg MP510
Voltage 115/230 Vac
Power consumtion from supply 185 W
CONFIGURATION, PERFORMANCE AND CAPACITY
CPU type and speed Intel Pentium 4
2.5 GHz
Hard-disk drive Western Digital
WD400/WD400BB-60DGA0
60 GB
CD-RW drive Hitachi GCE-84181B
Network interface card (dual port) Intel pro 100s
Memory Compaq 512MB 266MHz DDR
CL 2.5
Power Supply 115/230 Vac Compaq PDP11P/ps-7171-1cf1
Graphics card (two screen) Matrox G55MADDA32B (AGP)
(optional)
Graphics card (four screen) Matrox G450 MMS X4
Quad-display (PCI) (optional)
CAN interface iPC-I320/PCI (optional)
Serial interface Blue Heat/PCI2+2 485 (optional)
4 channels
External USB disk for History Station Maxtor Personal Storage 5000
and DP Logger DV (optional)
Size: width x depth x height 333 x 366 x 99 mm
Weight 9.1 kg
IP degree IP-21
Refer to Kongsberg Simrad Environmental Specification, reg. no.: 161011
LIFE CYCLE SPECIFICATION
MTBF calculated 108 206 hours
Table 1 MP510 technical specifications
16 176429/A
Fault Finding
FAULT FINDING
MP510.
176429/A 17
Kongsberg MP510
Fault location/identification
If an error situation has occurred, the fault is normally identified
from the symptoms observed. It is therefore important to record all
these observations to help the maintenance person or service
engineer. All error messages shown on the screen should be logged
for this purpose.
should contact your nearest Kongsberg Maritime service office for
advice or to request service on board.
The fault-finding table below assumes that the problem is caused
by the MP510 computer itself and no external factors are involved.
SOURCE
1 No visible or audible sign of External supply voltage is Check the 115/230 VAC
power present at MP510. Fans turned off or circuitbreaker power supply.
are not blowing. fuse has tripped.
Internal power supply defect Replace power supply
2 Applications are not loading Defective file system. Reinstall the software by
when booting the MP510. Only using the system backup CD.
3 Applications are not loading Defective hard-disk drive. Replace hard disk. See
when booting after the entire procedure in section
operating system software has Corrective maintenance.
been installed on MP510. Only
4 MP510 does not respond over Network task not running. Reboot MP510
network on either channel.
5 MP510 responds over network Defective network card or Replace network card.
on only one of tree channels. network part of main board.
6 MP510 crashes or hangs Possible defective RAM. Replace RAM.
unexpectedly.
Table 2 Fault-finding tips
18 176429/A
This section presents the preventive maintenance procedures
for the MP510.
Replacement procedures relating to preventive maintenance,

are described only in the Corrective maintenance section.
176429/A 19
Kongsberg MP510
How to clean the MP510 cabinet surface

cleaning. Use only a moistened cloth.
Preventive maintenance intervals

Note These procedures should be performed on each MP510 in the
system. Local evaluations should be made to determine
site-specific maintenance intervals.
ACTION INTERVAL RECOMMENDED

Clean cabinet surface Each month
Check for loose connectors and Each six month
wires
Table 3 Recommended preventive maintenance intervals
20 176429/A
This section presents the corrective maintenance procedures
for the MP510.

above should be performed by Kongsberg service personnel
only.
176429/A 21
Kongsberg MP510
Replacement procedures
Caution Electrostatic charges can damage components on the cards.
Notice the following precautions: Always wear a properly
connected earthing strap when handling unpacked cards. Place
unpacked cards only on a properly connected earthing mat or a
shielding bag. Keep cards in their shielding bags when not
installed. Never store cards near electromagnetic or electrostatic
devices.
Note Replacement procedures that require power to be turned off must

be preceded by shutting down the MP510 in a controlled manner.
Refer to the system operator manual for the appropriate
procedure.
WARNING To avoid the risks accompanying high voltages,

always turn off the power circuit supplying the
computer before you open the cabinet lid.
How to replace the hard-disk drive,

CD-RW drive and floppy drive
Disassemble
3 Standing in front of the computer press the two cabinet lid
locks (one at each side) inwards to release the lid and pull the
lid towards you (left lock shown below).
Figure 8 Left lock of cabinet lid shown
4 Pivot the drives assembly upwards by pulling at the

green/white arrow-labled handle.
22 176429/A
Figure 9 Drives assembly in opened position
5 Disconnect the flat cable and power connector from the

drive.
6 Release the drive from the assembly by pressing the
appropriate lock outwards and pull the drive out (see
example picture below).
Figure 10 Example shows releasing the hard-disk drive
7 Mark the old drive with a label and put it aside.
176429/A 23
Kongsberg MP510
Reassemble
8 Check that the new drive type is a recommended spare part
for MP510.
9 Set any mode jumpers of the new drive to the same positions
as for the replaced drive.
11 Verify proper operation. If the drive is a hard-disk drive the
disk must be resloaded with backup data (see this separate
procedure).
How to replace a socket-mounted PCI

card
Disassemble
lid towards you (Figure 8).
4 Pull the PCI card assembly upwards.
5 Remove the PCI card by first removing the screw and then
pulling the card from the socket card.
symptoms observed.
Reassemble
MP510.
10 If the card is a network card, perform the Checking Network
Cards procedure, else verify proper operation of MP510..
How to replace an AGP graphics card

Disassemble
24 176429/A
4 Pull the PCI card assembly upwards.

5 Remove the screw that attaching the card to the frame.
6 Remove the AGP card from the main board socket by pulling
it upwards.
symptoms observed.
Reassemble
MP510.
11 Verify that the new card works properly.
How to replace the power supply module
Disassemble
4 Pivot the power module upwards.
5 Disconnect all cables from the module.
6 Remove the two screws attaching the module to the chassis.
7 Put the power supply module aside and mark it with a label
describing the symptoms observed.
Reassemble
8 Check that the new power supply module is recommended
as spare part for MP510.
9 Reassemble by performing step 1 to 6 in reverse.
176429/A 25

This section contains lists of replaceable parts, recommended
spare parts and consumables used in MP510. Replacement
procedures for the listed parts are mainly described in the
Corrective maintenance chapter. No replacement procedures
are normally supplied for the consumeables.
176429/A 27
Kongsberg MP510
Replaceable basic parts and recommended spare

parts
The table shows replaceable basic parts and recommended spare
parts.

1 Hard-disk drive X 701787
Western Digital WD400/WD400BB-60DGA0
2 CD-RW drive 701783
Hitachi GCE-84181B
3 Floppy-disk drive, 3.5” 701784
Citizen ZIDE-58A
4 Network interface card (dual port) 701788
Intel pro 100s
5 Memory 701786
Compaq 512MB 266MHz DDR CL 2.5
6 Power Supply 115/230 Vac 701785
Compaq PDP11P/ps-7171-1cf1
7 Graphics card (two screen) 701789
Matrox G55MADDA32B (AGP) (optional)
8 Graphics card (four screen) 701865
Matrox G450 MMS X4 Quad-display (PCI)
(optional)
9 CAN interface 700783
iPC-I320/PCI (optional)
10 Serial interface 701058
Blue Heat/PCI2+2 485 (optional)
11 External USB disk for History Station and DP 701710
Logger
Maxtor Personal Storage 5000 DV (optional)
Table 4 Replaceable parts and recommended spare parts for the computer
Consumables
1 System Backup CD MP510 X 701872
28 176429/A
COS computer hard disk store/restore procedure
COS computer hard disk

store/restore procedure
This procedure is created to help you in solving any
hard disk problem that might show up with COS 100
and COS 200 computers.
171872/A 1
Kongsberg Simrad COS computer
Document revisions
Rev Date Written by Checked by Approved by
A 07.06.01 SAA/EIK SAA/EB EB
B
C
D
2 171872/A
Contents
1 INTRODUCTION ............................................................................................................. 5
1.1 General ............................................................................................................................. 5
1.2 Actions to be taken ......................................................................................................... 5
1.3 COS 100/COS 200 System Backup diskette................................................................ 5
2 PROCEDURES ................................................................................................................... 6
2.1 Main Menu ...................................................................................................................... 6
2.2 How to store the COS hard disk content to the CD-R? ............................................. 6
2.3 How to restore the COS hard disk content from the CD-R? .................................... 7
171872/A 3
Document history
Rev. A This is the first issue.
4 171872/A
1 INTRODUCTION
1.1 General
If the COS computer hard disk needs to have its software
restored or the disk needs to be replaced, you will in both cases
need a backup of its software as it was after last time it was
updated.
Together with this procedure you should have a CD-RW drive
installed on the COS computer and a dedicated floppy disk,
which holds the needed software.
1.2 Actions to be taken

The first you need to do is to create a backup of your COS
computer. hard disk on a CD-R disk. Use the CD store
procedure for this task.
If a disk error situation comes up, you should use the hard disk
restore procedure.
1.3 COS 100/COS 200 System Backup diskette

The COS 100/COS 200 System Backup diskette contains the
necessary programs and menus to run the procedures.
171872/A 5
2 PROCEDURES
2.1 Main Menu

You use selection 1 (Total System Backup) on the MAIN
MENU (see below) to make a complete backup of the hard disk
to the CD-R. You use menu selection 2 (Total System Restore) to
restore the information from the CD-R to the hard disk of COS.
MAIN MENU
1 Total System Backup

2 Total System Restore
To start select number and ENTER.
NOTE:
If this text reappear after the intended operation
is completed, then you have not removed the diskette!
Please remove the diskette and reboot.
2.2 How to store the COS hard disk content to the CD-
R?
The following procedure shows how to take a complete system
backup of a COS computer.
1. Insert a blank CD-R disk in the COS computer.
2. Insert the COS 100/COS 200 System Backup diskette.
3. Reboot the COS computer.
The MAIN MENU is shown.
4. Select 1 Total System Backup from the MAIN MENU
and press Enter.
5. Wait until the completed message appears on the screen
before you take out the CD-R disk.
6 171872/A
6. Label the CD-R disk with the name of the operator

station, COS serial number and date of the backup before
you store the backup CD in a safe place.
2.3 How to restore the COS hard disk content from the
CD-R?
The following procedure shows how to restore a complete
system backup of a COS computer.
1. Insert the backup CD-R into the CD drive.
2. Insert the dedicated floppy disk.
The MAIN MENU is shown.
4. Select 2 Total System Restore from the MAIN MENU on
the screen and press Enter.
The COS computer will now reformat the hard disk and
install all files from the CD-R.
5. Wait until the completed message appears on the screen
before you take out the CD-R disk.
The COS computer will now automatically start the Windows
NT and then the SXX application programs as appropriate. The
upgrade is now completed.
171872/A 7
RCU 510 SIGNAL RS 232 T BSS 1 T BSS 2 SIGNAL
1 T BSS_C T BSS_C 1 WD1
36 GND GND 5 0V
16 GND GND 6 0V
17 TX_TXN1 Tx1 7 TxA
18 RX_RXN1 Rx1 8 RxA
34 RT S_TXP1 RT S1 9 RT SA
35 CT S_RXP1 CT S1 10 CT SA
32 TX_TXN2 Tx2 13 TxB
33 RX_RXN2 Rx2 14 RxB
14 RT S_TXP2 RT S2 15 RT SB
15 CT S_RXP2 CT S2 16 CT SB
12 TX_TXN3 Tx3 19 TxC
13 RX_RXN3 Rx3 20 RxC
29 RT S_TXP3 RT S3 21 RT SC
30 CT S_RXP3 CT S3 22 CT SC
31 GND GND 23 0V
11 GND GND 24 0V
27 TX_TXN4 Tx4 25 TxD
28 RX_RXN4 Rx4 26 RxD
9 RT S_TXP4 RT S4 27 RT SD
10 CT S_RXP4 CT S4 28 CT SD
1 T BSS_C T BSS_C 1 WD1
26 GND GND 6 0V
7 TX_TXN5 Tx5 13 TxB
8 RX_RXN5 Rx5 14 RxB
24 RT S_TXP5 RT S5 15 RT SB
25 CT S_RXP5 CT S5 16 CT SB
22 TX_TXN6 Tx6 19 TxC
23 RX_RXN6 Rx6 20 RxC
4 RT S_TXP6 RT S6 21 RT SC
5 CT S_RXP6 CT S6 22 CT SC
6 Ser6_GND Isolatded GND6 23 0V
21 Ser7_GND Isolatded GND7 24 0V
2 TX_TXN7 Tx7 25 TxD
3 RX_RXN7 Rx7 26 RxD
19 RT S_TXP7 RT S7 27 RT SD
20 CT S_RXP7 CT S7 28 CT SD
Hardware Module Description
cJoy Operator Terminal

