COP05 OS-555 Built-in WS Mk2

Operator Station
Maintenance Manual

Kongsberg Maritime Part numbers:

COP05 K-Pos OS-555-BI SA WS Mk2: 370930
COP05 K-Chief OS-555-BI WS Mk2: 370935
COP05 K-Pos OS-555-BI Int WS Mk2: 370929
COP05 HiPAP-501 OS-555-BI WS Mk2: 370933
COP05 General OS-555-BI WS Mk2: 370934
COP05 K-Thrust OS-555-BI WS Mk2: 370928
COP05 K-Chief OS-555-BI CANBus WS Mk2: 373521
K-Chief OS-555-BI EAS WS Mk2: 377685

Display
Computer Service keyboard

Operator Panel Main Mounting Plate Side Plate

371472/E
July 2013 © Kongsberg Maritime AS
Document history
Document number: 371472
Rev. A May 2012 First version.
Updated Appendix A / Corrected the list of applicable drawings
Rev. B May 2012
for each item listed on the front page
Rev. C June 2012 Added CANBus parts list
Rev. D January 2013 The following changes have been made:
• K-Chief OS-555 EAS WS Mk2 (Part no. 377685) incl. kit
description has been added to KM product range.
• Former Dual Input Power kits (313307 and 313400) has been
replaced by kit no. 357742.
Rev. E July 2013 New display MD27. Information about alphanumeric keyboard
connection is updated. The alphanumeric keyboard is connected
directly to the MPxxxx computer.

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.

Comments
To assist us in making improvements to the product and to this manual, we welcome comments and
constructive criticism.
e-mail: [Link]@[Link]

Kongsberg Maritime AS
[Link]
 Maintenance Manual

Table of contents
Glossary....................................................................................................................5
HARDWARE DESCRIPTION................................................ 7
Operator Interfaces ...................................................................................................7
Display ........................................................................................................ 7
Operator panel .............................................................................................. 7
BU-xxx panels ......................................................................................... 7
ALC panel............................................................................................... 8
Heading Wheel panel ............................................................................... 8
Input panel .............................................................................................. 8
Joystick panel .......................................................................................... 8
Drop-In kits ............................................................................................. 8
Operator panel types ..................................................................................... 9
COP05 K-Pos OS-555-BI SA WS Mk2 and COP05 K-Pos OS-555-BI
Int WS Mk2 Operator panel .................................................................... 10
COP05 K-Thrust OS-555-BI WS Mk2 Operator panel.............................. 11
COP05 K-Chief OS-555-BI WS Mk2 Operator panel ............................... 12
COP05 General OS-555-BI WS Mk2 and COP05 HiPAP-501
OS-555-BI WS Mk2 Operator panel........................................................ 13
Alphanumeric keyboard .............................................................................. 14
Main mounting plate and Side plate configurations ...............................................14
Main mounting plate layout for COP05 General OS-555-BI WS Mk2,
COP05 K-Pos OS-555-BI Int WS Mk2, COP05 K-Thrust OS-555-BI WS
Mk2, COP05 K-Chief OS-555-BI WS Mk2, COP05 K-Chief OS-555-BI
CANBus WS Mk2 and K-Chief OS-555-BI EAS WS Mk2............................ 15
Main mounting plate layout for COP05 K-Pos OS-555-BI SA WS
Mk2........................................................................................................... 16
Side plate layout for K-Pos OS-555-BI......................................................... 17
COP05 K-Chief OS-555-BI WS Mk2 kits .................................................... 18
Main mounting plate layout for COP05 HiPAP-501 OS-555-BI WS
Mk2........................................................................................................... 25
Side plate layout for COP05 HiPAP-501 OS-555-BI WS Mk2 ....................... 26
Power supply and signal wiring .............................................................................27
All OS systems (except HiPAP) ................................................................... 27
HiPAP systems ........................................................................................... 29
Network connections ..............................................................................................30
Computer ................................................................................................................31
FAULT FINDING .............................................................. 33
Panel and Alarm lamps and buttons .......................................................................33
General fault finding and repair..............................................................................33
Reading power LED status and measuring supply voltages ..................................34

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COP05 OS-555 Built-in WS Mk2

All OS systems ........................................................................................... 34

The message system ...............................................................................................34
Online help .............................................................................................................34
Fault finding flowchart ...........................................................................................35
PREVENTIVE MAINTENANCE ........................................... 36
How to tighten screws in the field termination blocks ...........................................36
How to check connector locks................................................................................36
How to check buttons, lamps and panels ...............................................................36
BU-DP panel .............................................................................................. 36
BU-TC panel .............................................................................................. 37
BU-AUT panel ........................................................................................... 38
Input panel ................................................................................................. 39
How to clean the console housing ..........................................................................40
How to adjust the display settings ..........................................................................40
How to clean the display screen surface ................................................................41
How to maintain the computer ...............................................................................41
How to clean the buttons, panels and rollerball .....................................................41
How to clean the Heading Wheel panel .................................................................41
How to clean the Joystick panel .............................................................................41
OS preventive maintenance intervals .....................................................................42
CORRECTIVE MAINTENANCE ........................................... 43
Precautions and requirements before replacing a Module .....................................43
Switching off the OS ..............................................................................................43
Replacing the display .............................................................................................44
Replacing the computer..........................................................................................45
Replacing the panels in the Operator panel............................................................45
Replacing the power supply unit ............................................................................47
Replacing main switch and circuit breaker ............................................................48
Replacing the alphanumeric keyboard ...................................................................49
REPLACEABLE PARTS AND CONSUMABLES ...................... 50
Replaceable parts and recommended spare parts ...................................................50
Common spare parts ................................................................................... 50
K-Pos systems ............................................................................................ 51
K-Thrust systems........................................................................................ 51
K-Chief systems ......................................................................................... 52
HiPAP systems ........................................................................................... 52
General Operator panel ............................................................................... 52
A HARDWARE CONFIGURATION STATUS............................ 53

4 371472/E
 Maintenance Manual

Glossary
AC Alternating Current
ALC Alarm and Command
AUT Automation
BU Business Unit
CAN Controller Area Network
COP05 Common Operator Panel 05
DC Direct Current
DP Dynamic Positioning
EAP Extended Alarm Panel
EAS Extension Alarm System
GEN General
HiPAP High Precision Acoustic Positioning
HPR High Precision, or Hydro acoustic Position Reference
I/O Input/Output
KM Kongsberg Maritime
LAN Local Area Network
LED Light Emitting Diodes
NAV Navigation
OS Operator Station
PSU Power Supply Unit
TFT Thin Film Transistor
TC Thruster Control
UPS Uninterruptible Power Supply
USB Universal Serial Bus
VDU Vessel Display Unit
WS Widescreen

371472/E 5
COP05 OS-555 Built-in WS Mk2

6 371472/E
 Hardware description

Hardware description

This section describes the COP05 OS-555 Built-in WS Mk2 (BI) hardware configuration
for the part numbers listed on the front page of this document.
The Operator Station (OS) is delivered with a computer, a display, an alphanumeric
keyboard, an operator panel and a system specific Main Mounting Plate and an optional
Side Plate containing system dedicated equipment. These parts may be installed in
customer defined consoles.
For typical main parts of the OS, see the pictures on the front page of this document.

Operator Interfaces
Display
A high-resolution display provides the main graphic display for presentation of data. The
signal cable is connected to the graphic interface (DVI port) of the computer.

Operator panel
The Operator panel provides several controls and functions for the different console
types. Depending on configuration, the content of the panel system may vary; i.e.
different Panel types, alphanumeric keyboard, Heading Wheel panel or Joystick panel.
When installed they are all, except the alphanumeric keyboard, connected to the Input
panel in the Operator panel. The Input panel is connected to the computer via an USB
cable.
Available common panel groups are described in the following sections.

BU-xxx panels
Note
The xxx identifies the system, i.e. DP, TC, AUT etc.

371472/E 7
COP05 OS-555 Built-in WS Mk2

The Business Unit (BU) panel is dedicated to each built-in system, contains different
buttons and lamps, and is located in the Operator panel. The BU-xxx panel is connected
to the Input panel.

ALC panel
The Alarm and Command (ALC) panel is dedicated to each system, contains buttons
and lamps, and is located in the Operator panel. The ALC panel is connected to the
Input panel.

Heading Wheel panel

The Operator panel may provide a heading wheel with associated buttons, depending
on the system supported, to increase or decrease the heading setpoint. The Heading
Wheel panel is connected to the Input panel.

Input panel
The Input panel is dedicated to each system, contains buttons and is located in the
Operator panel. The Input panel is the interface for the Panels located in the Operator
panel. The Input panel is connected to the computer via an USB serial line.
If the length of the cable between the Input panel and the computer exceeds five metres,
then a USB extender kit (part number 334243) must be used.

