Kongsberg K-Chief 600

Marine Automation System

Maintenance Manual

357625/B
May 2011 © Kongsberg Maritime AS
Document history
Document number: 357625
Rev. B May 2011 K-chief 600 system restore description added.

Note
The information contained in this document remains the sole property of Kongsberg Maritime AS. No
part of this document may be copied or reproduced in any form or by any means, and the information
contained within it is not to be communicated to a third party, without the prior written consent of
Kongsberg Maritime AS.
Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly
stated, but does not accept liability for any errors or omissions.

Warning
The equipment to which this manual applies must only be used for the purpose for which it was
designed. Improper use or maintenance may cause damage to the equipment and/or injury to personnel.
The user must be familiar with the contents of the appropriate manuals before attempting to operate
or work on the equipment.
Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation,
use or maintenance of the equipment.

Comments
To assist us in making improvements to the product and to this manual, we welcome comments and
constructive criticism.
e-mail: km.documentation@kongsberg.com

Kongsberg Maritime AS
www.kongsberg.com
 Maintenance Manual

Table of contents
Admonitions .............................................................................................................4
Glossary....................................................................................................................5
INTRODUCTION ................................................................ 7
Purpose .....................................................................................................................7
Safety rules ...............................................................................................................8
PREVENTIVE MAINTENANCE ............................................. 9
Maintenance schedule ..............................................................................................9
Recommended maintenance intervals ......................................................................9
Cleaning buttons, panels and displays....................................................................10
Checking Watch Calling Panels .............................................................................10
Cleaning or replacing the MP7900 computer dust filter ........................................10
Checking the MP7900 computer cooling fans ....................................................... 11
UPS and battery care ..............................................................................................12
Tightening screws in termination blocks................................................................12
Checking connector locks ......................................................................................13
TROUBLESHOOTING........................................................ 14
Troubleshooting the MP7900 computer .................................................................15
Troubleshooting the UPS .......................................................................................16
Typical alarms and conditions...................................................................... 16
Silencing the alarm .................................................................................... 18
Running automatic battery tests .................................................................. 18
Troubleshooting the Watch Calling system............................................................19
DPU error codes .....................................................................................................20
DPU communication errors....................................................................................21
PSO-P reset.............................................................................................................24
CORRECTIVE MAINTENANCE ........................................... 25
Rebooting the Operator Station ..............................................................................26
Restoring the K-Chief 600 system .........................................................................26
Cleaning the Operator Panel’s mechanical trackball..............................................32
Replacing Watch Calling Panels ............................................................................35
Replacing and testing UPS batteries ......................................................................38
Replacing UPS batteries .............................................................................. 38
Testing new batteries .................................................................................. 40
Replacing Distributing Processing Units ...............................................................41
A SERVICE CONTACT FORM ................................................ 45

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Kongsberg K-Chief 600

Admonitions
The following admonitions found throughout this manual mark special messages to alert
the user of specific information concerning of the personnel, the equipment or the process.
WARNING
Text set off in this manner provides a warning notice that failure to
follow the directions in this WARNING can result in bodily harm or
loss of life and/or extensive damage to equipment.

Caution
Text set off in this manner provides a warning notice that failure to follow
the directions in this CAUTION can result in damage to equipment.

Note
Text set off in this manner presents clarifying information or specific instructions
pertinent to the immediate instruction.

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 Maintenance Manual

Glossary
BIST Built-In System Test
CAN Controller Area Network
CRP Control Room Panel
DPU Distributed Processing Unit
INP Input Panel
I/O Input/Output
LAN Local Area Network
LCD Liquid Crystal Display
LED Light Emitting Diode
OS Operator Station
RAM Random Access Memory
UPS Uninterruptible Power Supply
WBU Watch Bridge Unit
WCU Watch Cabin Unit

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 Introduction

Introduction

Purpose
The purpose of this Maintenance Manual is to present information required to perform
maintenance on the Kongsberg K-Chief 600 Marine Automation System.
The manual includes the following main chapters:

Topics
• Preventive maintenance on page 9
– This chapter describes the preventive maintenance actions to be carried out by
the maintenance engineer, and presents necessary actions and when they must
be carried out.
• Troubleshooting on page 14
– This chapter presents basic instructions for fault location and troubleshooting,
including relevant actions to be made.
• Corrective maintenance on page 25
– This chapter describes the corrective maintenance to be carried out by the
maintenance engineer, and contains specific procedures and actions required for
the replacement of units.
Note
This Maintenance Manual is intended for trained maintenance technicians or engineers
with experience of electronic and digital circuits, computers and electromechanical
design.