Kongsberg Maritime Part no. 603201
This document contains the Hardware Module Description
of the cJoy Operator Terminal.
Important notice:
178004 /C 1
Document revisions

A 11.06.04 EIK 02.08.04 JE 21.10.04 JM
B 04.02.05 PLB 17.02.05 EIK 17.02.05 JKM
C 28.02.05 CBM 16.03.05 EIK 16.03.05 JKM
D
E
F
Document history
Rev. B Part number corrected.
Rev. C Corrections made to Technical Specifications.
2 178004/C
Glossary
CAN Controller Area Network

DI Digital Input
DIP Dual In-line Package
DO Digital Output
DPC Dynamic Positioning Controller
ESD Electrostatic Discharge
GND Ground
IE Instrumentation Earth
IO Input/Output
KM Kongsberg Maritime
LAN Local Area Network
LED Light Emitting Diode
OS Operator Station
OT Operator Terminal
PE Protective Earth
USB Universal Serial Bus
VGA Video Graphics Array
178004 /C 3
Table of contents
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ethernet network interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Panel layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P2 and P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MAINTAINABLITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cleaning equipment housing and panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
178004 /C 5
OVERVIEW
The cJoy Operator Terminal serves as the main operator
interface for the cJoy Compact Joystick system.
The terminal can also be used as an additional joystick terminal
for the cPos and SDP range of DP systems.
The following list shows the main features of the operator
terminal.
· 3-axis joystick
· Joystick calibration function
· Heading wheel
· 6.5” high-resolution colour display
· Display page manoeuvring buttons
· Mode and function buttons with indicator lights
· Alarm indicator/buzzer with silence button
· Power indicator with power failure alarm.
· Panel and display illumination adjustment
· Panel test function.
· Detection of panel location and orientation from junction box
178004 /C 7
FUNCTION
Indicators Buzzer Buttons 3-axis Heading

Joystick Wheel
Flash
Disk
Serial line
µPC µC
Net B
Net A
AC/DC
Extra VGA
Keyboard
Display
120 ohm fixed

Mouse
Converter
USB
CANbus
Orientation termination
CAN Bus
Lid for Access to

Net B
Net A
24 VDC
PC Connectors
&ID
(CD3052)
Figure 1 cJoy Operator Terminal block diagram

The cJoy Operator Terminal (OT) is an operator interface with
display, buttons and indicators, joystick and heading wheel for
the cJoy Compact Joystick system.
The operator terminal is built from a PC104+ embedded mPC
running MicrosoftR WindowsR XP embedded operating
system. The mPC comprises one display and one flash disc. It
communicates with the system it belongs to through a single or
dual LAN.
The mPC communicates with a mController (mC) via a serial line
(see Figure 1). The mC interfaces different user interfaces such
as buttons, rotation knob, dimmer functions, buzzer, indicators
and a joystick located on the local panel. Further, the mC
interfaces a Kongsberg Maritime-closed standard CAN bus,
which is a multi-drop serial bus that allow communication with
several external terminals such as the Wing Terminal.
Connections
One main connector comprises the 24 Vdc supply wires, the
orientation and ID DIP-switch wires and the CAN bus wires.
Two LAN connectors (Net A and Net B) are available on the
operator terminal casing. The operator terminal is connected to
the junction box via these connectors.
8 178004/C
CAN bus
The CAN bus is connected via two pins on the main connector,
which is located on the operator terminal.
The CAN bus has a fixed 120 ohm termination resistor within
the operator terminal.
Ethernet network interface

The two network ports (Net A and Net B) are used by the mPC
(see Figure 1) to provide communication with the rest of the
system (to OSs and DPC).
Power
Power supply for the operator terminal is 24 Vdc and is supplied
via the main connector that is used for connection to the
junction box.
A DC/DC converter located within the terminal cabinet provides
the voltages used by the different terminal components.
User interface
The user interface comprises a display, a 3-axis joystick,
rotation knob, buzzer, buttons and LEDs (see Figure 2).
power
operation
reset Heading Wheel Color Monitor 3-axis Joystick
Gen. Stand Full

Test Dim setup Views by Take Give
thrust
power
operation
Sensor
enable
System cJoy
Thr. Day/ Station Auto Fore

Enter Joystick
enable night keeping pilot pivot
Auto Auto Auto Centre

Cancel Limits Alarms surge sway pivot
head.
Set Steer Pres Aft

heading + setup
Silence/
ack
Pres
head. pos. Spare
pivot
(CD3061A)
Figure 2 Panel layout
See the operator manual for the operator terminal for details on
the user interface.
178004 /C 9
Status LEDs
The power and operation LEDs at the left, far corner (see
Figure 2 for location) have the functions as listed in the table
below.
LED LED state LED state description
Power Green light Light indicates that the wing terminal is connected to a junction
box and its 24 VDC power supply is switched on.
Operation Steady green light The electronics inside the wing terminal are functioning cor-
rectly and communication with the system is established.
Flashing green light A local test or set-up function is active, i.e. panel test, panel
dimming or joystick calibration.
Flashing red light An internal error has been detected or the terminal has lost
communication with the system.
Table 1 Status LEDs description
Reset button
The reset button (located under the hole next to the operation
LED) allows you to reset the panel mController. You may use a
paper clip or equivalent tool to operate the button.
10 178004/C
TECHNICAL SPECIFICATIONS
Power specifications
Input voltage range 24 Vdc +/- 25%
Batteries None
Connections
Interface Power, CAN bus and hex switch
interface integrated in one con-
nector
2 x RJ-45 connectors for Net A
and B
Mechanical specification
Size (Width x Height x Depth ) 583 x 260 x 180 mm
Weight 6 kg
IP rating IP44
Lifting By Hand
Environmental requirements
Enclosure protection Shielded Cabinet
Noise level < 40 dB
Operating temperature -15 - +55 °C
Storage temperature -20 - +60 °C
Operating ambient humidity 40 to 90% RH (non-condensing)
Storage ambient humidity up to 95% RH (non-condensing)
848-161011
Table 2 Technical specifications
178004 /C 11
CONFIGURATION
There are no configurable parts within the cJoy Operator
Terminal.
Panel layout
The illustration below shows the handles, lamps, buttons and
display of the operator-terminal panel.
Heading Wheel Color Monitor 3-axis Joystick
Gen. Stand Full

Test Dim setup Views by Take Give
thrust
power
operation
Sensor
enable
System cJoy
Thr. Day/ Station Auto Fore

Enter Joystick
enable night keeping pilot pivot
Auto Auto Auto Centre

Cancel Limits Alarms surge sway pivot
head.
Set Steer Pres Pres Aft

heading + setup
Silence/
ack head. pos. Spare
pivot
(CD3062A)
Figure 3 Layout operator panel
Connectors
The illustration below shows the connector locations on the rear
of the operator terminal housing.
Data network connectors Main connector Handle
P2 P3
8 1 8 1
P1
(CD3063)
Figure 4 Connector locations
12 178004/C
P1
This is a male Phoenix multi-pin connector for connection with
a pre-manufactured cable to the corresponding junction box.
Power, CAN bus and Orientation/ID DIP-switch wires are
available on this connector.
P2 and P3
Two female RJ45 type 8-pin socket for 10Base-T/100Base-TX
are provided for P2 and P3.
(Vis1149)
Figure 5 Front view of P2 and P3 with pin layout
Pin P2 (Net A) P3 (Net B) Function
1 NETA_TX NETB_TX Forward transmit line for net channel x
2 ~NETA_TX ~NETB_TX Return transmit line for net channel x.
3 NETA_RX NETB_RX Forward receive line for net channel x.
4 NC NC Not connected
6 ~NETA_RX ~NETB_RX Return receive line for net channel x.
9 (1) 10nF to GND 10nF to GND Shield, isolated 500V
(1) Pin 9 and 10 are connected to the connector housing.
Table 3 P2 and P3 pin allocation
178004 /C 13
MAINTAINABLITY
Note There are no user servicable parts inside this equipment. It shall
only be opened and disassembled for service purposes by
Kongsberg Maritime authorised persons.
Cleaning equipment housing and panel

14 178004/C
INSTALLATION
Mechanical installation
A separate installation manual named Installation Manual cJoy
Operator Terminal is a guide for mechanical installation of this
product. The manual can be obtained from Kongsberg Maritime
on request.
Electrical installation
To install this equipment electrically you should follow the
procedure shown below.
Prerequisites are that power must be turned off to the cJoy
Operator Terminal Junction Box and that the junction box is
configured as required.
1 Connect the fixed cable from the cJoy Operator Terminal
Junction Box to connector P1 on the operator terminal.
2 Connect the network cables (one or two, as required)
between the junction box and connectors P2 and P3 on the
operator terminal.
3 Place the operator terminal in the console bracket.
4 Fasten the six bolt nuts attaching the operator terminal to
the console bracket.
5 Turn on the power to the junction box and wait
approximately 2 minutes to allow the operating system to
be up and running.
6 Check that the operation LEDs show OK status.
7 Verify that the application is working OK from this
operator terminal.
178004 /C 15
REPLACEMENT
To replace this equipment you should follow the procedure
shown below.
Prerequisites are that power must be turned off to the cJoy
Operator Terminal Junction Box and that the junction box is
configured as required.
1 Remove the six bolt nuts attaching the operator terminal to
the panel bracket.
2 Remove the operator terminal from the console bracket.
3 Disconnect the two network cables connected to P2 and
P3.
4 Disconnect the main cable to P1.
5 Remove the old operator terminal and mark it with a label
telling the fault sympthoms registered.
6 Connect the main cable from the cJoy Operator Junction
Box to connector P1 on the new operator terminal.
7 Connect the network cables (one or two, as required)
between the junction box and connectors P2 and P3 on the
new operator terminal.
8 Place the new operator terminal in the panel bracket.
9 Fasten the six bolt nuts attaching the operator terminal to
the console bracket.
10 Turn on the power to the junction box and wait
approximately 2 minutes to allow the operating system to
be up and running.
11 Check that the operation LEDs show OK status.
12 Verify that the application is working OK from this
operator terminal.
16 178004/C
cJoy Wing Terminal (cWing)

of the cJoy Wing Terminal.
Important notice:
178006 /C 1
cJoy Wing Terminal
Document revisions