Joystick panel
The Operator panel may provide 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 panel is connected to the BU-DP or the BU-TC panel.

Drop-In kits
An optional Drop-In kit contains the following:
• Drop-In panel (an example is shown in Figure 1)
• Terminal block (one of the options to the left in Figure 9 on page 17)
• A set of cables between the terminal block and the Drop-In panel
The Drop-In panels are located in the Operator panel of the OS for:
• COP05 K-Pos OS-555-BI SA WS Mk2/COP05 K-Pos OS-555-BI Int WS Mk2 (see
Figure 2 on page 10), or
• COP05 HiPAP-501 OS-555-BI WS Mk2 (see Figure 5 on page 13).

8 371472/E
 Hardware description

The following optional Drop-In kits are available:

• Drop-In panel, 2-position switch
• Drop-In panel, 3-position switch
• Drop-In panel, 4-position switch
• Drop-In panel, Fire backup switch
• Drop-In panel, Alert switch
• Drop-In panel, HPR Transducer Control

Figure 1 Example of Drop-In panel, 3-position mode switch

Example of a 3-position
Mode Selector switch in a
Drop in panel. Panel to be
installed in the Operator
panel.

Front cover is opened

cd090955a

Operator panel types

The Operator panel built-in types for different systems are as follows:
• COP05 K-Pos OS-555-BI SA WS Mk2 and COP05 K-Pos OS-555-BI Int WS Mk2
Operator panels (for Dynamic Positioning systems)
For K-Pos OS-555-BI two different types are available; one SA (Stand Alone) type
with network switch, and one Int (Integrated) type without network switch.
• COP05 K-Thrust OS-555-BI WS Mk2 or K-Pos OS-555-BI Operator panel (for
Thruster Control systems)
• COP05 K-Chief OS-555-BI WS Mk2 Operator panel (for Automation systems)
• COP05 General OS-555-BI WS Mk2 and COP05 HiPAP-501 OS-555-BI WS Mk2
(for General use and HiPAP systems)
The different layouts are described in the following sections.

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COP05 OS-555 Built-in WS Mk2

COP05 K-Pos OS-555-BI SA WS Mk2 and COP05 K-Pos OS-555-BI Int

WS Mk2 Operator panel
For COP05 K-Pos OS-555-BI SA WS Mk2 and COP05 K-Pos OS-555-BI Int WS Mk2
systems the following panel types are used as shown in Figure 2 on page 10.

Figure 2 Layout of COP05 K-Pos OS-555-BI SA WS Mk2 and COP05 K-Pos

OS-555-BI Int WS Mk2 Operator panel

BU-DP panel
The BU-DP panel is a status and command panel module. It provides buttons and lamps
for commands in DP systems and contains the following groups; Modes, Control, Views,
Thrusters, Sensors for DP commands.

ALC panel
The ALC panel is a status and command panel module. It provides buttons and lamps
for command control, and buttons, lamps and buzzers for handling alarms. It contains
the following groups; Panel, Command and Alarms and are used for fault indication,
command transfer, and alarm and administration.

Heading Wheel panel

The Heading Wheel panel comprises a heading wheel with seven buttons. It is mainly
used for setting or changing new heading for DP systems.

Input panel
The Input panel comprises a keypad for entering numbers and letters into the system and
a trackball for controlling cursor position on the OS screen. In addition a five port USB
hub is provided connecting all panel modules to the computer. It is a general panel for
VDU navigation on bridge systems, using alphanumeric keypad and trackball.

10 371472/E
 Hardware description

Joystick panel
The Joystick panel contains a three-axis joystick used as a joystick control for the DP
system. The joystick has three potentiometers that work in the three axis.
For details on each panel type described above, refer to the appropriate Hardware
Module Description.

COP05 K-Thrust OS-555-BI WS Mk2 Operator panel

Dynamic Positioning operations in conjunction with COP05 K-Thrust OS-555-BI WS
Mk2 may be performed by use of either the BU-TC panel or the BU-DP panel.
For COP05 K-Thrust OS-555-BI WS Mk2 systems the following panel types are used as
shown in Figure 3. However, the BU-DP panel may also be used as shown in Figure
2 on page 10.

Figure 3 Layout of COP05 K-Thrust OS-555-BI WS Mk2 Operator panel

BU-TC panel
The BU-TC panel is a status and command panel module. It provides buttons and
lamps for commands in Thruster Control systems and contains the following groups;
Manoeuvre Modes, Set Point, Speed Modes, Sub Modes, Thrusters, Auto Controls
for K-Thrust commands.

ALC panel
The ALC panel is a status and command panel module. It provides buttons and lamps
for command control, and buttons, lamps and buzzers for handling alarms. It contains
the following groups; Panel, Command and Alarms and are used for fault indication,
command transfer, and alarm and administration.

Heading Wheel panel

The Heading Wheel panel comprises a heading wheel with seven buttons. It is mainly
used for setting or changing new heading for DP systems.

371472/E 11
COP05 OS-555 Built-in WS Mk2

Input panel
The Input panel comprises a keypad for entering numbers and letters into the system and
a trackball for controlling cursor position on the OS screen. In addition a five port USB
hub is provided connecting all panel modules to the computer. It is a general panel for
VDU navigation on bridge systems, using alphanumeric keypad and trackball.

Joystick panel
The Joystick panel contains a three-axis joystick used as a joystick control for the DP
system. The joystick has three potentiometers that work in the three axis.
For details on each panel type described above, refer to the appropriate Hardware
Module Description.

COP05 K-Chief OS-555-BI WS Mk2 Operator panel

For COP05 K-Chief OS-555-BI WS Mk2 systems the following panel types are used as
shown in Figure 4.

Figure 4 Layout of COP05 K-Chief OS-555-BI WS Mk2 Operator panel

Note
The COP05 K-Chief OS-555-BI WS Mk2 Operator panel is also available in a smaller
version (320 mm x 300 mm) populated with the same panels.

BU-AUT panel
The BU-AUT panel is an input panel module. It provides buttons and lamps for
Automation systems and contains the View group as alarm panel for K-Chief systems.

12 371472/E
 Hardware description

ALC panel
The ALC panel is a status and command panel module. It provides buttons and lamps
for command control, and buttons, lamps and buzzers for handling alarms. It contains
the following groups; Panel, Command and Alarms and are used for fault indication,
command transfer, and alarm and administration.

Input panel
The Input panel comprises a keypad for entering numbers and letters into the system and
a trackball for controlling cursor position on the OS screen. In addition a five port USB
hub is provided connecting all panel modules to the computer. It is a general panel for
VDU navigation on bridge systems, using alphanumeric keypad and trackball.
For details on each panel type described above, refer to the appropriate Hardware
Module Description.

COP05 General OS-555-BI WS Mk2 and COP05 HiPAP-501 OS-555-BI

WS Mk2 Operator panel
For COP05 General OS-555-BI WS Mk2 and COP05 HiPAP-501 OS-555-BI WS Mk2
systems the following panel types are used as shown in Figure 5.

Figure 5 Layout of COP05 General OS-555-BI WS Mk2 and COP05 HiPAP-501

OS-555-BI WS Mk2 Operator panel

Input panel
The Input panel comprises a keypad for entering numbers and letters into the system and
a trackball for controlling cursor position on the OS screen. In addition a five port USB
hub is provided connecting all panel modules to the computer. It is a general panel for
VDU navigation on bridge systems, using alphanumeric keypad and trackball.
For details on the panel type described above, refer to the appropriate Hardware Module
Description.

371472/E 13
COP05 OS-555 Built-in WS Mk2

Alphanumeric keyboard
Layout of the alphanumeric keyboard is shown in Figure 6 on page 14.

Figure 6 Layout of alphanumeric keyboard

A standard alphanumeric keyboard is available, but is to be used for service purposes

only.