The level of information is based on Kongsberg Maritime’s maintenance philosophy:

The on-board technical personnel shall, with the help of the documentation and the
system’s built-in test functions, be able to identify malfunctions, locate the fault, and
replace major parts, modules and components. He/she shall however not attempt to
repair the units.
If you have any questions or problems with your K-Chief 600 system, contact your
nearest Kongsberg Maritime service office for advice or to request service.

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Kongsberg K-Chief 600

Table 1 Head office support

E-mail support km.support.dc@kongsberg.com

E-mail spare parts km.support.dc.spare@kongsberg.com
E-mail warranty km.support.dc.war@kongsberg.com
Phone +47-815-73700
+47-815-35355 24h
Fax +47-850-28082

Safety rules
Note
Kongsberg Maritime’s health and safety system must be adhered to at all times.
Kongsberg Maritime accepts no responsibility for any damage or injury to the system,
ship or personnel caused by drawings, instructions or procedures not prepared by
Kongsberg Maritime.

The Kongsberg K-Chief 600 Marine Automation System operates on 115/230 VAC
50/60 Hz.
WARNING
This voltage may be lethal!

The following safety precautions must be followed at all times during installation and
maintenance work:
• Always switch off all power before installation or maintenance. Use the main
circuit breaker, and label the breaker with a warning sign that informs others that
maintenance or installation work is being carried out on the system.
• Do not open cabinet doors while in rough seas. It may swing open suddenly and
cause damage or injury.
• For safety reasons during troubleshooting on the equipment with power ON, two
persons must always be present.
• Read and understand the first aid instructions for electric shock.
• Whenever maintenance is carried out, it is essential that a first aid kit is available,
and that the maintenance personnel are familiar with the first aid instructions for
electrical shock.
• The installation personnel shall be sufficiently qualified, and proper caution shall be
taken to avoid injuries or damage to life, health, environment, equipment and property.
• Certified lifting equipment must be used when handling heavy units.

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 Preventive maintenance

Preventive maintenance

Maintenance schedule
Preventive maintenance routines must be performed regularly and effectively to ensure
that the equipment is kept in top condition. Kongsberg Maritime recommends the
following preventive maintenance schedule for the K-Chief 600 Marine Automation
System:
• Weekly
• Monthly
• Every six months
Kongsberg Maritime recommends that the operation of effected units and its functions
is checked after any major maintenance. By major maintenance is understood the
removing, testing, calibrating and re-installing or replacement of sensors and system
components such as Operator Station components or DPUs.

Recommended maintenance intervals

The following table gives maintenance intervals as recommended by Kongsberg
Maritime. Based on own experience and the complexity of the system, on-board
personnel may establish additional maintenance check points as required.

Table 2 Recommended maintenance intervals

Action Interval recommended Procedure

Check panels and displays Weekly Cleaning buttons, panels and displays on page 10
Checking Watch Calling Panels on page 10
Check computers and UPS Monthly Cleaning or replacing the MP7900 computer dust
filter on page 10
Checking the MP7900 computer cooling fans on
page 11
Troubleshooting the UPS on page 16
Check / tighten screws / Every six months Tightening screws in termination blocks on page 12
connector locks Checking connector locks on page 13

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Cleaning buttons, panels and displays

This procedure is applicable for all operator equipment (for example OS displays and
CRP buttons).
1 Clean the surface of the buttons, panels and displays by using a clean damp cloth.
Use a solution of warm, mild soapy water. The cloth shall not be too wet.
Alcohol or similar non-abrasive cleaners can also be used to clean the surface.

Checking Watch Calling Panels

This procedure explains how to perform a lamp test to check the Watch Calling panels.
1 Push the LAMP TEST button.
All indicators should be lit and the buzzer turned on. The display (if any) should
display configuration data.
2 If the test fails, refer to Troubleshooting the Watch Calling system on page 19. for
further actions.
3 If one or more LEDs fail to illuminate or the buzzer is silent, replace the unit.

Cleaning or replacing the MP7900 computer

dust filter
This procedure explains how to clean or replace the MP7900 computer dust filter.
WARNING
Computer performance is dependent on sufficient air flow through
the chassis. A clogged or damaged dust filter may cause the
computer to break down.