A 11.06.04 EIK 05.11.04 JE 05.11.04 JM
B 04.02.05 PLB 17.02.05 EIK 17.02.05 JKM
C 04.03.05 CBM 16.03.05 EIK 16.03.05 JKM
D
E
F
Document history
Rev. C Technical Specification updated.
2 178006/C
Glossary

GND Ground
IO Input/Output
PE Protective Earth
178006 /C 3
Table of contents
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MAINTAINABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
178006 /C 5
OVERVIEW
The cJoy Wing Terminal is a remote operator terminal for cJoy
and cPos systems.
The terminal is designed for installation in outdoor
environment.
The following list shows the main features of the wing terminal.
· 3-axis joystick
· Monochrome display with buttons
· Power indicator with power failure alarm
· Panel and display illumination adjustment possibility
· Panel test function
· Panel ID and orientation code defined by the junction box
· High resistance against intrusion of water (IP56)
· One-cable connection with watertight connector
· Easy bracket mounting
178006 /C 7
cJoy Wing Terminal
FUNCTION
Display Indicators Buzzer Buttons 3-axis

Joystick
µC
DC/DC
Converter
CAN bus
Orientation
24 VDC
&ID
(CD3059)
Figure 1 cJoy Wing Terminal block diagram
The cJoy Wing Terminal is an operator terminal that provides

the operator with the necessary facilities to control a vessel in
joystick and auto heading mode.
The terminal can be located both indoor and outdoor, and it may
be bulkhead mounted or insert into a suitable surface. A
mounting bracket for the terminal is available.
The terminal can be disconnected from the present connected
junction box and moved to another junction box and
reconnected there without any system interruption.
The terminal is controlled by a mController (mC) that
communicates with the system via a CAN bus (see Figure 1).
Connections
Only one cable is needed for connecting the cJoy Wing
Terminal to its junction box. The interface cable contains power
lines, CAN bus and rotary switch signal wires.
The panel ID code and orientation code are set at the
corresponding junction box by the rotary hex switches.
CAN bus
8 178006/C
Power
junction box.
User interface
The user interface comprises a display, a 3-axis joystick, buttons
and LEDs (see Figure 2).
power
operation
reset
power
operation Full
Silence Dim Test Take
thrust
Stand
by
Fore
Joystick
pivot
Auto Centre
head. pivot
Set
+ Present
head.
Aft
pivot
cWing
(CD3060)
See the operator manual for the wing terminal for details on the
user interface.
178006 /C 9
cJoy Wing Terminal
Status LEDs
Figure 2 for the location) have the functions as listed in the table
below.
LED Mode Description
Table 1 Status LEDs’ mode description
Reset button
The reset button (located under the hole found next to the
operation LED) allows you to reset the panel micro controller.
You may use a paper clip or equivalent tool to operate the
button.
10 178006/C
Input voltage 24 VDC +10% / -15%
Typical Power consumption 20 W
Maximum Power consumption 25 W
Batteries None
Connections
nector
Weight 3 kg
IP degree IP 56
Lifting By Hand
Noise Level < 40 dB
Operating ambient temperature -25 - +70 °C
Operating ambient humidity up to 90%RH (non-condensing)
Storage humidity up to 95%RH (non-condensing)
848-161011
178006 /C 11
cJoy Wing Terminal
CONFIGURATION
There are no configurable parts within the cJoy Wing Terminal.
MAINTAINABILITY
Note There are no user serviceable parts inside this equipment. It
shall be opened and disassembled for service purposes by
Kongsberg Maritime authorised persons only.

12 178006/C
INSTALLATION
Wing Terminal is a guide for mechanical installation of this
on request.
Prerequisites are that power must be on and that the operator
station or cJoy operator terminal this terminal is connected to is
up and running.
1 Connect the cable from the cJoy Wing Junction Box to the
cJoy Wing Terminal.
2 Fix the wing terminal to its bracket by tighten the two
fixing wheels, one at each end.
3 Wait approximately 10 seconds to the terminal software is
up and running.
4 Check that this wing terminal status LEDs show OK
status.
5 Verify that the application is working OK from this wing
terminal.
178006 /C 13
cJoy Wing Terminal
REPLACEMENT
No special precaution is needed to be taken when replacing this
product.
up and running.
1 Loosen the two fixing wheels, one at each end and remove
the wing terminal.
2 Disconnect the cable from the cJoy Wing Junction Box to
the cJoy Wing Terminal and put the wing terminal aside.
new cJoy Wing Terminal.
up and running.
status.
terminal.
14 178006/C
cJoy OT Junction Box


of the cJoy OT Junction Box.
Important notice:

178005 /B 1
Document revisions

A 11.06.04 EIK 21.10.04 JE 27.10.04 JM
B 04.02.05 PLB 17.02.05 EIK 17.02.05 JKM
C
D
E
F
Document history
2 178005/B
Glossary

DI Digital Input
DO Digital Output
GND Ground
ID Identification
IO Input/Output
OT Operator Terminal
PE Protective Earth
178005 /B 3
Table of contents
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CAN bus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LAN connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Example of LAN cabling in cJoy system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Panel-ID code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Panel-orientation code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connectors and component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Valid for serial number range 1 to 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Valid for serial number range 31 and above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DL1 and DL2 - LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
U3 and U4 - Rotate switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
U3 - Panel-ID code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
U4 - Panel-orientation code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P1 to P7 - Operator terminal cable connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
P8 and P18 - Strap fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
P8 - Programming/normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
P18 - CAN bus termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
P15 to P17 and P20 to P22 - LAN connectors and terminals . . . . . . . . . . . . . . . 15
P32 - CAN bus connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
P33 - Power connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
P34 - For future use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
P36, P37 and P20 to P22 - LAN terminal blocks . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
178005 /B 5
OVERVIEW
The cJoy OT Junction Box provides the cJoy Operator Terminal
with distributed 24 Vdc, CAN bus interface for linking one or
several wing terminals and connections for LAN A, LAN B and
a Service LAN.
The junction box has one fixed cable with a dedicated connector
at the far end for connection to the cJoy operator terminal.
The junction box is provided with the functions listed below.
· Field terminals for LAN A, LAN B and Service LAN
· RJ-45 connectors for LAN A, LAN B and Service LAN
· Connector for 24 Vdc from external power supply
· Green status LEDs indicating 24 Vdc and 5 Vdc present
· CAN bus connector for field cable
· A strap field for selecting termination of the CAN bus
· Hex switch for operator terminal panel-ID code
· Hex switch for operator terminal panel orientation code
· Connector for operator terminal programming device
· A strap field for setting the operating terminal in
programming mode
178005 /B 7
FUNCTION
The illustration (Figure 1) shows a block diagram of the cJoy
OT Junction Box.
Power 24 VDC
input P33
5 VDC
DL2 GND
DL1
Part of layout 3
for Panel-ID
serial number P1
switch .
range 1 to 30 .
Operator
only 2 terminal
P18 P7
Panel- connection
CAN bus
orientation
terimination
switch
CAN bus
CAN bus
field cable P32
2
5 VDC
Programming Programming/
P8 Normal
equipment
connector
(9-pin D-sub) J1
Field cable 1 8 4 Service

LAN P36 LAN
RJ-45
4
LAN A
RJ-45
Field cable 2 P37 4 LAN B

LAN RJ-45
(Cd3067)
Figure 1 cJoy OT Junction Box block diagram

Two layout versions are valid. See Configuration section for
details.
Power
The junction box is supplied with 24 Vdc from outside, and a
LED (DL2) indicates the presence of this voltage.
A 5 Vdc is generated within the connected panel and is
distributed via the junction box. The 5 Vdc LED (DL1)
indicates both that the connection to the panel is present and the
existence of the +5 Vdc.
CAN bus connection

The CAN bus is used for communicating between the operator
terminal and wing terminals attached to this bus.
8 178005/B
A strap field P18 is provided for termination of the CAN bus in

this junction box. The termination is set active only if this
junction box is the last one on the CAN bus.
LAN connection
The junction box provides field terminals for LAN field cables
and has three RJ-45 connectors for local LAN patch cables. The
illustration (Figure 2) shows how the LAN wiring is
implemented within the junction box. The wiring follows IEC
colour standard with one exception, see Note below. RJ-45
connection is according to T-568 B standard.
Orange
Orange
Brown
Brown
Green
Green
Blue
Blue
pair
pair
pair
pair
pair
pair
pair
pair
LAN B IN LAN A IN
P37 1 1 P36
Signal pair
Connectors
valid for
serial number
range 1 to 30
only
P21 P20 P22

1 1 1
1 8 1 8 1 8
LAN B LAN A SERVICE LAN

(CD3068A)
Figure 2 LAN wiring within the junction box
Example of LAN cabling in cJoy system

Note Connection of Service LAN to field terminal block P36 does not
follow the standard T-568 B. The wiring is implemented in this
way to save one LAN field cable between the junction box and
the DP controller. See illustration in Figure 3.
178005 /B 9
The illustration in Figure 3 can be placed above illustration in

Figure 2 and thus they show the complete wiring from the RJ-45
connectors on the patch box in DPC to the RJ-45 connectors on
this junction box.
LAN B SERVICE LAN LAN A
8 1 8 1 8 1
Identical number series

but different sequences
Orange
Orange
Orange
Brown
Brown
Brown
Green
Green
Green
Blue
Blue
Blue
pair
pair
pair
pair
pair
pair
pair
pair
pair
pair
pair
pair
8 7 6 3 2 1 4 5 8 7 6 3 2 1 4 5 8 7 6 3 2 1 4 5
Blue
twisted
pair
Twisted Brown Twisted

pairs twisted pairs
pair
Cable LAN B Cable LAN A

Service LAN
(CD3069A)
Figure 3 LAN cable termination in the DPC patch box
Panel-ID code
A rotation hex switch (U3) is provided to set an ID for the
attached panel (cJoy OT). This is used for identifying each
operator terminal connected to the CAN bus. The rotation
switch has 16 positions of which six (1-6) values are valid by
the system.
Panel-orientation code
A rotation hex switch (U4) is provided to set the orientation
code for the attached panel (cJoy OT). The rotation switch has
16 positions of which four (0-3) values are accepted by the
panel to set the Fore, Stbd, Aft or Port orientation.
10 178005/B
Input voltage range 24 Vdc, +10% to -10%
Batteries None
Weight with cable 2.4 kg
IP degree IP22
Lifting By Hand
Noise level < 40 dB
Operating temperature -15 - +55°C
Storage temperature -15 - +55°C
Operating humidity up to 90% RH (non-condensing)
Storage humidity non-condensing
848-161011
178005 /B 11
CONFIGURATION
Connectors and component locations
Valid for serial number range 1 to 30
P33 P34 P32 LAN B IN LAN A IN