Main mounting plate and Side plate

configurations
The following internal configurations are available for the COP05 OS-555 Built-in
WS Mk2 configurations:
Operator Station type Mounting plate (and drop-in kits if available)
COP05 General OS-555-BI Main mounting plate layout for COP05 General OS-555-BI WS Mk2,
WS Mk2, COP05 K-Pos OS-555-BI Int WS Mk2, COP05 K-Thrust OS-555-BI WS
COP05 K-Pos OS-555-BI Int Mk2, COP05 K-Chief OS-555-BI WS Mk2, COP05 K-Chief OS-555-BI
WS Mk2, CANBus WS Mk2 and K-Chief OS-555-BI EAS WS Mk2 on page 15
COP05 K-Thrust OS-555-BI
WS Mk2 and
COP05 K-Chief OS-555-BI
WS Mk2
COP05 K-Chief OS-555-BI
CANBus WS Mk2
K-Chief OS-555-BI EAS WS
Mk2
COP05 K-Pos OS-555-BI SA Main mounting plate layout for COP05 K-Pos OS-555-BI SA WS Mk2
WS Mk2 on page 16
COP05 K-Pos OS-555-BI Side plate layout for K-Pos OS-555-BI on page 17
Int WS Mk2 and the COP05
Drop-In kits on page 8
K-Pos OS-555-BI SA WS
Mk2

14 371472/E
 Hardware description

Operator Station type Mounting plate (and drop-in kits if available)

COP05 K-Chief OS-555-BI COP05 K-Chief OS-555-BI WS Mk2 kits on page 18
WS Mk2
COP05 K-Chief OS-555-BI CANBus to Ethernet kit on page 19 COP05 K-Chief OS-555-BI
CANBus WS Mk2 CANBus WS Mk2
K-Chief OS-555-BI EAS WS EAS kit on page 20
Mk2
COP05 HiPAP-501 Main mounting plate layout for COP05 HiPAP-501 OS-555-BI WS
OS-555-BI WS Mk2 Mk2 on page 25
Side plate layout for COP05 HiPAP-501 OS-555-BI WS Mk2 on
page 26

Main mounting plate layout for COP05 General OS-555-BI

WS Mk2, COP05 K-Pos OS-555-BI Int WS Mk2, COP05
K-Thrust OS-555-BI WS Mk2, COP05 K-Chief OS-555-BI
WS Mk2, COP05 K-Chief OS-555-BI CANBus WS Mk2 and
K-Chief OS-555-BI EAS WS Mk2
Figure 7 Main mounting plate layout for COP05 General OS-555-BI WS Mk2, COP05
K-Pos OS-555-BI Int WS Mk2, COP05 K-Thrust OS-555-BI WS Mk2, COP05 K-Chief
OS-555-BI WS Mk2 and COP05 K-Chief OS-555-BI CANBus WS Mk2

Power supply (PSU1)

PSU1
Terminal blocks (X4, X5)

X4 X5

Cable ducts

Main switch (S1) and Circuit breaker (Q2) S1 Q2

Terminal blocks (X2, X3, PE)

Patch Panel (PP 1) X2 X3 PE PP 1

P.E I.E
Earth Bars (P .E, I.E)
Stretch relief

Cd090944e

The following main items are located on the Main mounting plate:
Power Supply Unit (PSU1) Converts 115/230 VAC to 24 VDC.
Terminals (X4 and X5) Main terminals for 24 VDC and 0 VDC (GND).
Cable ducts Used for collecting and feeding the interface cables on the Main
mounting plate.

371472/E 15
COP05 OS-555 Built-in WS Mk2

Main switch (S1) Main switch for the main supply voltage.
Circuit breaker (Q2) Main circuit breaker for the main outlet sockets (service purpose
only).
Terminals (X2, X3 and PE) Main terminals which are used as connection points for the ships
supply voltage (115/230 VAC) to the console.
Patch Panel Used for patching the interface cables from the Main mounting plate
and to the field (LAN cables).
PE Bar Used for connecting the equipment to P.E. earth (ground).
IE Bar Used for connecting the equipment to I.E. earth (signal ground)
Stretch relief Used for collecting and relieving the patch and interface cables.

Main mounting plate layout for COP05 K-Pos OS-555-BI SA

WS Mk2
In addition to the COP05 General OS-555-BI WS Mk2 Main mounting plate
configuration (see Figure 7 on page 15) the following items are added as shown in
Figure 8.

Figure 8 Main mounting plate layout for COP05 K-Pos OS-555-BI SA WS Mk2

Power supply (PSU1)

Terminal blocks (X4, X5) PSU1

X4 X5
Network switch

Cable ducts

Main switch (S1) and Circuit breaker (Q2) S1 Q2

Terminal blocks (X2, X3, PE)

X2 X3 PE PP 1
Patch Panel (PP 1)

P.E I.E
Earth Bars (P .E, I.E)

Stretch relief

Cd090944f

The following extra items are located on the Main mounting plate for the COP05 K-Pos
OS-555-BI SA WS Mk2.
Power Supply Unit (PSU1) Converts 115/230 VAC to 24 VDC.
Terminals (X4 and X5) Main terminals for 24 VDC and 0 VDC (Gnd).
Cable ducts Used for collecting and feeding the interface cables on the Main
mounting plate.
Main switch (S1) Main switch for the main supply voltage.

16 371472/E
 Hardware description

Circuit breaker (Q2) Main circuit breaker for the main outlet sockets (service purpose
only).
Terminals (X2, X3 and PE) Main terminals which are used as connection points for the ships
supply voltage (115/230 VAC) to the console.
Patch Panel Used for patching the interface cables from the Main mounting plate
and to the field (LAN cables).
PE Bar Used for connecting the equipment to P.E. earth (ground).
IE Bar Used for connecting the equipment to I.E. earth (signal ground).
Stretch relief Used for collecting and relieving the patch and interface cables.

Side plate layout for K-Pos OS-555-BI

Figure 9 Side plate layout for K-Pos OS-555-BI

CAN to DP converter
(option)

Patch Panel 2
(if specified in partlist)

Cable Ducts

PE Bar

Stretch relief

cd090946a

The following main items are located on the Side plate:

CAN to DP Converter Used for converting the CAN signals to RS232 format.
Patch Panel Used for patching the interface cables from the Side plate and to the
field (LAN cables).

371472/E 17
COP05 OS-555 Built-in WS Mk2

Cable duct Used for collecting and feeding the interface cables on the Side plate.
Terminals Main terminals for connecting field signals to terminals. Different
options for the terminals are shown at the left of Figure 9.
PE Bar Used for connecting the equipment to P.E. earth (ground).
Stretch relief Used for collecting and relieving the patch and interface cables.

COP05 K-Chief OS-555-BI WS Mk2 kits

Alarm Output kit

In addition to the COP05 General OS-555-BI WS Mk2 Main mounting plate
configuration (see Figure 7 on page 15) the following item are added as shown in
Figure 10.

Figure 10 Main mounting plate layout for Alarm Output kit

Relay (K1)

K1 X4 X5

24 V 0 V
Diode (D1)

P.E I.E

Cd090949b

The following extra items are located on the Main mounting plate by the Alarm Output
kit:
Relay (K1) The relay is connected to the Input Panel and gives alarm messages.
Diode (D1) Diode for the relay of the Alarm output kit.

18 371472/E
 Hardware description

CANBus to Ethernet kit

The following Side plate is added by the CANBus to Ethernet kit as shown in Figure 11.

Figure 11 Side plate layout for CANBus to Ethernet kit

The following main items are located on the Side plate:

Power Supply Unit (PSU2) 24 VDC and 115/230 VAC supplying the CANBus to Ethernet kit.
Circuit breaker (Q4) 24 VDC/10 A fuse for the CANBus to Ethernet kit.
CAN Converter Used to convert CAN signals to Ethernet signals to be connected to
the computer.
Terminals Terminals for input voltage and signals.

371472/E 19
COP05 OS-555 Built-in WS Mk2

EAS kit
The following EAS kit is recommended located on the Rear Mounting Plate as shown
in Figure 12.

Figure 12 Rear Mounting Plate layout for EAS kit

X10
X4

X5

X4
Terminals
(X10)

Switch
S1 Q2
X2

X3

PE

cd0909009a

The following main items are located on the Rear plate:

Moxa Switch Used to connect Ethernet signals to the Operator Station(s) and EAP
Loop(s) through the Patch Panel
Terminals (X10) Terminals for input voltage and signals.

The power principle for the kit is shown on the Power and Wiring Diagram for EAS. A
copy of this drawing can be found in the vessels System Drawings Manual

Dual Power Input kit

In addition to the COP05 General OS-555-BI WS Mk2 Main mounting plate
configuration (see Figure 7 on page 15) the following items are added as shown in
Figure 13.

20 371472/E
 Hardware description

Figure 13 Rear and left side mounting plate layout for Dual Power Input kit

S3
Main Switch (S3) X10
PSU 2 SW1

Power Supply Unit (PSU2)

Terminals (X10)

Switch (Sw1)

REAR PLATE

Q4

Circuit Breaker (Q4)

24VDC to 230V AC Inverter (INV1)

INV 1

(Cd090951d)

LEFT SIDE PLATE

The following extra items are located on the rear and left side mounting plates by the
Dual Power Input kit:
Main Switch (S3) The main switch for Emergency supply voltage.
Power Supply Unit (PSU2) The PSU converts 230 VAC mains input to 24 VDC output
Terminals (X10) Terminals for power alarms for Main- and Emergency Supplies as
well as for Inverter input/output failure

371472/E 21
COP05 OS-555 Built-in WS Mk2

Switch (SW1) The switch is a manual bypass switch

Circuit Breaker (Q4) Main circuit breaker for the Inverter
Inverter (INV1) The inverter converts 24 VDC input to 230 VAC output

The power principle for the kit is shown on the Power and Wiring Diagram for Dual
Power Input. A copy of this drawing can be found in the vessels System Drawings
Manual

Fibre Net kit

In addition to the COP05 General OS-555-BI WS Mk2 Main mounting plate
configuration (see Figure 7 on page 15) the following items are added as shown in
Figure 14.