Prior to performing the procedure, check that the following actions have been taken:
• Power to the MP7900 computer must have been turned off.
• If replacing the filter, check that the new filter is identical.
1 Remove the front cover securing screw.
2 Remove the front cover and locate the dust filter.

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 Preventive maintenance

Figure 1 Location of dust filter

3 Carefully remove the filter.

4 Either perform step 4a or 4b:
a Cleaning: Clean the filter using a vacuum cleaner. Clean both sides of the
filter so it becomes dust-free.
b Replacing: Replace the filter if the old one is extremely dirty or it is worn.
5 Insert the filter, verify proper installation and reassemble the computer.

Checking the MP7900 computer cooling fans

This procedure explains how to check the MP7900 computer cooling fans. The computer
chassis holds two cooling fans, an inlet fan behind the dust filter and an outlet fan at
the rear.
WARNING
Computer performance is dependent on sufficient air flow through
the chassis. Inactive cooling fans may cause the computer to break
down.

Prior to performing the procedure, check that the following action has been taken:
• Power to the MP7900 computer must have been turned off.
1 Remove the front cover securing screw.
2 Remove the front cover and the dust filter.
3 Locate the inlet fan and verify that the fan is running.

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Kongsberg K-Chief 600

Figure 2 Location of cooling fans

4 Reassemble the computer.

5 Locate the outlet fan and verify that the fan is running.
6 If needing fan replacement, contact Kongsberg Maritime for service.
WARNING
Do not check the fan by entering objects into the housing, as this
may damage the unit.

UPS and battery care

Note
This section is copied from Eaton UPS User’s Guide (document no. 164201718 Rev. 2).

For the best preventive maintenance, keep the area around the UPS clean and dust‐free.
If the atmosphere is very dusty, clean the outside of the system with a vacuum cleaner.
For full battery life, keep the UPS at an ambient temperature of 25 °C (77 °F).

Tightening screws in termination blocks

This procedure is applicable for all units where cables are terminated using termination
blocks (for example DPUs).

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 Preventive maintenance

1 Use an isolated-handle screwdriver to tighten any loose screws on all termination

blocks.
WARNING
Observe which terminals are connected to 115/230 VAC. This voltage
may be lethal!

Checking connector locks

This procedure is applicable for all units where cables are terminated using connector
locks (for example computers and displays).
1 Use a screwdriver to tighten locking screws on the connector houses.
2 Check if 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.
3 Check that cable strain reliefs are tightened properly.

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Kongsberg K-Chief 600

Troubleshooting

This chapter presents basic instructions for fault location and troubleshooting.

Topics
→ Troubleshooting the MP7900 computer on page 15
→ Troubleshooting the UPS on page 16
→ Troubleshooting the Watch Calling system on page 19
→ DPU error codes on page 20
→ DPU communication errors on page 21
→ PSO-P reset on page 24

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 Troubleshooting

Troubleshooting the MP7900 computer

If a fault 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.
Note
If you are not able to correct an error situation yourself, you should contact your nearest
Kongsberg Maritime service office for advice or to request service.

The fault-finding table below assumes that the problem is caused by the K-Chief 600
computer itself and that no external factors are involved.

Table 3 MP7900 computer fault-finding situations

ID Symptoms Probable error source Corrective action

No visible or audible sign of power External supply voltage is turned Check the 115/230 VAC power
1 present at the OS. Fans are not off or circuit-breaker fuse has supply.
blowing. tripped.
Internal power supply defect. Contact Kongsberg Maritime.
Applications are not loading when Defective file system. Contact Kongsberg Maritime.
2 booting the OS. Only blue screen
displayed.
The OS does not respond over Network task not running. Reboot the OS.
3 network on either channel.
The OS responds over network on Defective network card or network Contact Kongsberg Maritime.
4 only one of three channels. part of main board.
The OS crashes or hangs Possible defective RAM memory Contact Kongsberg Maritime.
5 unexpectedly. card.

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Kongsberg K-Chief 600

Troubleshooting the UPS

Note
This section is copied from Eaton UPS User’s Guide (document no. 164201718 Rev. 2).

Typical alarms and conditions

To check the UPS Status menu for a list of active alarms:
1 Press any button on the front panel display to activate the menu options.
2 Press the ↓ button until UPS STATUS displays.
3 Press the Enter button to display the list of active alarms.
To check the Event Log for a history of conditions:
1 Press any button on the front panel display to activate the menu options.
2 Press the ↓ button until EVENT LOG displays.
3 Press the Enter button to display the list of conditions.
The following table describes typical alarms and conditions.

