FS-400C-R1 Maintenance Manual 175811A
FS-400C-R1 Maintenance Manual 175811A
FS-400C-R1
Maintenance Manual
Important notice:
175811 /A 1
FS-400C-R1 Maintenance Manual
Document revisions
The original signatures are recorded on the company’s logistic data system.
Document history
Rev. A First version.
2 175811/A
FS-400C-R1 Maintenance Manual
HW Configuration Status
(This information is for Kongsberg Maritime use only)
The configuration status of documents describing the FS-400C-R1 hardware for this
revision of the Maintenance Manual are listed below:
Parts Lists
Parts List FS-400C-R1 (115/230 Vac): P20803, Rev. D
Drawings
General Arrangement, FS-400/FS-400C/FS-400C-R1: 504716, Rev. C
Cabinet Layout, FS-400/FS-400C/FS-400C-R1: 504717, Rev. C
Power and Wiring Diagram, FS-400/FS-400C/FS-400C-R1: 504726, Rev. E
Wiring Diagram, FS-400C-R1: 504730, Rev. C
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FS-400C-R1 Maintenance Manual
Table of contents
HARDWARE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power supply output monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RCU master/slave interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote I/O modules (RIO modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powering RIO modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Grounding RIO modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Serial Process Bus (SPBus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powering the SPBus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Serial-line interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Field Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Field cable termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spare cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General fault finding and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reading power status LEDs and measuring supply voltages . . . . . . . . . . . . . . . 18
Equipment status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fault finding flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to tighten screws in the termination blocks . . . . . . . . . . . . . . . . . . . . . . . . 22
How to check connector locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to clean cabinets/equipment housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preventive maintenance intervals for FS-400C-R1 . . . . . . . . . . . . . . . . . . . . . . 22
CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacing PSU1 or PSU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Replacing Q1, Q2 or Q3 circuit-breaker (MCB) . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacing RIO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replacing RCU or the fan in the RCU module . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replacing SPBus-Term module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replacing SPBus-Hub module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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FS-400C-R1 Maintenance Manual
6 175811/A
Hardware Description
HARDWARE DESCRIPTION
This section describes the FS-400C-R1 hardware
configuration.
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Kongsberg Maritime FS-400C-R1
Cabinet layout
The FS-400C-R1 cabinet has been provided with 12 dedicated
positions for Remote I/O (RIO) modules (see Figure 1 for
locations).
The Remote Controller Units (RCU) A and B are located on top
of the two rails on the rear wall. Network connections for RCU
A and B are located on the left side wall.
Power supplies and magnetic circuit breakers (MCBs) are
located in the lower part of the left wall. The corresponding net
filters are located above the MCBs.
The serial line termination board (TBSS) is located in the upper
part of the left wall.
SPBus Term module (Term 1) for SPBus A is located on top of
the left wall, and corresponding SPBus Term module (Term 2)
for SPBus B is located on top of the right wall.
Hub 1 for SPBus A is located below Term 1, and Hub 2 for
SPBus B is located below Term 2. These hubs are optional.
The RIO-modules are located on the left, rear and right wall.
(CD2993C)
8 175811/A
Hardware Description
Block diagram
The block diagram of FS-400C-R1 is shown below.
Power
Mains Outlet
Q3 Sockets Power
2A
Fuses
Fuses Hand-shake signals
FL1 PSU1
Q1
115/230 Vac +24 Vdc
6A Filter Power
Supply
FL2 PSU2
Q2
115/230 Vac +24 Vdc
6A Filter Power SPBus SPBus
Supply Hub1 Hub2
Net A/B Net A/B
SPBus SPBus
Term1 Term2
Fuses Net connector Net connector
(NET 1) (NET 2)
SPBus A
SPBus B
Power supply
FS-400C-R1 handles both 230 Vac and 115Vac as mains supply,
and it is delivered with a dual power supply.
The block diagram in Figure 2 shows the power supply
principles of of FS-400C-R1.
The main power passes an MCB before it reaches the AC/DC
power supply input (see Figure 2). The MCB trips and breaks
the circuit if the current exceeds the rated MCB current.
The power supply provides 24 Vdc for the RCU and RIO
modules and for the SPBus (serial process bus).
Diodes in the PSUs, connected in series with the power supply
outputs, are provided for interconnecting the two power supplies
to obtain the following two features:
· Enable independent monitoring of the power supplies
outputs.
· Prevent an error on one power supply output to block the
output from the other.
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Kongsberg Maritime FS-400C-R1
Fuse
+ 24 Vdc
NO
PSU1 out Common
NC
RCU input
channel
NO
PSU2 out Common
NC
(Cd3006A) GND
10 175811/A
Hardware Description
GND
RIO
X2 X4
module
GND GND
RIO
X2 X4
+24 Vdc module +24 Vdc
GND GND
(CD2992A)
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Kongsberg Maritime FS-400C-R1
RCU A
X1 RIO400 #1
SPBus
Hub 1 IO
X3 X2
P1
To next
cabinet
RIO400 #2
SPBus IO
Term 1
P1 P1
X1 P2
P3
(CD3013)
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Hardware Description
Serial-line interface
The modular serial-interface motherboard TBSS is used with
two plug-in adapters installed. Each TBSS provides circuitry for
a maximum of four serial channels. Used in a configuration with
the RCU, the first handles four channels and the second handles
three channels.
Figure 6 shows the cabling between the RCU(s) and two TBSS
motherboards. A split flat-cable is used between the P19
connector on the RCU and to the P1 connector on the TBSS.