Figure 14 Main mounting plate layout for Fibre Net kit

X4 X5

24 V 0 V
Converters
(Net -A, -B, -C)
NET A NET B NET C

Fiber Splicebox
(ST connectors on right
hand side of box)

Fiber Splicebox

P.E I.E

Cd090952b

The following extra items are located on the Main mounting plate by the Fibre Net kit:
Converters (Net A, B and C) Used to convert to/from Fibre signals from/to Ethernet on twisted
pair signals.
Fibre Splice Box Used as connection box for 8 fibre cables.

22 371472/E
 Hardware description

Network Net-A or Net-B kit

In addition to the COP05 General OS-555-BI WS Mk2 Main mounting plate
configuration (see Figure 7 on page 15) the following items are added as shown in
Figure 15.

Figure 15 Main mounting plate layout for Network Net-A or Net-B kit

Switch
(1 or 2) X4 X5

24 V 0V

Switch 1/Switch 2

Patch Panel
(1 or 2)

PP1/PP2

P.E I.E

Cd090953b

The following extra items are located on the Main mounting plate by the Network Net-A
or Net-B kit:
Network Switch 1 or 2 Used as switches for Net A (switch 1) or Net B (switch 2).
Patch Panel 1 or 2 Used as patch panel for Net A (patch panel 1) or Net B (patch panel
2).

371472/E 23
COP05 OS-555 Built-in WS Mk2

Network Net-C kit

In addition to the COP05 General OS-555-BI WS Mk2 Main mounting plate
configuration (see Figure 7 on page 15) the following items are added as shown in
Figure 16.

Figure 16 Main mounting plate layout for Network Net-C kit

Switch X4 X5
(1 and 3)

24 V 0 V

SWITCH 1 SWITCH 3

Patch Panel 1

PP 1

P.E I.E

Patch Panel 3
To be mounted on a 250 mm DIN rail.
Fasten the DIN rail inside the OS on
the left or right wall.

Cd090954b

The following extra items are located on the Main mounting plate by the Network
Net-C kit:
Network Switch 1 and 3 Used as switches for Net A (switch 1, managed) and Net C (switch
3 unmanaged).
Patch Panel 1 and 3 Used as patch panel for Net A (patch panel 1) and Net C (patch
panel 3).

24 371472/E
 Hardware description

Main mounting plate layout for COP05 HiPAP-501 OS-555-BI

WS Mk2
In addition to the COP05 General OS-555-BI WS Mk2 Main mounting plate
configuration (see Figure 7 on page 15) the following items are added as shown in
Figure 17.

Figure 17 Main mounting plate layout for COP05 HiPAP-501 OS-555-BI WS Mk2

Power Supply (PSU1)

X4 X5 PSU1 COM3 COM4 COM5 COM6

Terminal blocks (X4 and X5)

HPR Serial Line Kit (COM3,

COM4, COM5, COM6)

Main switch (S1) and

Circuit breaker (Q2) S1 Q2

Terminal blocks (X2, X3 and PE)

PP 1 RS-F34
X2 X3 PE
Patch Panel 1 (PP 1)
HPR Transducer Kit (RS-F34)
P.E I.E
Earth Bars (P .E and I.E)

Cd090947d

The following main items are located on the Main mounting plate:
HPR Serial line kit Kit for Hydro-acoustic Position Reference (HPR) system. Kit for
RS232; COM1 to COM4 ports.
Power Supply Unit (PSU1) Converts 115/230 VAC to 24 VDC.
Terminals (X4 and X5) Main terminals for 24 VDC and 0 VDC (Gnd).
Loose cables inside console Loose cables for RS485/422; COM7 to COM10.
Cable ducts Used for collecting and feeding the interface cables on the Rear
mounting plate.
Main switch (S1) Main switch for the main supply voltage.
Circuit breaker (Q2) Main circuit breaker for the main outlet sockets (service purpose
only).
Terminals (X2, X3 and PE) Main terminals which are used as connection points for the ships
supply voltage (115/230 VAC) to the console.
Patch Panel Used for patching the interface cables from the Rear mounting plate
and to the field (LAN cables).
PE Bar Used for connection the equipment to P.E. earth (ground).
I.E. Bar Used for connecting the equipment to I.E. earth (signal ground)
Stretch relief Used for collecting and relieving the patch and interface cables.

371472/E 25
COP05 OS-555 Built-in WS Mk2

Side plate layout for COP05 HiPAP-501 OS-555-BI WS Mk2

The following Side plate is available as shown in Figure 18.

Figure 18 Side plate layout for COP05 HiPAP-501 OS-555-BI WS Mk2

SWITCH
Ethernet Switch MOXA

Cable Duct

Ethernet Adapter

Fibre Splice Box

Fibre
Splice Box

P.E. bar
cd090945a

Stretch relief

The following main items are located on the Side plate:

Cable duct Used for collecting and feeding the interface cables on the Side plate.
Network Switch Used for converting the fibre signals to Ethernet.
Ethernet adapter USB Ethernet adapter.
Fibre Splice Box Used as connection box for 8 fibre cables.
PE Bar Used for connection the equipment to P.E. earth (ground).
Stretch relief Used for collecting and relieving the patch and interface cables.

26 371472/E
 PANEL SYSTEM

E 2.50m
** 1 X2 ** 1.50m PWR USB CABLE 2m
115/230V AC (50-60Hz) L1 2 DIM
1,0 INPUT PANEL
SHIP 1
S1 115/230V AC
SUPPL Y 115/230V AC (50-60Hz) L2 DIM
1,0
2 PWR PWM I/O
UPS

371472/E
3 4 COMPUTER HUB P.E
GND P.E. DIM
1,0
3

-3
-4
-2
DIM
1,0
4
DIM
1,0 NETSWITCH *** USB
5
NET A (PROCESS NET)
USB CABLES 1m
NET B (PROCESS NET)
X3 **
DIM
1,0 NET C (ADM. NET) USB
1
DIM
1,0 Display
2 COM1 VGA
port 1.60m
DIM
1,0 ALC PANEL***
3
** 1
2 DIM
1,0
4 1.60m
Display port to * P.E
Q2 4A DIM
1,0 NETSWITCH *** DVI adapter
5
3 4

P.E. 2.50m
** BU DP/TC P ANEL***
DIM
1,0 * P.E
1
DIM
1,0 1.50m PWR
2
DISPLAY 1
DIM
1,0 PWR PWM
3 DVI
DIM
1,0 (RIGHT DISPLAY IN 1200
4

-3
-4
-2
2.5
DIM CONSOLE)
DIM
1,0 NETSWITCH ***
5

*P.E PWR VGA

** * DISPLAY 2 ** *
JOYSTICK P ANEL***
X4 **
24V DC 1A 1,0
DIM (OPTIONAL)
F1
1A DIM
1,0 CHANGE OVERSW ./HOIST CTRL ***
F2
1A 1,0
DIM CAN 2 DP ***
F3 2.00m
PSU 1 1A DIM
1,0 SP ARE
** HEADING WHEEL
+ F4
L PANEL ***
- 4A 1,0
DIM I/O CONTROLLER ***
N
F5
PE
X5 **
QUINT 24VDC/10A OV 1,0
DIM
** *
1
1.50m I/O CONTROLLER ***
All OS systems (except HiPAP)

1,0
DIM CHANGE OVERSW ./HOIST CTRL ***
2
+1
DIM
1,0 CAN 2 DP *** +2 X10
WRIST 3
PATCH -3
STRAP 1,0
DIM SP ARE
4 PANEL 1 COMPUTER -4
1.50m
1,0
DIM I/O CONTROLLER *** **
5 1 NET A
PE BAR* 16mm² 2
NET B
IE 3
NET C
4
16mm²
1,5m 12 ALPHANUM. KEYB.
NET CONNECTION
PE BAR* ** * (RJ45)
2.00m
NET

1.80m *** options

Power supply and signal wiring

J1
L1
L2
P.E. * P.E

2.00m SOCKET
*P.E OUTLET
115/230 V AC
(SER VICE ONLY)
Cd090909p
Figure 19 COP05 OS-555 Built-in WS Mk2 equipment and interconnections

27
Hardware description
COP05 OS-555 Built-in WS Mk2

See Figure 19 for block diagram.