Table 4 Typical alarms and conditions

Alarm or Condition Possible Cause Action

On Battery A utility failure has occurred and the The UPS is powering the equipment
UPS is in Battery mode. with battery power. Prepare your
equipment for shutdown.
LED is on.

1 beep every 5 seconds.

On Battery The UPS is in Battery mode and the This warning is approximate, and
battery is running low. the actual time to shutdown may
vary significantly. Depending
on the UPS load and number of
LED is flashing slowly. Extended Battery Modules (EBMs),
the “Battery Low” warning may
1 beep every second. occur before the batteries reach 25%
capacity.
On Bypass The UPS is in Bypass mode. The equipment transferred to bypass
utility power. Battery mode is not
available and your equipment is not
protected; however, the utility power
LED is on. continues to be passively filtered
by the UPS. Check for one of the
1 beep every 5 seconds. following alarms: overtemperature,
overload, or UPS failure.
On Bypass The UPS is on bypass while The equipment transferred to bypass
operating on the High Efficiency utility power as a normal function
setting. of High Efficiency operation.
Battery mode is available and your
LED is on. equipment is protected.

No beeping.

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 Troubleshooting

Table 4 Typical alarms and conditions (cont’d.)

Alarm or Condition Possible Cause Action

Batteries Disconnected The UPS does not recognize the If the condition persists, contact
internal batteries. your service representative.
The batteries are disconnected. Verify that all batteries are properly
LED is on. connected. If the condition persists,
contact your service representative.
1 beep every second.
Overload Power requirements exceed the Remove some of the equipment
UPS capacity (greater than 100% of from the UPS. The UPS continues to
nominal). operate, but may switch to Bypass
LED is on. mode or shut down if the load
increases. The alarm resets when the
condition becomes inactive.
1 beep every second.
Overtemperature The UPS internal temperature is If the UPS transferred to Bypass
too high or a fan has failed. At the mode, the UPS will return to normal
warning level, the UPS generates operation when the temperature
the alarm but remains in the current drops 5°C below the warning level.
LED is on. operating state. If the temperature If the condition persists, shut down
rises another 10°C, the UPS transfers the UPS. Clear vents and remove any
1 beep every second. to Bypass mode or shuts down if heat sources. Allow the UPS to cool.
bypass is unusable. Ensure the airflow around the UPS
is not restricted. Restart the UPS.
If the condition continues to persist,
contact your service representative.
Battery Overvoltage The UPS battery voltage is too high. The UPS turns off the charger until
the next power recycle. Contact your
service representative.
LED is on.

1 beep every second.

Site Wiring Fault “i” and “G (AU)” Models Only. Rotate the Schuko input connector.
The polarity of the UPS input power
cord connector is incorrect.
LED is on. “i” and “G (AU)” Models Only. Have a qualified electrician correct
The ground wire connection does the wiring. If the UPS is installed to
1 beep every second. not exist. input supply without ground, disable
the “Site Wiring Fault Alarm”
setting .
The UPS does not provide the The batteries need charging or Apply utility power for 48 hours
expected backup time. service. to charge the batteries. If the
condition persists, contact your
service representative.
Power is not available at the UPS The UPS is in Standby mode. Supply power to the connected
output receptacles. equipment: Press the On/Off button
for at least 1 second, until the front
panel displays “UPS starting...”
The UPS does not start. The power cord is not connected Check the power cord connections.
correctly.
The Remote Emergency Power-off If the UPS Status menu displays the
(REPO) switch is active or the “Remote Emergency Power Off”
REPO connector is missing. notice, inactivate the REPO input.

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Kongsberg K-Chief 600

Table 4 Typical alarms and conditions (cont’d.)

Alarm or Condition Possible Cause Action

The UPS operates normally, The equipment is not connected Verify that the equipment is plugged
but some or all of the protected correctly to the UPS. into the UPS receptacles.
equipment is not on.
Battery test did not run or was One of the conditions listed in the Resolve the condition, then restart
interrupted. “Running Automatic Battery Tests” the test.
procedure was not present. See
Running automatic battery tests on
page 18.
The UPS does not transfer to Bypass The bypass utility does not qualify. Check the bypass utility. The UPS
mode. is receiving bypass utility power
that may be unstable or in brownout
conditions.
Bypass mode is disabled. Check that the Bypass settings
are configured correctly. Contact
Kongsberg Maritime.