1 1
16
P37 P36
CANH
P7
24 V
CANL
0V 1
P18
P6 DL1 1
P8
P5 11 DL2
U3 U4
J1
P4
P3 6 1 1 1
P2 P21 P20 P22
P1
1 RJ45 RJ45 RJ45
Cable SERVICE LAN

(CD3066) LAN B OUT LAN A OUT
Figure 4 Connectors and component locations
Valid for serial number range 31 and

above
P32 P34 P33
1 BIT1
P1
CANH
CANL
BIT2
24 V
0V
BIT3
P2 BIT4
BIT5
LAN B IN LAN A IN
P3 CANL 1 1
TO PANEL
CANH
TO PANEL P37 P36
P4 J1
DL1
0 V TO U3 U4 1
P5 PANEL
24 V TO
1-2 PROGR.
2-3 NORMAL
PANEL
5 V FROM
P6 PANEL
DL2 P8
RX232
P7 TX232
16 PROG P16 P15 P17
RJ45 RJ45 RJ45
(Cd3066A)
LAN B OUT LAN A OUT SERVICE LAN
12 178005/B
DL1 and DL2 - LEDs

Two green LEDs DL1 and DL2 are provided for indicating
POWER ON.
· DL2 indicates (when lit) that 24 Vdc is present.
· DL1 indicates (when lit) that 5 Vdc is present from the panel.
Whenever the cable between the panel and the junction box
is connected this LED should be lit. In case the DL2 is lit but
not DL1, then either the cable is not connected appropriately
or the panel is by some reason not turned on.
U3 and U4 - Rotate switches

Two hexadecimal rotate switches U3 and U4 are provided.
U3 - Panel-ID code
This switch provides the Panel-ID code for the operator terminal
connected.
Switch position 0&8 1&9 2&A 3&B 4&C 5&D 6&E 7&F
Panel-ID code 0 1 2 3 4 5 6 7
Table 2 Switch position versus Panel-ID code
U4 - Panel-orientation code
This switch provides the Panel-orientation code.
Switch position Orientation Orientation code

0, 4, 8, C Fore 0
1, 5, 9, D Stdb 1
2, 6, A, E Aft 2
3, 7, B, F Port 3
Table 3 Switch position versus panel orientation and Panel
orientation code
178005 /B 13
P1 to P7 - Operator terminal cable connector

P1 to P7 comprise the cable connector for the operator terminal.
Pin Terminal name Function
1 P1:1 Bit 1 ID code
4 P2:1 Bit 4 Orientation code
6 P3:1 CAN L to panel (future use)
7 P3:2 CAN H to panel (future use)
8 P4:1 CAN L from panel
9 P4:2 CAN H from panel
10 P4:3 0 V to panel
13 P6:1 -
14 P6:2 RX232 from the programming device
15 P7:1 TX232 to the programming device
16 P7:2 Programming mode signal
Figure 6 P1-P7 terminal allocation
P8 and P18 - Strap fields

Two 3-pin strapfields P8 and P18 are provided.
P8 - Programming/normal mode
This strap filed has two setting options.
· Strap in position 1-2: Programming of micro controller is
allowed. If the strap is set to this position, all LEDs on the
panel may be lit.
· Strap in position 2-3: Normal operation takes place.
P18 - CAN bus termination

Note This strap field is valid only for serial numbers 1 to 30.
This strap field has two setting options.
· Strap in position 1-2: Termination resistor is disconnected.
This position is to be used if CAN out signals on connector
P32 are wired. This will be the case when more than one
junction box are connected in the same branch of CAN
connections.
14 178005/B
· Strap in position 2-3: Termination resistor is connected.

This is to be used if CAN out signals on connector P32 are
not wired.
P15 to P17 and P20 to P22 - LAN connectors and

terminals
Note P15 to P17 are valid for serial numbers 31 and above. P20 to
P22 are valid only for serial numbers 1 to 30.
Three female RJ45 type 8-pin socket for 10Base-T/100Base-TX
are used for the P15 to P17connectors. Where the P20 to P22
connectors are used, three RJ45 connectors are wired via P20 to
P22 (see Figure 4). These connectors allow LAN patch cables to
be connected between the junction box and the operator terminal
and allow a service terminal to be connected to the system.
(Vis1149)
Figure 7 Front view of RJ45 with pin layout
Pin P2 (Net A) P3 (Net B) Function
1 NETA_TX NETB_TX Forward transmit line for net channel x
2 ~NETA_TX ~NETB_TX Return transmit line for net channel x.
3 NETA_RX NETB_RX Forward receive line for net channel x.

6 ~NETA_RX ~NETB_RX Return receive line for net channel x.
(1) Pin 9 and 10 are connected to the connector housing.
Table 4 RJ45 pin allocation
178005 /B 15
P32 - CAN bus connector

Terminal sequence differs between layout in Figure 4 and 5. See
actual serial number for correct terminal allocation.
If the system contains cWing terminals, the CAN field cable to
the cWing OT junction boxes is terminated on this connector.
P33 - Power connector

Terminal sequence differs between layout in Figure 4 and 5.
See actual serial number for correct terminal allocation.
Power (24 Vdc) to this junction box is terminated on this
connector.
P34 - For future use

The two terminals are intended for future use.
P36, P37 and P20 to P22 - LAN terminal blocks

The LAN terminal blocks have colour codes according to IEC
standard T-568 B.
Pin Terminal colour

1 Brown
2 White&brown
3 Green
4 White&green
5 Orange
6 White&orange
7 Blue
8 White&blue
Table 5 LAN terminal block colour codes
Note P20, P21, P22 are terminal blocks valid for serial numbers 1 to
30 layout only.
16 178005/B
INSTALLATION
Operator Terminal Junction Box is a guide for mechanical
installation of this product. The manual can be obtained from
Kongsberg Maritime on request.
A prerequisite is that power on the power lines is turned off.
1 Remove the lid of the junction box by removing the 6
bolts fixing it to the box.
2 Connect the LAN wires to the terminal blocks P36 and
P37 as appropriate. Two field cables are needed for
maximum configuration (dual process LAN and the
service LAN).
3 Connect CAN field cable to P32 (two wires). See text on
circuitboard for correct polarity.
4 Connect power cable to P33 (two wires). See text on
5 Verify the strap in strap field P8 is sett between pin 2 and
3.
6 If junction box serial number is in the range 1 to 30, verify
the strap in strap field P18 is set correctly.
7 Set rotary switch U3 to the value given by the vessel
software specification for the cJoy OT.
8 Set rotary switch U4 to match the orientation of the
operator panel.
9 Before connecting the operator terminal to the cable from
this junction box, turn on the power supply and verify the
DL2 LED is lit. If lit, 24 V is supplied to the junction box.
10 Turn off the power.
11 Connect the junction box cable to the operator terminal
(cJoy OT).
12 Verify that all cables are connected correctly at both ends.
13 Turn on the power to the junction box and the controller
cabinet.
178005 /B 17
14 Wait for the operator terminal to finish running up.

15 Verify proper operation from the operator terminal.
18 178005/B
REPLACEMENT
shown below.
A prerequisite is that the cJoy system is turned off.
1 Switch off the power to the junction box.
2 Remove cable connection to the operator terminal.
3 Remove the lid of the junction box by removing the 6
4 Disconnect the power cable to P33 (two wires).
5 Disconnect the CAN field cable to P32 (two wires).
6 Disconnect the LAN wires to the terminal blocks P36 and
P37.
7 Remove the four fixing bolts/screws and put the old box
aside with a label describing the error symptoms
registered.
8 Remove the lid of the new junction box by removing the 6
9 Reconnect the LAN wires to the terminal blocks P36 and
P37 as appropriate. Two field cables are needed for
maximum configuration (dual process LAN and the
service LAN).
10 Reconnect CAN field cable to P32 (two wires). See text
on circuitboard for correct polarity.
11 Reconnect power cable to P33 (two wires). See text on
12 Verify strap in strap field P8 is sett between pin 2 and 3.
13 If junction box serial number is in the range 1 to 30, verify
the strap in strap field P18 is set correctly.
14 Set rotary switch U3 to same value as for the old junction
box.
15 Set rotary switch U4 to same value as for the old junction
box.
16 Connect the junction box cable to the operator terminal
(cJoy OT).
17 Turn on the power to the junction box and the controller
cabinet.
18 Wait for the operator terminal to finish running up.
19 Verify proper operation from the operator terminal.
178005 /B 19
cJoy Wing Terminal (cWing)

of the cJoy Wing Terminal.
Important notice:
178006 /C 1
cJoy Wing Terminal
Document revisions

A 11.06.04 EIK 05.11.04 JE 05.11.04 JM
B 04.02.05 PLB 17.02.05 EIK 17.02.05 JKM
C 04.03.05 CBM 16.03.05 EIK 16.03.05 JKM
D
E
F
Document history
Rev. C Technical Specification updated.
2 178006/C
Glossary

GND Ground
IO Input/Output
PE Protective Earth
178006 /C 3
Table of contents
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MAINTAINABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
178006 /C 5
OVERVIEW
The cJoy Wing Terminal is a remote operator terminal for cJoy
and cPos systems.
The terminal is designed for installation in outdoor
environment.
The following list shows the main features of the wing terminal.
· 3-axis joystick
· Monochrome display with buttons
· Power indicator with power failure alarm
· Panel and display illumination adjustment possibility
· Panel test function
· Panel ID and orientation code defined by the junction box
· High resistance against intrusion of water (IP56)
· One-cable connection with watertight connector
· Easy bracket mounting
178006 /C 7
cJoy Wing Terminal
FUNCTION
Display Indicators Buzzer Buttons 3-axis

Joystick
µC
DC/DC
Converter
CAN bus
Orientation
24 VDC
&ID
(CD3059)
Figure 1 cJoy Wing Terminal block diagram
The cJoy Wing Terminal is an operator terminal that provides

the operator with the necessary facilities to control a vessel in
joystick and auto heading mode.
The terminal can be located both indoor and outdoor, and it may
be bulkhead mounted or insert into a suitable surface. A
mounting bracket for the terminal is available.
The terminal can be disconnected from the present connected
junction box and moved to another junction box and
reconnected there without any system interruption.
The terminal is controlled by a mController (mC) that
communicates with the system via a CAN bus (see Figure 1).
Connections
Only one cable is needed for connecting the cJoy Wing
Terminal to its junction box. The interface cable contains power
lines, CAN bus and rotary switch signal wires.
The panel ID code and orientation code are set at the
corresponding junction box by the rotary hex switches.
CAN bus
8 178006/C
Power
junction box.
User interface
The user interface comprises a display, a 3-axis joystick, buttons
and LEDs (see Figure 2).
power
operation
reset
power
operation Full
Silence Dim Test Take
thrust
Stand
by
Fore
Joystick
pivot
Auto Centre
head. pivot
Set
+ Present
head.
Aft
pivot
cWing
(CD3060)
See the operator manual for the wing terminal for details on the
user interface.
178006 /C 9
cJoy Wing Terminal
Status LEDs
Figure 2 for the location) have the functions as listed in the table
below.
LED Mode Description
Table 1 Status LEDs’ mode description
Reset button
The reset button (located under the hole found next to the
operation LED) allows you to reset the panel micro controller.
You may use a paper clip or equivalent tool to operate the
button.
10 178006/C
Input voltage 24 VDC +10% / -15%
Typical Power consumption 20 W
Maximum Power consumption 25 W
Batteries None
Connections
nector
Weight 3 kg
IP degree IP 56
Lifting By Hand
Noise Level < 40 dB
Operating ambient temperature -25 - +70 °C
Operating ambient humidity up to 90%RH (non-condensing)
Storage humidity up to 95%RH (non-condensing)
848-161011
178006 /C 11
cJoy Wing Terminal
CONFIGURATION
There are no configurable parts within the cJoy Wing Terminal.
MAINTAINABILITY
Note There are no user serviceable parts inside this equipment. It
shall be opened and disassembled for service purposes by
Kongsberg Maritime authorised persons only.