The OS handles both 115 VAC and 230 VAC as mains supply. The AC voltage is usually
fed from an Uninterruptible Power Supply (UPS) and is terminated on main switch S1
located on the Main mounting plate inside the OS.
The main switch (S1) and circuit breaker (Q2) are located on the Main mounting plate.
The main voltage passes the circuit breaker Q2 and trips and breaks the circuits if the
mains current exceeds the rated Q2 current.
The UPS/AC ship supply is distributed, via main switch S1 and row terminals X2 and
X3 (and PE for ground), to supply the computer and display(s).
The Panel system gets its mains supply from terminals X2, X3 and PE, via a power
supply unit (PSU1) which supplies the Panel system with 24 VDC. The 24 VDC is
entered at the Input panel of the Panel system and supplies the system panels and heading
wheel via USB connections. The I/O Controller (option) gets it supply voltage directly
from the 24 VDC power supply unit (PSU1). The Joystick, if used is supplied via the
BU-DP or the BU-TC panel.
If the length of the cable between the computer and the Input panel is greater than five
metres, a USB extender kit (part number 334243) will be used.
The UPS/AC ship supply also passes the circuit breaker Q2 before it is passed to 115/230
VAC mains outlet socket. The outlet socket is used for service purpose only.
Caution
Do not use the mains outlet for other purposes than servicing the system.
Heavy or noisy loads connected here may damage the system.

28 371472/E
 PANEL SYSTEM

2.50m
** X2 ** 1.50m P WR USB CABLE 3m
115/230V AC (50-60Hz) L1 1 2 DIM
1,0 INPUT PANEL
SHIP 1
S1 115/230VAC
SUPPL Y 115/230V AC (50-60Hz) L2 DIM
1,0
2 PWR PWM I/O

371472/E
UPS 3 4 COMPUTER HUB
GND P.E. P.E
3

-3
-4
-2
DIM
1,0
4
1.50m US B
5
NET A (P ROCES S NET)

NET B (P ROCES S NET)

X3 ** 2.00m
1,0
DIM NET C (ADM. NET) US B
1 FROM X4:F2
Display
FROM X5:2
2 DIM
1,0
COM1 port US B 1.60m
DIMMER
3
** 1
2 DIM
1,0
4 1.60m HOIST CONTROL PANEL
Display port * P.E ** *
Q2 4A to
5 DVI adapter
3 4
HiPAP systems

P.E. 2.50m
**
DIM
1,0 * P.E
1
DIM
1,0 1.50m P WR
2
DISPLAY 1
3 DVI USB CABLE 2m
DIM
1,0 (RIGHT DISPLAY IN 1200
4 ALPHANUM. KEYB.
DIM
2.5 CONSOLE)
5

1 1.80m
*P.E

X4 ** 2.00m
24V DC 1A 1,0
DIM
F1 * P.E
1A 1,0
DIM HOIS T CONTROL
F2
1A DIM
1,0 MOXA S WITCH
F3
PSU 1 1,0
DIM MOXA SWITCH
1A S PARE
+
** F4
L 1.00m G1
- 4A DIM
1,0 S PARE
N
F5 V1+
PE V1-
X5 **
QUINT 24VDC/10A OV 1,0
DIM G2 G3 USB-NET
1
ADAPTER
1,0
DIM HOIS T CONTROL
2
1,0
DIM MOXA S WITCH 1.00m
WRIST 3 PATCH
STRAP 1,0
DIM S PARE PANEL 1
4 **
DIM
1,0 S PARE
5 NET A
1

1
2
3
4
16mm² NET B
P E BAR* 2
FIBRE
IE NET C 1.00m
3 SPLICE BOX
4
16mm²
1,5m

P E BAR* ** *
NET CONNECTION
(RJ45)
2.00m
NET
Figure 20 COP05 OS-555 Built-in WS Mk2 HiPAP systems

J1
L1
L2
P.E.

2.00m SOCKET
*P.E OUTLET Cd090909n
115/230 V AC
(SER VICE ONLY)

29
Hardware description
COP05 OS-555 Built-in WS Mk2

Some additions apply for the HiPAP version compared with the other OSes, refer to
Figure 19 on page 27 and Figure 20.
In addition to a standard version, a Side plate is added with the following equipment:
• A Fibre Splice Box
• A Moxa Switch
These two components splice and switch the incoming field signals to Ethernet and
connects them to the computer.
• An USB Net Adapter – This is an adapter that converts from Ethernet to USB on
the computer.

Network connections
Figure 21 Example of network connection (OS without switch)

30 371472/E
 Hardware description

Figure 22 Example of network connection (OS with switch on Net A, e.g. DP OS)

Note
The OS may have a network switch installed for either Net A or Net B. If the OS is
without a network switch Figure 21 applies.

Computer
Computer versions
Different computer versions are available, depending on the COP05 OS-555 Built-in
WS Mk2 system it is supporting.
For a detailed description of the different computer types, refer to the MPxxxx
Maintenance Manual or the APCxx Maintenance Manual.

Computer damper kits

The computer is mounted on shock absorbers or a damper kit.
The available kits for the MPxxxx are:
• Vertical mounted kit
• Horizontal mounted kit

371472/E 31
COP05 OS-555 Built-in WS Mk2

Figure 23 Damper kit, vertical Figure 24 Damper kit, horizontal

32 371472/E
 Fault finding

Fault finding

This section presents the fault finding principles for the COP05 OS-555 Built-in WS
Mk2.

Panel and Alarm lamps and buttons

The Panel and Alarm lamps and buttons are located in two groups on the ALC panel
(see Figure 2 on page 10).
The Panel group comprises two lamps:
• POWER - The lamp is lit green when power is OK.
• FAULT - The lamp is lit red when lost contact with the computer, else it is off.
The Alarms group comprises one lamp and three buttons without status lamp:
• ALARM - The lamp is flashing red when an alarm has been detected. The lamp is
steadily lit when the ACK button has been pressed and the alarm is still active.
• ACK - The button, when activated, provides a signal to the computer.
• “Silence” - The button, when pressed, silences the buzzer locally and provides a
signal to the computer.
• ALARM VIEW - The button, when activated, provides a signal to the computer.

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. Refer to the
appropriate Hardware Module Description for details.
• Status of power voltages and fuses in the system. Refer to the appropriate Hardware
Module Description for details.
• System-specific diagrams, lists and drawings. Refer to the appropriate System
Drawings for details.

371472/E 33
COP05 OS-555 Built-in WS Mk2

• Replacement procedures for replaceable modules. Refer to Corrective Maintenance

on page 43, the appropriate Hardware Module Description or the appropriate
Maintenance Manual for details.

Reading power LED status and measuring

supply voltages
For all systems, the mains voltage can be measured, where appropriate, using a
multimeter with AC-range.

All OS systems
The power supply unit (QUINT-PS/1AC/24DC/10) is a 115/230 VAC to 24 VDC
converter. The status of this power supply unit is shown by a green LED on front of the
unit, which when lit green corresponds to an OK state.
The power supply unit is located inside the panel section (see Figure 7 on page 15).

The message system

The COP05 OS-555 Built-in WS Mk2 systems contain self tests that continually check
for faults while the system is running. System messages are generated to inform you
of any incorrect system operation or to bring any other relevant information to your
attention.
The COP05 OS-555 Built-in WS Mk2 related system messages are displayed on the OS
and/or on the event/alarm printer to inform the operator about controller/process station
faults or to bring any other relevant information to the operator's attention.
For detailed information concerning system messages, refer to the appropriate
Operator/User Manual for detailed information on reading the equipment status.

Online help
When system is running, the Message Line in the display layout or Event Window
shows the most recent warning, alarm or emergency message that has not yet been
acknowledged. Right-clicking the message text opens the System Messages Help with
the relevant message explanation displayed online on the OS.
For detailed information concerning online help information, refer to applicable
Operator/User Manual.

34 371472/E
 Fault finding

Fault finding flowchart

No picture on
S ta rt Monitor or no P a ne l
lights .

Che ck input volta ge

on X1

No
Is the
input volta ge
on X1 OK?

Ye s

Che ck s ta tus of
Ma in s witch (S 1)

Is the
No
Ma in s witch
(S 1) clos e d?

Clos e the Ma in s witch (S 1)

Ye s a nd wa it for Compute r to
come up

No
Is pa ne l s ys te m
OK? Doe s the
Ma in s witch (S 1)
Ye s trip a ga in?
Ye s

No
No Is Compute r P owe r
LED lit ?

Is pa ne l No Che ck/re pa ir
s ys te m pa ne l s ys te m Ye s
powe r OK? powe r

Ye s

Is the OS OK?
No No ma ins volta ge pre s e nt. No
Are a ny pa ne l Re pa ir compute r a nd the
lights lit? Re pa ir the Ma ins/UP S .
colour monitor a s
Re s ta rt s ys te m
a ppropria te
Ye s
Ye s

Re pa ir or re pla ce fa iling
BU xxx a s a ppropria te

Ye s
Is the OS / P a ne l
s ys te m OK?

No

Conta ct Kongs be rg
Ma ritime for
re comme nde d a ction

End
(Vis 090502d)

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.