Silencing the alarm

Press any button on the front panel display to silence the alarm. Check the alarm
condition and perform the applicable action to resolve the condition. If the alarm status
changes, the alarm beeps again, overriding the previous alarm silencing.

Running automatic battery tests

Automatic battery tests run approximately every 30 days, unless disabled. During the
test, the UPS transfers to Battery mode and discharges the batteries for 25 seconds
under the existing load.
Note
The “UPS on Battery” notice and the “Battery Low” alarm do not activate during
a battery test.

For automatic battery tests to run:

• The “Automatic Battery Support Tests” setting must be enabled.
• The UPS must be in Normal mode, with no active alarms.
• The batteries must be fully charged.
• The bypass voltage must be acceptable.
• No manual battery test was initiated previously in the same charging cycle.
To pass the battery test, the battery voltage must remain above the threshold value during
discharge.

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 Troubleshooting

Troubleshooting the Watch Calling system

The troubleshooting of the Watch Bridge and Watch Cabin Units are identical. Use
the following flow diagram to determine the problem when troubleshooting the Watch
Calling system.

Figure 3 WBU/WCU troubleshooting flow diagram

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Kongsberg K-Chief 600

DPU error codes

All Distributed Processing Units have a Built-In Self-Test (BIST) functionality. These
tests report errors to the Operator Stations on the system channel. The following table
gives an overview of the error codes and gives appropriate actions to be taken:
Error code Error description Action
49 RAM fail Replace the module.
48 Transmitter overcurrent (RAi-16) Check all channels for high current load.
47 Fuse fail (RDi-32) Check all inputs.
46 CPU Board temperature high Check the ambient temperature.
45 Configuration fail Value = Config fail channel *64 + 45. Tag
details gives detailed information.
42 EEPROM read failure C3 and C4 only.

CAN 1 — plug X8
40 CAN controller bus off Check CAN connections.
39 CAN controller error status set
38 CAN controller overrun
37 Rx queue overrun
36 HP Tx queue overrun
35 LP Tx queue overrun
34 Transmit fault

CAN 1 — plug X9
30 CAN controller bus off Check CAN connections.
29 CAN controller error status set
28 CAN controller overrun
27 Rx queue overrun
26 HP Tx queue overrun
25 LP Tx queue overrun
24 Transmit fault

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 Troubleshooting

DPU communication errors

If the Operator Station gives a communication error for one of the Distributed Processing
Units, the LEDs on the front panel of the DPU in question must be checked.

Figure 4 DPU front panel LED indicators (typical)

Power indicator
1 Locate the DPU for which the communication error is given.
2 Check the power LED indicator and, if applicable, perform corrective actions
according to the table below.
Power mode Power LED Corrective actions
Power OK Green None.
Power with wrong Red Correct the power polarity and check again.
polarity If the Power indicator is still red, replace the
DPU.
No power Dark Check power supply and wiring.
If the power supply and wiring is OK, replace
the DPU.

Fuse failure indicators

Analogue and digital inputs are protected by internal circuit breakers. Short-circuiting
due to faulty sensors and/or damaged wires are indicated by the DPU. Note that these
indicators are only available for the DPUs listed in this section.

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Kongsberg K-Chief 600

Indication of fuse failure can either be for multiple channels simultaneously (typically
displayed by a LED mounted in the vicinity of the power LED) or for separate channels
(displayed by the LED also giving channel status). See the tables below for details.
1 Locate the DPU for which the communication error is given.
2 Check the fuse failure indicator(s) and, if applicable, perform corrective actions
according to the tables below.
Multiple channels
Applicable for RDi-32 (digital channels 1 to 32)
Channel mode Fuse blown LED Corrective actions
All channels are OK Dark None.
24 V to all digital Red Isolate the fault by first pulling out one by
channels is broken one terminal block. After finding the relevant
terminal block, unscrew wires for each sensor
until the faulty sensor has been identified.
Replace the sensor.
If sensors with wiring are OK, replace the DPU.

Separate channels
Applicable for RAi-16 (analogue channels 1 to 16)
Channel mode Fuse blown LED Corrective actions
Inactive channel Dark None.
24 V fuse is broken Red Disconnect 10–20 sec.
If the sensor with wiring is OK, replace the
DPU.

Separate channels
Applicable for RIO-C2 (digital channels 9 to 16), RIO-C4 (digital channels 9 to 12)
Channel mode Fuse blown LED Corrective actions
Inactive channel Dark None.
Active channel Green None.
24 V is broken Red Unscrew the sensor connected to the reported
channel. Replace the sensor.
If the sensor with wiring is OK, replace the
DPU.