The serial-line cable from the second RCU is connected to the
P2 connector on the TBSS(s).
Serial channels
1 to 4
TBSS
P1/P2 1
Serial channels
RCU 5 to 7
TBSS
A/B P1/P2 2
(CD3014)
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Kongsberg Maritime FS-400C-R1
The Rx-line of the serial lines from the field to the two RCU A
and B, is equally connected to each controller. Only the master
controller is connected to the Tx-line via a switch to the field.
The switching is made from the watchdog & application status
signal from each controller to the TBSS card as shown in Figure
7. See TBSS Hardware Module Description for details.
P2 Tx Tx (to field)
RCU B P19
Rx Rx (from field)
P3
(CD3015)
Field Cabling
Spare cores
It may differ between vessels how and where the spare cores are
terminated. Normally, spare cores should be terminated to either
PE or IE bar.
14 175811/A
Hardware Description
Technical specifications
POWER SUPPLY REQUIREMENTS
Voltage 115/230 Vac
Typical power consumption 560 W
Maximum power consumption 1600 W
MECHANICAL SPECIFICATION
Size: width x height x depth 806 x 2202 x 805 mm
Weight 270 kg
ENVIRONMENTAL REQUIREMENTS
EMC Non-shielded cabinet
IP degree IP44
Typical heat dissipation 230 W
Maximum heat dissipation 440 W
Noise level < 40 dB
Also refer to Kongsberg Maritime Environmental Specification, reg. no.:
161011
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Fault Finding
FAULT FINDING
This section presents the fault finding principles for the
FS-400C-R1.
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Kongsberg Maritime FS-400C-R1
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Fault Finding
Equipment status
The RIO modules run built-in test programs that continually
check for faults while the system is running. Field-station
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 8 for a general fault finding
flowchart when system messages/alarms are given.
1.5 Power error reported for this One of the two power Verify presence of
FS-400C-R1. connections to this 115/230 Vac supply voltage.
FS-400C-R1 has been lost.
MCB Q1 or Q2 has tripped. Close Q1 or Q2 as
appropriate.
PSU1 or PSU2 output voltage Restart PSU1 or PSU2 power
has been cut off due to supply as appropriate.
overload.
An alarm relay output on PSU Replace PSU1 or PSU2 as
is defective. appropriate.
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Kongsberg Maritime FS-400C-R1
Is power to RIO
modules OK?
No
No
Yes
FS response is OK?
Yes
No
Yes
Contact Kongsberg Maritime
for recommended action
(Vis1126) End
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Preventive Maintenance
PREVENTIVE MAINTENANCE
This section presents the preventive maintenance
procedures for the FS-400C-R1.
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Kongsberg Maritime FS-400C-R1
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Corrective Maintenance
CORRECTIVE MAINTENANCE
This section presents the corrective maintenance
procedures for the FS-400C-R1.
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Kongsberg Maritime FS-400C-R1
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 front door of FS-400C-R1.
2 For the case of your safety, turn off the magnetic circuit
breakers (MCBs) Q1 and Q2 for PSU1 and PSU2
respectively.
3 Remove wires attached to the PSU by using a flat-bit
screwdriver.
4 Remove the faulty PSU by removing the four screws
holding the clamp bracket.
5 Attach the new PSU by holding it in position and fix the
clamp bracket by fastening the four screws.
6 Re-attach the wires to the PSU by using the flat-bit
screwdriver
7 Turn on the power lines to FS-400C-R1.
8 Turn on MCBs Q1 and Q2 for PSU1 and PSU2
respectively.
9 Verify that the RCU modules’ RUN LED is turned from
red to green after a while and that Verify that the RIO
modules’ RUN LED is turned from blinking to red and
then to green after a while.
10 Verify that the RCUs and RIO modules are working OK
by watching operator station status.
11 Close front door of FS-400C-R1.
24 175811/A
Corrective Maintenance
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 front door of FS-400C-R1.
2 For the case of your safety, turn off circuit breakers
(MCBs) that shall not be replaced.
3 Remove wires attached to the MCB by using a flat-bit
screwdriver.
4 Remove faulty MCB.
5 Attach the new MCB.
6 Re-attach the wires to the MCB by using the flat-bit
screwdriver.
7 Turn on the power lines to FS-400C-R1.
8 Turn on MCBs Q1 and Q2 for PSU1 and PSU2
respectively.
9 Verify that the RCU modules’ RUN LED is turned from
red to green after a while and that Verify that the RIO
modules’ RUN LED is turned from blinking to red and
then to green after a while.
10 Verify that the RCUs and RIO modules are working OK
by watching operator station staus.
11 Close front door of FS-400C-R1.
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Kongsberg Maritime FS-400C-R1
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Replaceable Parts and Consumables
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Kongsberg Maritime FS-400C-R1
28 175811/A
Replaceable Parts and Consumables
Consumables
Note Where-used references that are listed in the table below are
referred to the standard product. Vessel-specific field stations
can deviate from this table. See the vessel specific drawings for
the correct references in use.
List Part name Where used Part
ident. number
1 Fuse, 5x20 mm, X21: F3-F5, 43522218
6.3 A AF X31: F2-F4,
X41: F2-F4
X51: F3-F5
2 Fuse, 5x20 mm, 4 A AF X11: F1-F2 43505858
X21: F1-F2
X51: F1-F2
X61: F1-F6
3 Fuse, 5x20 mm, 2 A AF X11: F3-F4 43505833
X31: F1
X41: F1
Table 5 Consumables
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