371472/E 35
COP05 OS-555 Built-in WS Mk2

Preventive Maintenance

This section provides the preventive maintenance for the COP05 OS-555 Built-in WS
Mk2.

How to tighten screws in the field termination

blocks
Use a screwdriver with isolated handle to tighten any loose screws on patch panel and
field termination.

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.
Flat-cable connector locks should be checked by visual inspection only. Ensure that
the locks are in correct position.

How to check buttons, lamps and panels

Note
For all panels, the light intensity of the backlighting and status lamps can be dimmed
from the OS of which the panel is a part.

BU-DP panel
Figure 25 on page 37 shows the front layout of the BU-DP panel. It contains 56 buttons.
All buttons except for those in the VIEWS group are provided with status lamps.

36 371472/E
 Preventive Maintenance

To perform lamp test the application must be running. Then click the following from the
menu bar: View →Panel →Lamp Test. In the displayed Panel Lamp Test dialog box,
click Start Lamp Test button and all the panel button status lamps should be lit.
Press in turn, each button that has a status lamp. Each status lamp should extinguish
when its associated button is pressed.

Figure 25 Front layout of the BU-DP panel

A more detailed description of the BU-DP panel can be found in the COP-05 BU-DP
Panel Hardware Module Description.

BU-TC panel
Figure 26 on page 38 shows the front layout of the BU-TC panel. It contains 30 buttons
and lamps. All buttons group are provided with status lamps.
To perform lamp test the application must be running. Then click the following from the
menu bar: View →Panel →Lamp Test. In the displayed Panel Lamp Test dialog box,
click Start Lamp Test button and all the panel button status lamps should be lit.
Press in turn, each button that has a status lamp. Each status lamp should extinguish
when its associated button is pressed.

371472/E 37
COP05 OS-555 Built-in WS Mk2

Figure 26 Front layout of the BU-TC panel

A more detailed description of the BU-TC panel can be found in the COP-05 BU-TC
Panel Hardware Module Description.

BU-AUT panel
Figure 27 on page 39 shows the front layout of the BU-AUT panel. It contains 28 buttons
and lamps. All buttons are provided with status lamps.
To perform lamp test the application must be running. Then click the following from the
menu bar: View →Panel →Lamp Test. In the displayed Panel Lamp Test dialog box,
click Start Lamp Test button and all the panel button status lamps should be lit.
Press in turn, each button. Each status lamp should extinguish when its associated
button is pressed.

38 371472/E
 Preventive Maintenance

Figure 27 Front layout of the BU-AUT panel

A more detailed description of the BU-AUT panel can be found in the COP-05 BU-AUT
Panel Hardware Module Description.

Input panel
Figure 28 on page 40 shows the front layout of the Input panel. It contains a 19 buttons
keypad for screen navigation, entering numbers and text into the system and a Trackball
with seven buttons integrated in the circular Trackball cover.
A function test related to numeric input may be tested when doing ordinary operation
interactions.
The Trackball with Rollerball, mouse buttons and arrow buttons may also be checked her
(see also How to clean the buttons, panels and rollerball on page 41).
Note
The sign of a contaminated Rollerball is when the cursor does not follow the movement
of the Rollerball, but stops for short periods.

371472/E 39
COP05 OS-555 Built-in WS Mk2

Figure 28 Front layout of the Input panel

Note
The 'abc...' button act as a toggle button between letters and numbers, and the 'a/A'
button acts as CapsLock.

A more detailed description of the Input panel is found in the Hardware Module
Description.

How to clean the console housing

Use a lint-free, non-abrasive cloth and a neutral or mild soap solution for best result. Use
only moistened cloth. Do not use a dripping wet cloth when cleaning.

How to adjust the display settings

Adjust the appropriate settings in accordance with the display, refer to the appropriate
display Hardware Module Description and/or sub-supplier User Manual.

40 371472/E
 Preventive Maintenance

How to clean the display 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 maintain the computer

For preventive maintenance of the computer, refer to the MPxxxx Maintenance Manual
or the APCxx Maintenance Manual.

How to clean the buttons, panels and

rollerball
Use a vacuum cleaner with a soft brush to avoid damage to buttons and panels. If
required, clean the buttons and panel with a non-abrasive cloth.
Note
The sign of a contaminated Rollerball is when the cursor does not follow the movement
of the Rollerball, but stops for short periods.

If the Rollerball has been contaminated with dust particles or similar, it should be cleaned
using the procedure given in the COP-05 Input Panel Hardware Module Description.

How to clean the Heading Wheel panel

If the heading wheel has been contaminated with dust particles and grease, it should be
cleaned using a vacuum cleaner with a soft brush to avoid damage to the buttons and the
panel. If required, clean the buttons and panel with a non-abrasive cloth.

How to clean the Joystick panel

If the Joystick panel has been contaminated with dust particles and grease, it should be
cleaned using a vacuum cleaner with a soft brush to avoid damage to the buttons and the
panel. If required, clean the panel with a non-abrasive cloth.

371472/E 41
COP05 OS-555 Built-in WS Mk2

OS preventive maintenance intervals

Note
Local evaluation should be made to determine site-specific maintenance intervals.

Table 1 Recommended OS maintenance intervals

Action Interval recommended

Clean the display screen. One week.
Clean the console housing. One month.
Check the computer. One month.
Clean the buttons and panels. One month or as required.
Adjust the display settings. Three months or as required.
Clean the rollerball. Three months or as required.
Tighten the termination block screws. Six months.
Clean the heading wheel. Six months or as required.
Clean the Joystick panel. Six months or as required.
Check the connector locks. Twelve months.

For preventive maintenance of the computer MPxxxx, refer to the MPxxxx Maintenance
Manual and for the display, refer to the sub-supplier User Manual supplied with the
display.

42 371472/E
 Corrective Maintenance

Corrective Maintenance

This section presents the corrective maintenance procedures for the COP05 OS-555
Built-in WS Mk2.
Corrective maintenance procedures not described in this section are to be found in
the appropriate Hardware Module Description 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.

Precautions and requirements before

replacing a Module
Caution
Be careful not to strain the cables between the operator panel and system
frame.

Switching off the OS

Before performing corrective maintenance on the OS, power must be turned off as
follows:
1 Run the standard shut-down procedure as described in the applicable Operator
Manual.
2 When the shut-down procedure has been completed and the application has closed
down, turn off main switch S1 (see Figure 7 on page 15).
Note
Circuit breaker Q2 must be turned off, if power to the main outlet socket (for service)
is to be turned off.

371472/E 43
COP05 OS-555 Built-in WS Mk2

Replacing the display

1 Find someone to help you.
This procedure is to be performed by two people.
2 Make sure the new display is the recommended spare part for third-party consoles
(see Replaceable Parts and Consumables on page 50).

Figure 29 Example of display

3 Obtain a large (approx. 100 cm x 100 cm) piece of protective foam (or similar) and
place it over the operator panel.
4 Shut down and turn off power to the operator station).
5 Remove the four M6 umbraco screws (two at the top and two at the bottom) of the
defective display.
6 Carefully tilt the defective display down on to the protective foam (or similar) that
you have placed over the operator panel.
Do not allow the whole weight of the display to rest on the foam.
7 While your partner supports the defective display, disconnect the cables from the
defective display.
8 Remove the defective display from the console, mark it with a label describing the
symptoms observed, pack it in a shielding bag, and put it in a secure place.
9 Lift the new display on to the console, and carefully tilt it down on to the protective
foam (or similar) that you have placed over the operator panel.
Do not allow the whole weight of the display to rest on the foam.
10 While your partner supports the new display, attach the cables to the display.
Make sure the cables are firmly attached: the console will be subject to vibration
while the vessel sails and over time this can cause the cables to work loose if they
are not properly inserted.
11 Carefully raise up the new display and put it into position inside the console frame.

44 371472/E
 Corrective Maintenance

12 Screw in the four M6 umbraco screws (two at the top and two at the bottom) of the
new display.
13 Start the operator station by using the main switch inside the console and then
pressing the POWER switch on the computer.
You may also need to press the POWER switch on the front of the new display.

Replacing the computer

For corrective maintenance of the computer, refer to the MPxxxx Maintenance Manual

Replacing the panels in the Operator panel

Note
Different OS configurations are available, so the Operator panel may look different than
that shown in Figure 30 on page 45 and Figure 31 on page 46.

The following step must be done before performing this procedure:

• Ensure that the different panels are the recommended spare part for COP05 OS-555
Built-in WS Mk2.
The panels located in the Operator panel are replaced as follows:
1 Shut-down and turn-off power as described in Switching off the OS on page 43.
2 Remove the six 6/12 mm umbraco screws from the top of the Operator panel (three
at the front and three at the rear).

Figure 30 Example of Operator panel layout

3 Lift the Operator panel plate by taking hold of the plate and raising it upwards
about 2 cm.

371472/E 45
COP05 OS-555 Built-in WS Mk2

The Operator panel is now ready to be lifted and tilted up.