Status indicators
1 Locate the DPU for which the communication error is given.
2 Check each status LED indicator and, if applicable, perform corrective actions
according to the table below.

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 Troubleshooting

Operational Run LED Watch Dog Info. LED End Init. Corrective actions
mode LED LED
Normal operation Green Dark Flashing Green The unit seems to be
yellow working OK.
Check the cabling.
Restart the unit by turning
power off and then on
again.
If the Operator Station
is still reporting an error
replace the DPU.
No application Dark Red Dark Green This indicates that the
loaded Distributed Processing
Unit has boot software
installed, but no basic
software. Use the Rio
load program to install the
appropriate software.
Not initialised Dark Red Dark Dark Return the item to
Kongsberg Maritime.
Application Dark Red Dark Green Restart the unit by turning
stopped power off and then on
again.
If the Watch Dog indicator
is still lit replace the DPU.

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Kongsberg K-Chief 600

PSO-P reset
A reported communication error on the DPU’s Control Panel may be a result of a short
circuit or otherwise tripped fuse in the PSO-P power supply.

The PSO-P has 2 power-in (1–2 X) and 5 power-out (3–7 X), and
status is displayed using LED indicators.
Use these indicators, installation drawings and unit markings
to identify any tripped circuit.

Fuses are found on the side of the PSO-P along with a label
relating switches to their corresponding circuits.
To reset, Push OFF and back ON, and then verify LED indication.

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 Corrective maintenance

Corrective maintenance

Corrective maintenance procedures must be performed to replace faulty parts in the event
of a malfunction. The corrective maintenance performed by the operator is limited to
content of this manual.
If you are not able to correct an error situation yourself, you should contact your nearest
Kongsberg Maritime service office for advice or to request service.

Topics
→ Rebooting the Operator Station on page 26
→ Restoring the K-Chief 600 system on page 26
→ Cleaning the Operator Panel’s mechanical trackball on page 32
→ Replacing Watch Calling Panels on page 35
→ Replacing and testing UPS batteries on page 38
→ Replacing Distributing Processing Units on page 41

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Kongsberg K-Chief 600

Rebooting the Operator Station

This procedure can only be performed by a user with privileges set to Master or a higher
level. When the correct user level is set, the Shut down button will be visible from the
Menu button. Please refer to the K-Chief 600 Operator Manual (document number
338857) for further information.
1 Select Menu→System→Shut down in the top bar of the K-Chief 600 application.

This opens the Shut down dialogue.

2 Click Shut down computer.

The computer shuts down.
3 Press the Power button on the MP7900 computer.
The K-Chief 600 application will automatically start up. This may take a few
minutes.

Restoring the K-Chief 600 system

This procedure can be used to restore the Windows 7 operating system and the Operator
Station software if SSD hard-disk failure occurs in the Operator Station.
Do the following steps to restore the OS from the backup USB hard-disk.

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 Corrective maintenance

1 Locate the defect OS. Disconnect the power cable on the computer.
2 Replace the defect hard-disk with a new one.
3 Connect the keyboard and USB backup hard-disk to USB ports.
4 Reconnect the power cable and push the Power button.
5 When the computer starts, push the F9 button (F9 = Boot Menu).

6 Select USB Device as Boot device.

7 Select WD My Passport from the list of devices.

Note
Device type and model can vary because it is project dependent.

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Kongsberg K-Chief 600

8 Select US in the drop-down list, and click on the Next button.

9 Click on the No button.

10 Select “Restore your computer using a system image…” , and click on the Next
button.

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 Corrective maintenance

11 Select “Select a system image”, and click on the Next button.

12 Choose correct backup file according to the OS number. Click on the Next button.

13 Select the backup file, and click on the Next button.

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Kongsberg K-Chief 600

14 Click on the Next button.

15 Click on the Finish button.

16 Confirm by clicking on the Yes button.

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 Corrective maintenance

17 Wait until the process is completed. Disconnect the USB backup device when it
is done.

18 Restart the computer.

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Kongsberg K-Chief 600

Cleaning the Operator Panel’s mechanical

trackball
This procedure is used to clean the mechanical trackball installed on the Control Room
Panels (CRP) and Input Panels (INP).
Note
The trackball should only be cleaned if the screen cursor does not respond correctly with
the trackball movements.