12 178006/C
INSTALLATION
Wing Terminal is a guide for mechanical installation of this
on request.
up and running.
cJoy Wing Terminal.
up and running.
status.
terminal.
178006 /C 13
cJoy Wing Terminal
REPLACEMENT
No special precaution is needed to be taken when replacing this
product.
up and running.
1 Loosen the two fixing wheels, one at each end and remove
the wing terminal.
2 Disconnect the cable from the cJoy Wing Junction Box to
the cJoy Wing Terminal and put the wing terminal aside.
new cJoy Wing Terminal.
up and running.
status.
terminal.
14 178006/C
cJoy WT Junction Box


of the cJoy WT Junction Box.
Important notice:

178007 /B 1
Document revisions

A 11.06.04 EIK 05.11.04 JE 05.11.04 JM
B 04.02.05 PLB 17.02.05 EIK 17.02.05 JKM
C
D
E
F
Document history
2 178007/B
Glossary

DI Digital Input
DO Digital Output
GND Ground
IO Input/Output
PE Protective Earth
WT Wing Terminal
178007 /B 3
Table of contents
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CAN bus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Panel-ID code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Panel-orientation code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connectors and component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DL1 and DL2 - LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
U3 and U4 - Rotate switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
U3 - Panel-ID code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
U4 - Panel-orientation code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
P1 to P7 - Operator terminal cable connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P8 and P18 - Strap fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P8 - Programming/normal mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P18 - CAN bus termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
P32 - CAN bus in connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
P33 - Power connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
P34 - CAN bus out connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
178007 /B 5
OVERVIEW
The cJoy WT Junction Box provides the cJoy Wing Terminal
with 24 Vdc supply voltage and CAN bus interface.
The junction box is provided with the following functions.
· Connection for 24 Vdc from external power supply
· Green status LEDs indicating 24 Vdc and 5 Vdc present
· CAN bus interface in and out for CAN bus field cables
· Strap field for termination of CAN bus
· Hex switch for wing terminal ID
· Hex switch for wing terminal orientation
· Connector for wing terminal programming device
· Strap field for setting programming mode
178007 /B 7
FUNCTION
The illustration (Figure 1) shows a block diagram of the cJoy
WT Junction Box.
Power 24 VDC
input P33
5 VDC
DL2 GND
DL1
3
Panel-ID P1 Operator
switch . terminal
2 . connection
P7
Panel-
orientation
switch
CAN bus
incoming P32 CAN bus in
field cable
P18
CAN bus
terimination
CAN bus
outgoing P34 CAN bus out
field cable
Programming 5 VDC
equipment Programming/
P8 Normal
connector
(9-pin D-sub) J1
(Cd3073)
Figure 1 cJoy WT Junction Box block diagram
Power
The junction box is supplied with 24 Vdc from outside, and a
LED (DL2) indicates the presence of this voltage.
A 5 Vdc is generated within the connected panel and is
distributed via the junction box. The 5 Vdc LED (DL1)
indicates both that the connection to the panel is present and the
existence of the +5 Vdc.
CAN bus connection

The CAN bus is used for communicating between the cJoy
operator terminal or cPos operator panel and the wing terminals
attached to this bus.
A strap field P18 is provided for termination of the CAN bus in
this junction box. The termination is set active only if this
junction box is the last one on the CAN bus.
8 178007/B
Panel-ID code
A rotation hex switch (U3) is provided to set an ID for the
attached panel (cJoy WT). This is used for identifying each
operator terminal connected to the CAN bus. The rotation
switch has 16 positions of which six (1-6) values are valid by
the system.
Panel-orientation code
A rotation hex switch (U4) is provided to set the orientation
code for the attached panel (cJoy WT). The rotation switch has
16 positions of which four (0-3) values are accepted by the
panel to set the Fore, Stbd, Aft or Port orientation.
178007 /B 9
Input voltage range 24 Vdc +10% to -10%
Batteries None
Weight 3 kg
IP degree IP56
Lifting By Hand
Noise level < 40 dB
Operating temperature -25 - +70 °C
Operating ambient humidity up to 90% relative humidity
Storage ambient humidity up to 95% RH non-condensing
848-161011
10 178007/B
CONFIGURATION
Connectors and component locations
P8
J2 1 1-2 Programming +5V
2-3 Normal
3 DL1
Programming 1 +24V
1-2 “No termination”
U3 U4 2-3 “Termination active” DL2
3
P18
P7 P6 P5 P4 P3 P2 P1 P32 P34 P33
BIT 1
CANL IN
CANH OUT
CANL OUT
PROG
CANH IN
24V IN
0V IN
TX232
RX232
5V TO PANEL
24V TO PANEL
0V TO PANEL
CANH TO PANEL
CANL TO PANEL
BIT 5
BIT 4
BIT 3
BIT 2
CANL FROM PANEL
CANH FROM PANEL
(CD3145)
DL1 and DL2 - LEDs

Two green LEDs DL1 and DL2 are provided for indicating
POWER ON.
· DL2 indicates (when lit) that 24 Vdc is present.
· DL1 indicates (when lit) that 5 Vdc is present from the panel.
Whenever the cable between the panel and the junction box
is connected this LED should be lit. In case the DL2 is lit but
not DL1, then either the cable is not connected appropriately
or the panel is by some reason not turned on.
178007 /B 11
U3 and U4 - Rotate switches

Two hexadecimal rotate switches U3 and U4 are provided.
U3 - Panel-ID code
This switch provides the Panel-ID code for the operator terminal
connected.
Switch position 0&8 1&9 2&A 3&B 4&C 5&D 6&E 7&F
Panel-ID code 0 1 2 3 4 5 6 7
Table 2 Switch position versus Panel-ID code
U4 - Panel-orientation code
This switch provides the Panel-orientation code.
Switch position Orientation Orientation code

0, 4, 8, C Fore 0
1, 5, 9, D Stdb 1
2, 6, A, E Aft 2
3, 7, B, F Port 3
Table 3 Switch position versus panel orientation and Panel
orientation code
12 178007/B
P1 to P7 - Operator terminal cable connector

P1 to P7 comprise the cable connector for the wing terminal.
Pin Terminal name Function

6 P3:2 CAN L to panel
7 P4:1 CAN H to panel
8 P4:2 CAN L from panel
9 P4:3 CAN H from panel
13 P6:2 -
14 P7:1 RX232 from the programming device
15 P7:2 TX232 to the programming device
16 P7:3 Programming mode signal
Figure 3 P1-P7 terminal allocation
P8 and P18 - Strap fields

Two 3-pin strapfields P8 and P18 are provided.
P8 - Programming/normal mode
This strap filed has two setting options.
· Strap in position 1-2: Programming of micro controller is
allowed. If the strap is set to this position, all LEDs on the
panel may be lit.
· Strap in position 2-3: Normal operation takes place.
178007 /B 13
P18 - CAN bus termination

This strap field has two setting options.
· Strap in position 1-2: Termination resistor is disconnected.
This position is to be used if CAN out signals on connector
P32 are wired. This will be the case when more than one
junction box are connected in the same branch of CAN
connections.
· Strap in position 2-3: Termination resistor is connected.
This is to be used if CAN out signals on connector P32 are
not wired.
P32 - CAN bus in connector

See circuit-board printing for correct terminal allocation.
The CAN field cable from the cJoy OT, cPos OP or the previous
cJoy WT in the sequence of junction boxes, is terminated on this
connector.
P33 - Power connector

Power (24 Vdc) to this junction box is terminated on this
connector.
P34 - CAN bus out connector

The CAN field cable to the next cWing OT junction box is
terminated on this connector.
14 178007/B
INSTALLATION
Wing Terminal Junction Box is a guide for mechanical
installation of this product. The manual can be obtained from
Kongsberg Maritime on request.
Prerequisites are:
· The junction box is fixed to a suitable surface
· Neither power nor signals must be activated on the cables to
be connected to the junction box.
1 Connect the wing terminal cable’s one end to this junction
box.
2 Connect the power field cable to the P33 connector. Verify
that the voltage polarity is correctly connected before the
power is turned on. See the printed text on the
3 Connect the CAN bus in cable to connector P32 and the
CAN bus out cable to connector P34. See the printed text
on the circuitboard for correct polarity.
Note If the CAN bus out cable is not to be used, the P18 jumper must
be set in position 1-2 to terminate the CAN bus with the built-in
resistor.
3.
5 Set rotation switch U3 to the value given by the vessel
software specification for this cJoy wing terminal.
6 Set rotation switch U4 to match the orientation of the cJoy
wing terminal.
7 Before connecting the wing terminal to the cable from this
junction box, turn on the power supply and verify the DL2
LED is lit. If lit, 24 V is supplied to the junction box.
8 Turn off the power.
9 Connect the junction box cable to the cJoy wing terminal.
178007 /B 15

11 Turn on the power to the junction box from the controller
cabinet.
12 Wait until the wing terminal is up and running. The status
LEDs on the wing terminal will show OK status.
13 Verify proper operation from the wing terminal.
16 178007/B
REPLACEMENT
shown below.
Prerequisite is:
· Neither power nor signals must be active on the cables to be
disconnected from the junction box.
1 Loosen and remove the field cables for the power supply,
CAN in and CAN out.
2 Disconnect the cable to the cJoy wing terminal.
3 Remove the four fixing bolts for the junction box.
4 Put the junction box aside and mark it with a label telling
the error symptoms.
5 Put the new junction box in position and fasten it with the
four fixing bolts.
6 Connect the cJoy wing terminal cable to the junction box.
7 Connect the power field cable to the P33 connector. Verify
that the voltage polarity is correctly connected before the
power is turned on. See the printed text on the
8 Connect the CAN bus in cable to connector P32 and the
CAN bus out cable to connector P34 as appropriate.
3.
10 Set rotation switch U3 to the value given by the vessel
software specification for this cJoy wing terminal.
11 Set rotation switch U4 to match the orientation of the cJoy
wing terminal.
13 Turn on the power to the junction box from the controller
cabinet.
14 Wait until the wing terminal is up and running. The status
LEDs on the wing terminal will show OK status.
15 Verify proper operation from the wing terminal.
178007 /B 17
JC/DPC-401 Maintenance Manual
JC/DPC-401
Maintenance Manual

maintenance information for the JC/DPC-401.
Important notice:

177970 /C 1
Document revisions

A 08.06.04 EIK 17.08.04 GKN 20.08.04 BF
B 16.02.05 CBM 17.02.05 EIK 17.02.05 JKM
C 25.02.05 CBM 25.02.05 SvSo 25.02.05 EB
D
E
F
Document history
Rev. B 24 VDC Version added, HW Config. Status and Technical Specifications

updated.
Rev. C Additions made to the 24 Vdc version.
2 177970/C
The configuration status of documents describing the JC/DPC-401 hardware for this
revision of the Maintenance Manual are listed below:
Parts Lists
Parts List JC/DPC-401 (115/230 Vac): P20110, Rev. B
Parts List JC/DPC-401 (24 Vdc): P20100, Rev. B
Drawings
General Arrangement, JC/DPC-401, Cabinet 600x800x250: 1001531, Rev. D
Layout Drawing, JC/DPC-401, 600x800x250: 1001538, Rev. D

Power and Wiring Diagram, JC/DPC-401, DPC w/RIO Modules: 1001536, Rev. B
Layout Drawing, JC/DPC-401, 24VDC, 600x800x250,

AE 1058.600: 1004098, Rev. A
Power and Wiring Diagram, JC/DPC-401, 24VDC: 1004100, Rev. A
Wiring Diagram, JC/DPC-401, Net/Serial Lines: 1001537, Rev. A

Wiring Diagram, JC/DPC 401/411, Isolation Amplifiers: 1000957, Rev. A
Wiring Diagram, Interface Cable, RCU510 - TBSS: 1001144, Rev. C
177970 /C 3
Table of contents
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuse-status indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reading power status LEDs and measuring supply voltages . . . . . . . . . . . . . . . 16
Equipment status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preventive maintenance intervals for JC/DPC-401 . . . . . . . . . . . . . . . . . . . . . . 20
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
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
177970 /C 5
This section describes the JC/DPC-401 hardware
configuration.
177970/C 7
Kongsberg Maritime JC/DPC-401
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 JC/DPC-401 cabinet is made for wall mounting. It has two

dedicated positions for RCU modules on its rear wall (see
Figure 1).
Isolation amplifiers for analog outputs are located on the upper
left of the rear wall.
LEFT WALL REAR WALL RIGHT WALL
NET SW1
SWITCH
NET ISO 1
(optional) TBSS1
PATCH PP1
PANEL U1
ISO 6
ISO 7
RCU510
TBSS2
CABLE DUCT
CABLE DUCT
CABLE DUCT
CABLE DUCT
ISO 12
PSU1 (optional)
F1 X11
FL1
X12 U2
Q1
BUSBAR RCU510
Q2 I.E.
MAINS
OUTLET
SOCKET
(Cd3050)
Figure 1 Layout of JC/DPC-401 (115/230 Vac version)
Power supply, mains filter and magnetic circuit-breakers

(MCBs) are located on the the left wall together with the LAN
connections for the RCUs.
Up to two serial line interface boards (TBSS) are located on the
right wall.
Field cabling to JC/DPC-401 are routed through the cabinet
bottom.
Note The 24 Vdc version does not have the Q2 circuit breaker and the
Mains Outlet Socket.
8 177970/C
Block diagram
A block diagram of JC/DPC-401 is shown in Figure 2.
Net Switch
Fuses
To 3-Way Isolation (optional)
Amplifiers ISO 1-6 and ISO 7-12
SW1
Network Cable
FL1 PSU1
Q1
115/230 Vac +24 Vdc NET A & B NET A & B
6A Filter Power RCU RCU
Supply
(optional)
Mains Outlet
U1 U2
Q2 Sockets
Busbar
6A
Serial Lines
ISO 1-6 ISO 7-12
24 Vdc to equipment
outside DPC cabinet Field Signal Loops
Field Signal Loops

(optional)
TBSS1 TBSS2
(CD3051) Field Serial Lines Field Serial Lines
Figure 2 Block diagram of JC/DPC-401 (115/230 Vac version)
Power supply
JC/DPC-401 (type 115/230Vac) handles both 230 Vac and
115Vac as mains supply.
JC/DPC-401 (type 24 Vac) handles 24 Vdc as mains supply.
The block diagram in Figure 2 shows the power supply
principles of JC/DPC-401, type 115/230 Vac.
Note For the 24 Vdc version, the current rating of circuit breaker Q1
is increased from 6A to 16A. Also, in the 24 Vdc version the
circuit breaker Q2 and the Mains Outlet Socket is removed and
the power supply PSU1 (115/230 Vac to 24 Vdc) is changed into
a new 24 Vdc to 24 Vdc power supply.
The power supply supplies up to two RCU510s and TBSSs
(serial termination boards), optional net switch, 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.
177970/C 9
Fuse-status indication
The fuses designated Fnn (F1, F2, etc.) in JC/DPC-401, 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.
F1 - Fnn
Supply
voltage Load
R
LED
D
(CD2902)
Figure 3 Fuse status indicator circuitry
Power supply (24 Vdc) monitoring and

alarming
To monitor the supply voltage (24 Vdc) each RCU510 reads the
voltage with high precision at the power terminals on X1 to X4
and gives system alarm if voltage is outside predefined values.
Grounding RCU modules

Each RCU module shall be grounded. FL1 fast-on terminal is
connected to PE (or to IE if specified).
See also the RCU510 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 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 at one
end and connector P1 on TBSS 1 and P1 on TBSS 2 (optional)
at the split end.
10 177970/C
Serial channels
1 to 4
TBSS 1
P1
Serial channels
5 to 7
RCU TBSS 2
P1
(CD3083)
Figure 4 Principle of internal serial-line cabling using TBSS
Data network
Network field cables are terminated on the Mini Patch Box
located on upper left wall.
There are two options of network solutions available:
· Patch cables with RJ45 connectors at both ends are connected
between the patch box PP1 and an 8-port net switch SW1 for
the net A. Patch cables are connected between the net switch
and the RCUs’ A network connectors (see Figure 5,
alternative 1). Only one field cable is then necessary.
· Patch cables with RJ45 connectors at both ends are connected
directly between the patch box and the RCUs’ A network
connectors. In this option no net switch is in use (see
Figure 5, alternative 2). One field cable for each RCU is
then necessary.
Option 1: With net switch Option 2: Without net switch

Field
Field Mini Cables Mini
Cable Patch Patch
Box Box
Net A Net A
Net Switch
SW1 (Net A)
Net A Net A
Net A Net A
RCU RCU RCU RCU

Net A Net B Net A Net B Net A Net B Net A Net B
U1 U2 U1 U2
(CD3057)
Figure 5 Network principles in JC/DPC-401
177970/C 11
See also the separate network topology drawing in the Drawing

File for which ports on the switch are used for which RCUs.
Galvanic isolation of output signals

The output signals, mainly used to control thrusters, are normally
provided with configurable, universal isolation amplifiers
(location ISO 1 to ISO 12 in Figure 1) to obtain galvanic isolation.
Note See the vessel specific documentation for details on which
signals are provided with galvanic isolation.
The isolation amplifiers provide both voltage and current output
(see the appropriate Hardware Module Description for details).
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 terminal blocks on the
RCU and TBSS modules.
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.
12 177970/C
Supply voltage (type P20100) 24 Vdc
Supply voltage (type P20110) 115/230 Vac (+10 %/-15 %)
Size: width x height x depth 600 x 800 x 250 mm
Weight 40 kg
EMC Non-shielded cabinet
IP degree IP44
Typical heat dissipation 50 W
Maximum heat dissipation 100 W
Noise level < 40 dB
Also refer to Kongsberg Maritime Environmental Specification, reg. no.:
161011
Table 1 JC/DPC-401 technical specifications
177970/C 13
Fault Finding
FAULT FINDING
JC/DPC-401.
177970/C 15

To correct the system, if an error situation has occurred, the
flowcharts in Figure 6 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 AC/DC
converter and RCU modules. See the appropriate Hardware
· Values of power-output voltages and fuse state in the system.
See the appropriate Hardware Module Description for more
information.
appropriate Drawing File for details.
Corrective Maintenance section or the appropriate Hardware
If you are not able to correct the error situation yourself, you
Reading power status LEDs and measuring supply

voltages
PSU 1 is 115/230 Vac to 24 Vdc AC/DC converters. The status
of the PSU 1 is shown by a LED on the front of the power
module. OK state corresponds to green LED colour.
The power supply module is located on the left sidewall inside
the cabinet. Its output voltage can be measured on its
voltage-output terminals.
The mains voltage can be measured, where appropriate, using a
multimeter with AC-range.
16 177970/C
Fault Finding
Equipment status
The RCU modules run built-in test programs that continually
check for faults while the system is running. JC/DPC-401
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.
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.
SOURCE
1 Configuration: Single power supply, single LAN with net switch
1.1 One RCU module in this Defective RCU module. Replace RCU module.
JC/DPC-401 has lost contact
Network connection to RCU is Replace patch cable
with the system. Local LED is
defective. or
red.
move to other port on net
switch
1.2 Both RCU modules in this The power connection to the Verify presence of
JC/DPC-401 have lost contact JC/DPC-401 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 is lit Defective fuse in field terminal Replace fuse in terminal
block. block.
1.4 A LED in X11 is not lit Defective LED in field Replace LED terminal block.
although the corresponding terminal block.
fuse has blown.
Table 2 Fault finding JC/DPC-401

Figure 6 shows a general fault finding flowchart telling how to
re-establish the field station after lost contact with one or two
RCUs or blocks with I/O.
177970/C 17
Start System reports:

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

No and check LED status on the
RCU module that is not
responding
Open JC/DPC cabinet door and
check Q1, PS1 LED, fuse LEDs,
SW1 LEDs and RCU LED status
Is the LED lit red?
Is power to
RCU modules and
net switch OK?
Yes
Yes
No No
Is network switch
working OK?
Yes
No
Replace network switch Repair power or

or patch cables as Replace RCU module replace AC/DC module
appropriate as appropriate
Is JC/DPC
response OK?
No
Contact Kongsberg Maritime

for recommended action Yes
End
(Vis1177A)
Figure 6 Fault finding flowchart at JC/DPC-401 error
18 177970/C
procedures for the JC/DPC-401.
177970/C 19

Use an isolated-handle (if power is on) screwdriver with 2 or 3
mm wide bit, as appropriate, and tighten any loose screws.

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.