4 When lifting the Operator panel upwards, carefully tilt the front of the panel
backwards, about 120° (see Figure 31 on page 46).
The panels located in the Operator panel are all attached to the panel plate from
underneath by 4 nuts and screws attached to the underside of the Operator panel.

Figure 31 Operator panel seen from underneath

5 For the panel to be replaced, disconnect the USB cable and then remove the four
nuts attaching the panel to the Operator panel.
For further details, refer to following for the different panel types:
a Replacing the ALC panel, refer to the COP05 ALC Panel Hardware Module
Description.
b Replacing the BU-DP panel, refer to the COP05 BU-DP Panel Hardware
Module Description.
c Replacing the BU-TC panel, refer to the COP05 BU-TC Panel Hardware
Module Description.
d Replacing the BU-AUT panel, refer to the COP05 BU-AUT Panel Hardware
Module Description.
e Replacing the Input panel, refer to the COP05 Input panel Hardware Module
Description.
f Replacing the Heading Wheel panel, refer to the COP05 Heading Wheel
Panel Hardware Module Description.
g Replacing the Joystick panel, refer to the COP05 Hardware Module
Description.
6 Mark the defective panel with a label describing the symptoms observed, carefully
pack in a shielding bag and place on a secure place.
7 When defective panel has been replaced, connect the cables to the panel.

46 371472/E
 Corrective Maintenance

8 Lower the Operator panel back down into position.

9 Refit the six 6/12 mm umbraco screws back into to the top of the Operator panel
(three at the front and three at the rear).
10 Switch on power to the OS by turning on main switch S1.

Replacing the power supply unit

The power supply unit is located on the Main mounting plate (see Figure 7 on page 15).
The following step must be done before performing this procedure:
• Ensure that the new power supply unit module is the recommended spare part for
COP05 OS-555 Built-in WS Mk2.
1 Shut-down and turn off power to the OS as described in Switching off the OS on
page 43.
2 Locate the defective power supply unit on the Main mounting plate.
3 Locate the cables connected to the defective power supply unit and disconnect them
from the defective power supply unit.
Make sure the cables are correctly marked so they can be identified for reconnection
to the new power supply unit.
4 Insert a flat-head screwdriver into the slot in the mounting plate as shown in Figure
32 on page 48.
5 Push the screwdriver handle in the direction shown in Figure 32 on page 48 to
retract the lock.
6 With the lock retracted, remove the power supply unit from the DIN mounting rail.
7 Carefully unscrew the mounting plate from the power supply unit.
8 Mark the defective power supply unit with a label describing the symptoms
observed, then pack it in a shielding bag and store it in a safe place.
9 Fasten the mounting plate to the new power supply unit.
10 Position the new power supply unit over the DIN rail with the mounting plate
pressed against the DIN rail.
11 Repeat steps 4 and 5 while holding the new power supply unit firmly against the
DIN rail.
12 Remove the screwdriver from the slot.
13 Make sure that the new power supply unit is firmly attached to the DIN rail.
14 Connect the cables to the new power supply unit.
15 Switch on power to the OS by turning on main switch S1.
16 Verify, by measuring at the Output DC 24 V 10 A terminals (+ and –) on the new
power supply unit , that the correct voltage (24 VDC) is present.
17 Close and lock the front door of the OS.

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COP05 OS-555 Built-in WS Mk2

Figure 32 Removing the power supply unit from the DIN rail

Replacing main switch and circuit breaker

The following step must be done before performing this procedure:
• Ensure that the new main switch or circuit breaker is the recommended spare part
for COP05 OS-555 Built-in WS Mk2.
1 Run the standard shut-down procedure as described in applicable Operator Manual.
2 When the shut-down procedure has been completed and the application has closed
down, switch off the ships supply/UPS to the OS.
Note
If Dual Power Input (for Safety system) are used, two separate supplies/UPS.
Remember to turn off both supplies/UPS.

3 Locate the defective main switch (S1) or circuit breaker (Q2).

4 Verify that there is no voltage on the input terminals.
5 Remove the busbar between S1 and Q2, and then remove the wires connected to S1.
6 Remove the defective main switch (S1) or circuit breaker (Q2).
7 Install the new main switch (S1) or circuit breaker (Q2).
8 Re-attach the busbar and wires to S1 and/or Q2.
9 Turn on the new main switch (S1) or circuit breaker (Q2).
10 Switch on the ships supply/UPS to the OS.
Note
Safety systems have two separate supplies/UPS. Remember to turn on both
supplies/UPS.

11 Switch on the ships supply/UPS to the OS.

48 371472/E
 Corrective Maintenance

Note
Safety systems have two separate supplies/UPS. Remember to turn on both
supplies/UPS.

12 Verify, by measuring at the terminals of X3, that 115/230 VAC is present at X3-1
and X3-6.

Replacing the alphanumeric keyboard

1 Make sure that the new keyboard is the recommended spare part (see Replaceable
Parts and Consumables on page 50).
2 Shut down and turn off power to the operator station.
3 Locate the defective keyboard.
The keyboard is normally located in a drawer or compartment beneath the operator
panel.
4 Inside the console, locate the USB cable from the keyboard and disconnect it from
the computer.
5 Remove the keyboard from its compartment.
6 Mark the defective keyboard with a label describing the symptoms observed,
carefully pack it in a shielding bag and store it in a safe place.
7 Put the new keyboard into the keyboard compartment and connect its USB cable to
the computer.
8 Power up the operator station.

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COP05 OS-555 Built-in WS Mk2

Replaceable Parts and

Consumables

This section contains lists of replaceable parts, recommended spare parts and
consumables used in COP05 OS-555 Built-in WS Mk2. Replacement procedures for the
listed parts are described in Corrective Maintenance on page 43 and in the appropriate
Hardware Module Description.

Replaceable parts and recommended spare

parts
Common spare parts

Table 2 Common replaceable parts and recommended common spare parts

List Recommended Part

ident. Part name as spare part number
1 Display 22" LCD MD22 MK2 X 383408
2 Display 24" LCD MD24 MK2 X 383050
3 Display 27" LCD MD27 MK2 X 383048
4 Alphanumeric keyboard 704363
5 One of the following computers: Refer to MPxxxx
Maintenance
• MP7900 Manual
• MP8200
6 Power supply unit Quint-PS/1AC/24DC/10 (not for K-Bridge) X 326396
7 Fuse Siemens 4A, 2p (not for K-Bridge) X 702801
8 Main switch 2–pole/40 A IS-40/2 (not for K-Bridge) X 358913
9 Net Switch (not for K-Bridge) X (if installed) 702403
10 USB extender kit X (if installed) 334243

50 371472/E
 Replaceable Parts and Consumables

K-Pos systems

Table 3 Replaceable parts and recommended spare parts for K-Pos system

List Recommended Part

ident. Part name as spare part number
1 BU-DP panel X 603530
2 ALC panel X 603526
3 Input panel (with mechanical trackball) X 330951
4 Heading Wheel panel 603550
5 Joystick panel (Kwant Controls) 304849
6 Kits for Drop in Panels (if used):

• Drop in panel, 2-position switch 603595

• Drop in panel, 3-position switch 603596

• Drop in panel, 4-position switch 603697

• Drop in panel, Fire backup switch 310771

• Drop in panel, Alert switch 304048

• Drop in panel, HPR Transducer Control 603591

7 CAN Kit (if used):

• CAN2DP Kit 312478

K-Thrust systems

Table 4 Replaceable parts and recommended spare parts for K-Thrust system

List Recommended Part

ident. Part name as spare part number
1 BU-TC panel X 603531

BU-DP (according to delivery) 603530

2 ALC panel X 603526
3 Input panel (with mechanical trackball) X 330951
4 Heading Wheel panel 603550
5 Joystick panel (Kwant Controls) 304849

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COP05 OS-555 Built-in WS Mk2

K-Chief systems

Table 5 Replaceable parts and recommended spare parts for K-Chief system

List Recommended Part

ident. Part name as spare part number
1 BU-AUT panel X 603529
2 ALC panel X 603526
3 Input panel (with mechanical trackball) X 330951
4 Standard kits (if used):

• Kit, Alarm Output 312700

• Kit, CANBus to Ethernet 313308

• Kit, EAS 376178

• Kit, Dual Power Input, OS/BI with Inverter 357742

• Kit, Fibre Net 313309

• Kit, Network Net-A or Net-B 313310

• Kit, Network Net-C 313311

HiPAP systems

Table 6 Replaceable parts and recommended spare parts for HiPAP systems

List Recommended Part

ident. Part name as spare part number
1 Input panel (with mechanical trackball) X 330951
2 For kits, see List ident. 6 in Table 3 on page 51.