1 Release and remove the

trackball protection cover.
Insert a screwdriver into
one of the two holes at
the top next to the top
pushbuttons and lift to
release — if one end is
difficult to release try the
other.

2 Verify that the pushbutton

plate is a replacable model
with mechanical sensors.
Look for three large screws
— head in front indicate
optical sensor and shall not
be cleaned in the field.

If the plate is fastened with 4 If the plate is fastened with

small screws only — proceed. 4 small and 3 large screws
— Stop! Please contact
Kongsberg Maritime for more
information.

3 Release the four nuts (only) attaching the pushbutton plate to

the panel — three large screws are holding the trackball parts
together and may be difficult to reconnect.

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 Corrective maintenance

4 Remove the pushbutton plate.

5 Remove the trackball from the socket.

6 Clean the trackball, the socket and 3 mechanical rollers.

Clean the pushbutton electrical contacts if needed. Use an
evaporating cleaning liquid, preferably containing alcohol —
caution: water may damage the electronics!

7 Replace the trackball into the socket. Replace the pushbutton

plate. Pushbutton contacts must be connected — notice that
the nut-holes and four plastic spikes are asymmetrical, so the
pushbutton plate will only fit in one direction.

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Kongsberg K-Chief 600

8 Replace the four screws attaching the pushbutton plate to the

panel. Fasten the screws so that the pushbutton electrical
contacts are connected — using force may damage the
electronics.

9 Replace the protection

cover — notice that
the four asymmetrical
connectors, put them over
the connectors on the
pushbutton plate and press
to fasten.

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 Corrective maintenance

Replacing Watch Calling Panels

Replacing a Watch Calling Panel is performed in two main steps, first by physically
replacing the unit, and then by configuring the new unit using the K-Chief 600
application.

Disassembly
1 Remove the mounting screws.
2 Lift the panel up.
3 Unscrew and remove the left side cover plate.
4 Slide the top panel out.
5 Disconnect the cable.
6 Write down the LMT address for both the old and the new unit.
Each Watch Bridge Panel has an unique ID, called a LMT address. This address
can be found on a label placed on the side of the panel.

Figure 5 Label with LMT address

The LMT address can be found at the bottom of the label. In this case:
NORCTRLWCPANEL00000000053564

Figure 6 Label with the last part of the LMT address

You can also find the LMT address by pushing the LAMP TEST button. Be aware
that the power must be connected if you want to find the number this way. The LMT
address will be displayed in line 3 on the LCD display.

Disassembly
7 Connect the cable for the new unit.
8 Slide it into place. Be careful not to damage the cable.
9 Mount the side cover and make sure the screws are securely tighten.

OS configuration
Note that panel configuration only can be performed from the master Operator Station.
10 Change the user privileges to Master or a higher level.

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Kongsberg K-Chief 600

11 Click on the Watch Call button in the top bar on the K-Chief 600 application using
Operation Station 1 (OS1).
12 Extend the dialogue using the chevron button.

13 Select the Network tab. Locate the module which is not communicating with the
system.

14 Click on the serial number cell and enter the new serial number (without leading
zeros). Wait about 30 seconds. The communication with the new panel will
automatically be re-established.

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 Corrective maintenance

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Kongsberg K-Chief 600

Replacing and testing UPS batteries

Note
This section is copied from Eaton UPS User’s Guide (document no. 164201718 Rev 2).

Expected life of the UPS batteries is five years. The replacement interval recommended
by Kongsberg Maritime is four years.

Replacing UPS batteries

When to replace batteries

When the indicator illuminates, the audible alarm beeps, and the “Battery Needs
Service” alarm displays, the batteries may need replacing. Contact your service
representative to order new batteries.

Replacing Tower UPS internal batteries

Caution
The UPS internal batteries are heavy. Use caution when handling the heavy
batteries.

The internal batteries are located behind the UPS front cover. The internal batteries are
packaged together as one unit for easier handling.
To replace the batteries in the UPS:
1 Remove the UPS front cover.
To remove the cover, push down on the top of the cover and pull the cover toward
you to unclip it from the cabinet.
Note
A ribbon cable connects the LCD control panel to the UPS. Do not pull on the
cable or disconnect it.

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 Corrective maintenance

Figure 7 Removing the UPS front cover

2 Remove and retain the two screws holding the internal battery connector. Disconnect
the internal battery connector.

Figure 8 Replacing the UPS internal batteries

3 Remove and retain the two screws holding the battery cover plate. Grasp an edge of
the battery cover plate and pull it forward gently. Remove and retain the battery
cover plate.
4 Carefully pull the handle on the battery tray and slide the battery package slowly out
onto a flat, stable surface; use two hands to support the battery package.