Preventive maintenance intervals for JC/DPC-401


Tighten screws in the Every six months
termination blocks
housing
Table 3 Recommended maintenance intervals for JC/DPC-401
20 177970/C
procedures for the JC/DPC-401.

personnel only.
177970/C 21
Replacing PSU1
defective power supply PSU1 in JC/DPC-401.
JC/DPC-401 and have a spare power supply module.
1 Open the front door of JC/DPC-401.
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 JC/DPC-401.
11 Close the front door of JC/DPC-401.
Replacing Q1 or Q2 circuit-breaker (MCB)

defective circuit breaker (MCB) among Q1and Q2.
JC/DPC-401 and have a spare MCB.
2 For the case of your safety, turn off circuit breaker
(MCBs) that shall not be replaced.
22 177970/C
3 Remove the busbar between the MCBs Q1 and Q2, and

remove the 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 and the wires to the MCBs by using
the flat-bit screwdriver.
7 Turn on the power lines to JC/DPC-401.
8 Turn on the MCBs for PSU1.
Replacing Isolation Amplifier (ISO1 to ISO12)

Caution Electrostatic charges can damage electronic
components. Notice the following precautions:
Always wear a properly connected earthing strap when
handling electronic components. Never store near
electromagnetic or electrostatic devices.
2 Turn off power to the faulty module (X31: F2 or F3).
3 Disconnect the input and output cables from the faulty
module.
4 Remove the faulty module from the rail (see Figure 7).
Figure 7 Detachment of module from rail
177970/C 23
5 Ensure that the replacement module is marked (check

marks on external decals) for the correct configuration of
the appropriate part number. If not, check and configure
the module according to settings of the faulty module (see
Figure 8 how to open the module). Settings to be used are
provided in a drawing located in the Drawing File for the
vessel (for further information about this module see the
appropriate Hardware Module Description in the
Maintenance Manual).
Figure 8 Checking DIP switch settings
6 Clip the replacement module on the rail.

7 Connect the input and output cables to the appropriate
terminals on the replacement module.
8 Turn on mains power to the loop power supplies.
9 Move the label from the faulty module to the replacement
module.
10 Turn on loop power and verify that the green Power On
LED on the front of the module is lit.
11 Verify that the application is working OK by watching
operator station status.
24 177970/C
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 the
replacement procedure.
Replacing TBSS module

Reuse power off and on steps from the PSU procedure above
See the TBSS Hardware Module Description for the replacement
procedure.
177970/C 25

recommended spare parts and consumables used in
JC/DPC-401. Replacement procedures for the listed parts
are described in the appropriate Hardware Module
Description. No replacement procedures are supplied for
the consumeables.
177970/C 27

1 Power Supply, MWS-240 X 47749445
115/230 Vac/24 Vdc/10 A (P20110)
2 Power Supply ; DC/DC conv. X 703424
SD-350B 24V/24V 245W (P20100)
used at Q1 and Q2 (P20110)
used at Q1 (24 Vdc version) (P20100)
5 RCU510 X 601418
6 A (P20110)
16 A (24 Vdc version) (P20100)
8 Telesafe Mini Patch Box, 702252
8 x RJ45
9 TBSS 37960309
10 TBSL RS232 ISO 37767522
11 TBSL RS422 ISO 37767563
12 MCR-C-UI-UI-DCI-SOKS X 701567
3-Way Isolation Amplifier
13 Moxa EtherDevicet Switch X 702485
EDS-308 (optional)
14 Terminal Block WSI 6 LD 47753397
28 177970/C
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.
ident. number
1 Fuse, 5x20 mm, 2 A F X11: F3, F7 43505833
2 Fuse, 5x20 mm, X11: F1-F2 43522218
6.3 A F
3 Fuse, 5x20 mm, X11: F4-F6, F8-F12 43505817
0.50 A F
Table 5 Consumables
177970/C 29
cJoy Maintenance Information
This document contains the system level information for

understanding and maintaining the cJoy system installed on
a vessel.
Important notice:

178769/B 1
Document revisions

A 01.02.05 PLB 02.02.05 EIK 03.02.05 JKM
B 03.02.06 PLB 03.02.06 EIK 06.02.06 JKM
C
D
E
F
Document history
Rev. B 24 Vdc version of DPC-401 added plus minor changes to CANbus network
and address settings.
2 178769/B
Table of contents
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hardware Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
cJoy Controller (JC-401) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
cJoy Operator Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
cJoy Wing Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
cJoy Operator Terminal Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
cJoy Wing Terminal Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
cJoy local area network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
cJoy CANbus network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
cJoy operator and wing terminal address settings . . . . . . . . . . . . . . . . . . . . . . . . 12
CJOY SYSTEM START-UP AND SHUT-DOWN . . . . . . . . . . . . . . . . 13
System start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sensors and position-reference systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
cJoy controller JC-401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
cJoy controller JC-401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Sensors and position-reference systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MAINTENANCE PHILOSOPHY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Qualifications of the system technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Recommended spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SYSTEM FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
System level fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fault finding flowchart, cJoy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
178769/B 3
System Overview
SYSTEM DESCRIPTION
This section contains an description of the cJoy system.
178769/B 5
Kongsberg cJoy
System Arrangement
The cJoy is a joystick control system comprising a joystick
controller (JC-401), an operator terminal for mounting into a
console (cJoy Operator Terminal) and optional wing terminals
(cJoy Wing Terminal) (see Figure 1).
cJoy Wing Terminal #1 cJoy Wing Terminal #2

(optional) (optional)
WT Cable cJoy WT WT Cable cJoy WT

Junction Box #1 Junction Box #2
(optional) CANbus (optional)
OT Cable NET A Patch Cable

CANbus cJoy OT
Junction Box
cJoy Controller
JC-401
LAN NET A
Field Cable
24 Vdc 24 Vdc
Mains supply
Field Loops
(CD3087A)
Figure 1 cJoy system arrangement
The joystick controller and the operator terminal communicate

via a single network.
The operator terminal and optional wing terminals are
connected to the system via dedicated junction boxes.
The system provides interfaces to the thrusters, reference
systems and sensors.
Mains supply voltage (115/230 Vac or 24 Vdc) is supplied only
to the joystick controller (JC-401) from where 24 Vdc is
distributed to all system modules.
6 178769/B
System Overview
Hardware Modules
cJoy Controller (JC-401)
Figure 2 cJoy Controller
The cJoy controller performs coordinated joystick control,

closed loop control (e.g. automatic heading control), and takes
actions to operator commands and interfaces the various sensors
and reference systems to provide the correct control signals for
the vessel’s propulsion and thruster system.
The cJoy controller is connected to the mains supply voltage
(115/230 Vac or 24 Vdc). It generates 24 Vdc for internal use
and for use by the operator terminal, optional wing terminals
and junction boxes.
All field signal cables are terminated in this cabinet.
For further details, refer to the JC/DPC-401 Maintenance
Manual.
178769/B 7
Kongsberg cJoy
Figure 3 cJoy Operator Terminal
The computer and all electronics are housed in a self-contained

desk/console mountable unit.
The terminal communicates with the cJoy Controller and other
cJoy Operator Terminals via a LAN. It is connected to the
system via a dedicated junction box (see cJoy Operator
Terminal Junction Box on page 9).
For further details, refer to the cJoy Operator Terminal
Hardware Module Description.
cJoy Wing Terminal
Figure 4 cJoy Wing Terminal
The wing terminal can be located at any location on the vessel,

both indoor and outdoor. The electronics are housed in a
self-contained unit, which may be bulkhead mounted or insert
into a suitable surface. A mounting bracket for the terminal is
available.
The wing terminal communicates with the cJoy Operator
Terminal via a CANbus. It is connected to the system via a
dedicated junction box (see cJoy Wing Terminal Junction Box on
page 9).
For further details, refer to the cJoy Wing Terminal (cWing)
8 178769/B
System Overview
cJoy Operator Terminal Junction Box
Figure 5 cJoy Operator Terminal Junction Box

The junction box can be located on a wall or bulkhead.
There are five fittings on the box.
· One is for the cable to the operator terminal.
· Two are for the network field cables. Only one of them is
used in cJoy for LAN network A.
· One is for the CANbus cable. It is used if one or more wing
terminals are used.
· One is for the 24 Vdc supply voltage.
Three RJ45 connectors are for network patch cables, but only
one is used here for connection to the operator terminal.
The junction box contains connectors where to terminate the
cables, and it contains switches and strap fields for setting
parameter values to the corresponding operator terminal.
For further details, refer to the cJoy OT Junction Box Hardware
Module Description.
cJoy Wing Terminal Junction Box
Figure 6 cJoy Wing Terminal Junction Box

The junction box can be located on a wall or bulkhead either
indoors or outdoors. The multiplan connector on the box is for
the cable to the wing terminal.
178769/B 9
Kongsberg cJoy
There are three fittings on the box.

· Two fittings are for the CANbus input and output cables.
Only the input one is used if this is an end junction box on
the CANbus.
· One is for the 24 Vdc supply voltage.
The junction box contains connectors where to terminate the
cables, and it contains switches and strap fields for setting
parameter values to the corresponding wing terminal.
For further details, refer to the cJoy WT Junction Box Hardware
Module Description.
10 178769/B
System Overview
cJoy local area network

In the cJoy system the local area network (LAN)
communication comprises the cJoy Operator Terminal and the
JC-401.
A single LAN is implemented in the cJoy system. The LAN is
built around an ethernet switch located in JC-401 (see Figure 7).
For further details concerning the ethernet switch, refer to the
JC/DPC-401 Maintenance Manual.
cJoy
Operator Terminal
mPC A
cJoy OT
Junction Box
LAN Net A
Field Cable
LAN Net A
Patch Cables Patch Box JC-401
Net Switch
A A
RCU510 RCU510
(optional)
(CD3088)
Figure 7 cJoy system network connection
178769/B 11
Kongsberg cJoy
cJoy CANbus network

In the cJoy system a CANbus is used for the communication
between the operator terminal and the wing terminals (see
Figure 8).
The CANbus is a balanced 2-wired multi-drop bus which uses a
shielded or un-shielded twisted pair in a cable that always has an
outer shield. The twisted pair based bus must be terminated at
both ends with a 120 ohm resistor.
The cJoy system uses a high data rate for communication on the
CANbus, and consequently the total CANbus length is limited
to 500 m.
cJoy Optional cJoy Optional cJoy

Operator Terminal Wing Terminal #1 Wing Terminal #2
Serial
Line
mPC mC mC mC
cJoy WT
Junction Box
120 ohm fixed Cable
CANbus Optional
cJoy OT Optional
termination cJoy WT
Junction Box cJoy WT
Junction Box
Junction Box Jumper
Cable
120 ohm
selectable
CANbus Field Cable CANbus
termination
(CD3093)
Figure 8 cJoy CANbus communication
cJoy operator and wing terminal address settings

To distinguish between the different operator and wing terminals
connected to the CANbus each of them must be provided with a
unique system address.
The cJoy operator terminal is provided with an address defined
by the 8-values rotate-switch setting in the cJoy OT junction
box.
Each cJoy wing terminal is provided with a two digit address
defined by merging the OT junction box setting (m-, where
m = 1, 2, 3,...7) and the WT terminal setting (-n, where n = 0,
1, 2, 3, ...7) defined by the 8-values rotate-switch setting in the
cJoy WT junction box. The total address (mn) is used to identify
each wing terminal (e.g. mn = 10, 11, 12, 13, ...17).
For further details, refer to the cJoy OT or cJoy WT Junction
Box Hardware Module Description as appropriate.
12 178769/B
Basic System Operation
cJoy SYSTEM START-UP AND SHUT-DOWN

This section contains procedures for start-up and shut-down
of the cJoy system.
178769/B 13
Kongsberg cJoy
System start-up
The cJoy controller cabinet and consequently the operator
terminal and the optional wing terminals are usually left with
the power switched on. However, if the system has been shut
down, use the following procedures to restart the system.
Note The sequence of the items below follows the recommended
start-up sequence of the corresponding equipment.
UPS
At the UPS cabinet, switch on the power as described in the
manufacturer’s manual.
Sensors and position-reference systems