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Kongsberg K-Chief 600

Note
Verify that the replacement batteries have the same rating as the batteries being
replaced.

5 Slide the new battery package into the cabinet. Push the battery package in firmly.
6 Replace the battery cover plate into the slots at left, threading the battery connector
through the access slot. Reinstall the retained screws.
Caution
A small amount of arcing may occur when connecting the internal
batteries. This is normal and will not harm personnel. Connect the
cables quickly and firmly.

7 Reconnect the internal battery connector. Connect red to red, and black to black.
Press the two parts tightly together to ensure a proper connection.
8 Place the connector between the screw mounts and reinstall the retained screws.
9 Replace the UPS front cover.
To replace the cover, verify that the ribbon cable is protected, then insert the clips on
the back of the cover into the cabinet and push firmly to snap the cover into place.
10 Continue to the Testing new batteries section below.

Testing new batteries

To test new batteries:
1 Plug the UPS into a power outlet for 48 hours to charge the batteries.
2 Press any button to activate the menu options.
3 Select CONTROL then START BATTERY TEST.
The UPS starts a battery test if the batteries are fully charged, the UPS is in Normal
mode with no active alarms, and the bypass voltage is acceptable.
During the battery test, the UPS transfers to Battery mode and discharges the
batteries for 25 seconds. The front panel displays “Battery test running” and the
percentage of the test completed.

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 Corrective maintenance

Replacing Distributing Processing Units

Distributed Processing Units are located in dedicated cabinets. DPUs are designed to
be easily replaceable, using the same procedure. Make sure the replacement unit is
of exactly the same type as the failing unit. The type specification is available on the
label for each unit.
Caution
Never replace more than one DPU unit at a time.

Replacing a DPU is performed in two main steps, first by physically replacing the unit,
and then by configuring the new unit using the K-Chief 600 application.

Disassembly
Do the following:
1 Disconnect all connector plugs, starting with power. Always
power off the DPU before disconnecting further.
ESU and SCU have dual redundant power.
2 Dismount cable screen termination bracket and store the
screws safely, as loose metal objects could cause damage
and short-circuiting.
3 Detach bracket from DPU with cables and connector plugs
attached to bracket.

Figure 9 DPU electrical disconnection

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Kongsberg K-Chief 600

Figure 10 DPU cable bracket

Figure 11 DPU mechanical disconnection

4 Loosen the mounting screws but do not remove.

5 Lift the DPU off the screws and remove the unit.
6 Pack the faulty unit using the packing case from the
replacement unit, and return to Kongsberg Maritime for
repair.

Reassembly
7 Reverse mechanical disconnection procedure and tighten screws properly.
8 Reverse electrical disconnection procedure, and attach power plug last.
9 Note the DPU serial number.
10 Seal the DPUs cabinet properly.

OS configuration
11 Select Menu→Tools→DPU replacement in the top bar of the K-Chief 600 application.

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 Corrective maintenance

This opens the DPU replacement dialogue, showing a list of DPUs that are defect
or not configured.

12 Right click the requested DPU from the list to get access to the Start scan button.

13 Click Start scan.

This opens the Replace DPU dialogue, showing serial numbers for new hardware
units.

14 Select the requested DPU and click OK.

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Kongsberg K-Chief 600

The DPU will load relevant node address software and automatically be configured.
This may take a few minutes.

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 Appendix A Service contact form

Appendix A
Service contact form

When requesting service from Kongsberg Maritime, please fill in and submit the
following contact form:

Purchasing
Service ordered by
Company name

Address

Purchase/order no.
Your ref.
Name of contact person
(in block letters)

E-mail address, contact

person
Name of vessel
Date/port of service

Invoicing
Invoicing/mailing
address if different
from above
Company name

Address

E-mail address
Accounts

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Kongsberg K-Chief 600

Support details
Priority level (*)
Yard/Hull/IMO no.
Location of vessel
Agent details

Further vessel schedule

Further agent details

Description of faults

Actions done by crew

(*) Explanation of priority level:

• High: System is not functioning and/or operation of vessel cannot be performed.
• Medium: Part of system is not in working order, but vessel operation can still be
performed.
• Low: Queries about functions/system and/or parts to be replaced. The system is
operational.

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 Appendix A Service contact form

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©2011 Kongsberg Maritime