1 Ensure that the required gyro compass sensors are
switched on and run up.
Note Running up a gyro compass from “cold” state can require
between one and three hours (see the gyro compass manual).
2 Ensure that the required wind sensors are switched on and
available.
3 Ensure that the required position-reference systems are
switched on and available.
4 Ensure that the other sensors are switched on and
available.
Note MRU sensors are normally supplied with power from the cJoy
controller JC-401.
14 178769/B
Basic System Operation
cJoy controller JC-401

Note Ensure that the cJoy system cannot, at this stage, send control
signals to the vessel’s propulsion system, i.e. control of the
vessel’s propulsion system has been transferred to the manual
control levers.
1 Open the door of the controller cabinet.
2 Switch on the Q1 (115/230 Vac or 24V dc) circuit breaker
(see Figure 9).
3 Wait for approximately one minute.
4 Check that the RUN LED on the RCU(s) shows green.
5 If installed, check that the required MRU sensors are
switched on and available.
6 Close the door of the controller cabinet.
Note Switching on the power for the joystick controller will also
provide power to the operator terminal and the optional wing
terminals.
RUN LED
RCU
Q1
(CD3091)
Figure 9 Location of circuit breaker Q1 (115/230 Vac version)
178769/B 15
Kongsberg cJoy
System shut-down
The cJoy controller cabinet and consequently the operator
terminal and the optional wing terminals are usually left with
the power switched on.
If the system is to be shut down for any reason, use the
following procedures.
Note The sequence of the items below follows the recommended
shut-down sequence of the corresponding equipment.
cJoy controller JC-401

Note Ensure that the cJoy system cannot, at this stage, send control
signals to the vessel’s propulsion system, i.e. control of the
vessel’s propulsion system has been transferred to the manual
control levers.
1 Open the door of the controller cabinet.
2 Switch off the Q1 (115/230 Vac or 24 Vdc) circuit breaker
(see Figure 9).
3 Close the door of the controller cabinet.
Note Switching off the power for the joystick controller will also
remove power to the operator terminal and the optional wing
terminals. This will cause an audible alarm from the operator
terminal. The alarm horn can be silenced by pressing the
Silence button on the operator terminal.
Sensors and position-reference systems

Switch off the sensors and position-reference systems as
required.
Note Before switching off a gyro compass, remember that running up
the gyro compass from “cold” state can require between one
and three hours (see the gyro compass manual).
UPS
At the UPS cabinet, switch off the power as described in the
manufacturer’s manual.
16 178769/B
Maintenance Philosophy
MAINTENANCE PHILOSOPHY
This section contains the Kongsberg Maritime Maintenance
Philosophy for the cJoy system.
178769/B 17
Kongsberg cJoy
Fault finding
If an error situation has occurred with the cJoy system onboard
the vessel, a system technician should perform the fault finding
task and then follow up with necessary corrective actions.
The system technician can either be a skilled person available
for the vessel or a visiting service engineer from one of the
Kongsberg Maritime service offices. See also subsection
Qualifications of the system technician below.
A separate section in this document deals with fault finding in
the cJoy system. The instructions given on the form of
procedures and flow charts, are located in the System fault
finding section and should be tried prior to contacting
Kongsberg Maritime for any assistance.
Preventive maintenance is the periodic work (may be limited to
visual inspection) performed by a system technician to obtain an
optimum up-time for the system at all times. This work should
be performed according to a schedule specifying each
maintainable unit in the system, the maintenance operations and
the intervals between these operations for each unit.
Typical units and modules that need preventive maintenance are:
· The main units of the UPS system(s) shall be checked
regularly to ensure that back-up power is available when
needed.
· The terminal block screws shall be checked regularly for
loose connections and tightened as necessary.
· Power supplies with long-term voltage-drift shall be checked
regularly and adjusted as necessary.
No special tools or equipment, except a calibrated multimeter,
are required for performing preventive maintenance in the cJoy
system.
Recommended preventive maintenance schedules are provided
where applicable throughout the manual.
Corrective maintenance is the unscheduled work performed by a
system technician to correct the system when a fault, that either
stops or reduces the system throughput/performance, has
occurred.
18 178769/B
Maintenance Philosophy
The system technician must gather all available fault symptoms,

convert these to the most probable source of the fault, perform
the necessary corrective action and ensure that the fault has been
rectified.
System fault finding procedures are provided in this section of
the manual. Fault finding procedures for the individual units are
provided where applicable throughout the manual.
The replacement procedures for the more complex replaceable
modules are found in the corresponding Hardware Module
Descriptions.
Note Different precautions shall be taken when correcting a system
that is on-line compared to a system that is off-line. These
precautions should be planned in detail by the vessel system
technician for the pertinent mode of operation.
Qualifications of the system technician

A qualified system technician needs a thorough understanding
of the system functionality to be able to perform fault finding,
periodic and corrective maintenance.
To obtain this the following are required:
· A formal basic knowledge and skills of electronics,
instrumentation and computers.
· Having attended a Kongsberg Maritime cJoy Maintenance
course to be skilled in understanding the functions, layout
and the interconnection of the system units down to the
lowest replaceable module, and trained in fault finding and
repair.
Recommended spare parts and consumables

In addition to having skilled personnel available to maintain the
system, the vessel itself or the local vessel service office should
be provided with the most common spare parts and consumables
to reduce the risk of interrupted operations.
Lists of recommended spare parts are provided where applicable
throughout the manual.
During normal operation there will be no need for consumables
other than printer paper and toner cartridges in those
installations where a system printer is a part.
Lists of consumables are provided where applicable throughout
the manual.
178769/B 19
System Fault Finding
SYSTEM FAULT FINDING

This section contains fault finding methods and procedures
on the cJoy system level.
178769/B 21
Kongsberg cJoy
System level fault finding

If an error situation has occurred that results in no system
response at all, or if a system error message from the system is
displayed on the operator terminal, perform steps 1 to 5 as listed
below to solve the problem.
For further details, refer to the JC/DPC-401 Maintenance
Manual or the appropriate Hardware Module Description.
1 Verify that the mains voltage is present on the joystick
controller by reading its function indicators.
2 Verify that the supply voltage for the operator terminal is
present by reading its function indicators.
3 Verify that the supply voltage for the optional wing
terminals is present by reading its function indicators.
4 Verify that the status of the network switch including the
network cables is OK by reading the function indicators
on the network switch.
5 Verify that the power supply and signal cables for the
optional external equipment is OK by reading the
corresponding function indicators.
If an error situation has occurred that results in the
operation indicator flashing at the operator terminal or a
wing terminal, perform step 6.
6 If the operation indicator flashes red, an internal error has
been detected or the terminal has lost communication with
the cJoy controller, perform fault finding in accordance
with the appropriate Maintenance Manual and/or
for advice or to request for service on board.
22 178769/B
System Fault Finding
Fault finding flowchart, cJoy
Start
System response?
No
Yes
Verify the status of the

equipment listed below by checking
their supply voltages, status LEDs
and displays:
Joystick Controller (JC-401) Operator Terminal
Network Switch Alarm?
cJoy Operator Terminal Yes
CANbus
cJoy Wing Terminal
External equipment
Replace the faulty
Operator Terminal,
or repair
Joystick Controller,
network
Re-establish voltage or other
as appropriate No equipment as
appropriate
Restart system Restart system
System OK?
No
Yes
Contact Kongsberg
Maritime
End
(Vis1180)
Figure 10 Fault finding flowchart at cJoy system level error
178769/B 23

recommended spare parts and consumables used in the
cJoy system.
Replacement procedures for the listed parts are normally

found in their corresponding documentation, i.e. either a
maintenance manual for a unit or a hardware module
description for a module.
Definitions of units and modules are as follows:

· A unit contains modules and components that can be
replaced. The unit is normally documented by a maintenance
manual (e.g. JC-401).
· A module contains components that can be replaced only by
the manufacturer. The module is documented by a hardware
module description (e.g. cJoy Operator Terminal).
· A component is typically a common-known, single-function,
off-the-shelf part, and needs no detailed description. A
component is referred to in Kongsberg Maritime
documentation by its name and part number only (e.g.
magnetic circuit breaker, MCB).
No replacement procedures are supplied for the
consumables.
178769/B 25
Kongsberg Maritime Joystick Control System

1 JC-401 (115/230 Vac) Refer to the P20110
JC/DPC-401
Maintenance
Manual
2 JC-401 (24 Vdc) Refer to the P20100
JC/DPC-401
Maintenance
Manual
3 cJoy Operator Terminal 603201
4 cJoy Wing Terminal 603205
5 cJoy OT Junction Box with cable 603202
6 cJoy WT Junction Box 603206
7 cJoy Wing Terminal Cable 603203
5 m long
603204
2 m long
8 Network Patch Cable, 47738141
used between cJoy Operator 5 m long
Terminal and cJoy OT Junction
47738117
Box
2.5 m long
Consumables
Note For consumables for the cJoy controller, refer to the
JC/DPC-401 Maintenance Manual.
26 178769/B

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OS-500-SDP-MP5xx-BI Maintenance Manual

MP5xx Computer LCD Colour Monitor

Service Keyboard Operator Panel

Written by Checked by Approved by

Ship's Supply: Alarm & Function

* Note: The Network Hub is not implemented for

Figure 1 OS-500-SDP-MP5xx-BI Power Supply and Signal Wiring

SDP Operator Panel, Built-in version

The panel controller is connected via a serial line to the Computer’s

24 VDC BUILT-IN OPERATOR

Heading control (optional) Numeric & special functions panel Trackball

Figure 2 Layout of SDP Operator Panel, Built-in version

Alarm and Function Panel

Numeric and Special Function Panel

Heading wheel (optional)

DP/Manual switch panel (optional)

Alphanumeric keyboard (optional)

Figure 3 Mounting plate layout

Power supply and signal wiring

A double mains outlet socket is provided for service use only. It is

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

Note This lamp does not indicate failures in the DP controller

No network response from SDP Process Unit

General fault finding and repair

Reading power LED status and measuring supply

Fault finding flowchart

Check status of circuit

Figure 4 Fault finding flowchart for OS-500-SDP-MP5xx-BI

How to tighten screws in the termination blocks

How to check connector locks

How to clean equipment housing

How to adjust colour monitor settings

How to maintain the Computer

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 components

Preventive maintenance intervals for OS

Action Interval recommended

Table 1 Recommended maintenance intervals OS

Corrective maintenance procedures not described in this

Caution Always be careful not to strain the cables or connectors.

Note For shutting down an operator station, refer to the operator

Preparation for replacement of a part in

Caution Be careful not to strain the cables or connectors.

Finish replacement of a part in the

Preparation for calib./test of a part in the

6 Carefully lower the front edge of the bottom protective box

Finish calib./test of a part in the

PNC 100, numeric and special function panel, and

Trackball unit replacement procedures

Figure 5 Trackball unit replacement

Trackball button board replacement procedures

Joystick calibration procedures

b If not, loosen the two screws slightly that secure the

Joystick replacement procedures

9 Reconnect the two earth cables to the joystick earth

Joystick panel replacement procedures