General Operator panel

Table 7 Replaceable parts and recommended spare parts for General Operator panel

List Recommended Part

ident. Part name as spare part number
1 Input panel (with mechanical trackball) X 330951

52 371472/E
 Appendix A Hardware configuration status

Appendix A
Hardware
configuration status

This manual is based on the following parts lists and drawings.

Parts List and Drawings – COP05 K-Pos OS-555-BI SA WS Mk2 370930
Outline Drawing, Display 27” LCD MD27 354260
Layout Drawing, KM05 OS-555 SL WS Mk2, El. Mech. Rear, K-Pos, Built-in 370971
Layout Drawing, OS-555-DP-BI, Built in 1016173
Outline Drawing, Display MD27, Desktop & Ceiling Bracket 364667
Outline Drawing, MP7900 Mounting Kit 333313
Power and Wiring Diagram, K-Pos/ K-Thrust Panel System 313401
Power and Wiring Diagram, KM05 K-Pos, El. Mech SL/BI 370977
Power and Wiring Diagram, KM05 K-Pos OS WS Mk2, SlimLine/Built-in 370981
Power and Wiring Diagram, KM05 OS-650 DP/DP Cabinets WS Mk2, Network 370995
Structure, Single System
Power and Wiring Diagram, KM05 OS-650 DP/DP Cabinets WS Mk2, Network 370993
Structure, Double System
Power and Wiring Diagram, KM05 OS-650 DP/DP Cabinets WS Mk2, Network 370997
Structure, Triple System
Power and Wiring Diagram, KM05 K-Pos DPC-21, DPC-11 Backup WS Mk2, 371000
Network Structure
See also Common Kit Drawings list.

Parts List and Drawings – COP05 K-Chief OS-555-BI WS Mk2 370935

Outline Drawing, Display 22" LCD MD22 383408
Outline Drawing, Display 24" LCD MD24 383050
Outline Drawing, Display 27" LCD MD27 354260
Layout Drawing, KM05 OS-650 WS Mk2, El. Mech. DP/IAS, DeepLine 370987
Outline Drawing, Display MD22, Desktop & Ceiling Bracket 357881
Outline Drawing, Display MD24, Desktop & Ceiling Bracket 364666
Outline Drawing, Display MD27, Desktop & Ceiling Bracket 364667
Outline Drawing, MP7900 Mounting Kit 333313

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COP05 OS-555 Built-in WS Mk2

Parts List and Drawings – COP05 K-Chief OS-555-BI WS Mk2 370935

Power and Wiring Diagram, KM05 K-Chief OS WS Mk2, Deep Line/Built-in, 370975
KM05
Power and Wiring Diagram, KM05 Slimline/Deepline/Built-in WS Mk2, 370984
Standard El. Mech
See also Common Kit Drawings list.

Parts List and Drawings – COP05 K-Pos OS-555-BI Int WS Mk2 370929
Outline Drawing, Display 27” LCD MD27 354260
Layout Drawing, KM05 OS-650 WS Mk2, El. Mech. DP/IAS, DeepLine 370987
Layout Drawing, OS-555-DP-BI, Built in 1016173
Outline Drawing, Display MD27, Desktop & Ceiling Bracket 364667
Outline Drawing, MP7900 Mounting Kit 333313
Power and Wiring Diagram, K-Pos/ K-Thrust Panel System 313401
Power and Wiring Diagram, KM05 K-Pos/K-Thrust OS WS Mk2, 370979
(SlimLine)/DeepLine/Built-in
Power and Wiring Diagram, KM05 Slimline/Deepline/Built-in WS Mk2, 370984
Standard El. Mech
See also Common Kit Drawings list.

Parts List and Drawings – COP05 HiPAP-501 OS-555-BI WS Mk2 370933

Outline Drawing, Display 27” LCD MD27 354260
Layout Drawing, KM05 OS-650 WS Mk2, El. Mech. DP/IAS, DeepLine 370987
Layout Drawing, KM05 OS-650 WS Mk2, El. Mech. HiPAP/ DeepLine 370980
Layout Drawing, OS-555-GEN-BI, Built In 1016217
Layout Drawing, Drop In Panel HPR/HiPAP, COP-05 Panel System 1016318
Layout Drawing, El. Mech. DP, Mounting Plate Rear Side, OS-650–HiPAP 311043
Deepline/Slimline
Outline Drawing, Display MD27, Desktop & Ceiling Bracket 364667
Power and Wiring Diagram, HiPAP 501 Kit, Slimline/Deepline, KM05 314202
Power and Wiring Diagram, KM05 HiPAP 501 OS WS Mk2, Slim Line/Deep 370964
Line/Built-in
Power and Wiring Diagram, KM05 Slimline/Deepline/Built-in WS Mk2, 370984
Standard El. Mech
Wiring Diagram, HPR Serial Line, Kit KM05, 4 x RS232 + 4 x RS422 309087
Wiring Diagram, Transducer Control HPR with Gate Vale Status, Drop In Panel 1016321
See also Common Kit Drawings list.

Parts List and Drawings – COP05 General OS-555-BI WS Mk2 370934

Outline Drawing, Display 27” LCD MD27 354260
Layout Drawing, OS-555-GEN-BI, Built In 1016217
Layout Drawing, KM05 OS-650 WS Mk2, El. Mech. DP/IAS, DeepLine 370987

54 371472/E
 Appendix A Hardware configuration status

Parts List and Drawings – COP05 General OS-555-BI WS Mk2 370934

Outline Drawing, Display MD27, Desktop & Ceiling Bracket 364667
Outline Drawing, MP7900 Mounting Kit 333313
Power and Wiring Diagram, KM05 General OS WS Mk2, Slim Line/Deep 370965
Line/Built-in
Power and Wiring Diagram, KM05 Slimline/Deepline/Built-in WS Mk2, 370984
Standard El. Mech
See also Common Kit Drawings list.

Parts List and Drawings – COP05 K-Thrust OS-555-BI WS Mk2 370928

Outline Drawing, Display 27” LCD MD27 354260
Layout Drawing, KM05 OS-650 WS Mk2, El. Mech. DP/IAS, DeepLine 370987
Layout Drawing, OS-555-TC-BI, Built In 1016248
Outline Drawing, Display MD27, Desktop & Ceiling Bracket 364667
Outline Drawing, MP7900 Mounting Kit 333313
Power and Wiring Diagram, KM05 K-Pos/K-Thrust OS WS Mk2, 370979
(SlimLine)/DeepLine/Built-in
Power and Wiring Diagram, KM05 Slimline/Deepline/Built-in WS Mk2, 370984
Standard El. Mech
See also Common Kit Drawings list.

Common Drop-in Kit Drawings

Layout Drawing, Drop In Panel 2 Position Switch, Deep/Slim Line KM05, Built-in 302424
Wiring Diagram, Drop In Panel 2 Position Switch, COP-05 Panel System 302427
Layout Drawing Drop In Panel 3 Position Switch, COP-05 Panel System 302428
Wiring Diagram, Drop In Panel 3 Position Switch, COP-05 Panel System 302431
Layout Drawing Drop In Panel 4 Position Switch, COP-05 Panel System 1016419
Wiring Diagram, Drop In Panel 4 Position Switch, COP-05 Panel System 1016400
Layout Drawing, Drop In Panel Alert Switch, Deep/Slim Line KM05, Built-in 302965
Wiring Diagram, Drop In Panel Alert Switch, Deep/Slim Line KM05, Built-in 302966
Layout Drawing Drop In Panel 2 Position Switch, Deep/Slim Line KM05, Built-in 302424
Wiring Diagram, Drop In Main/Backup DP Switch, KM05 310951
See also Common Kit Drawings list.

Parts List and Drawings – COP05 K-Chief OS-555-BI CANBus WS Mk2 373521
Outline Drawing, Display 22" LCD MD22 383408
Outline Drawing, Display 24" LCD MD24 383050
Outline Drawing, Display 27" LCD MD27 354260
Layout Drawing, KM05 OS-650 WS Mk2, El. Mech. DP/IAS, DeepLine 370987
Outline Drawing, Display MD22, Desktop & Ceiling Bracket 357881
Outline Drawing, Display MD24, Desktop & Ceiling Bracket 364666

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COP05 OS-555 Built-in WS Mk2

Parts List and Drawings – COP05 K-Chief OS-555-BI CANBus WS Mk2 373521
Outline Drawing, Display MD27, Desktop & Ceiling Bracket 364667
Outline Drawing, MP7900 Mounting Kit 333313
Power and Wiring Diagram, KM05 K-Chief OS WS Mk2, Deep Line/Built-in, 370975
KM05
Power and Wiring Diagram, KM05 Slimline/Deepline/Built-in WS Mk2, 370984
Standard El. Mech
See also Common Kit Drawings list.

Parts List and Drawings – K-Chief OS-555-BI EAS WS Mk2 377685

Outline Drawing, Display 22" LCD MD22 383408
Outline Drawing, Display 24" LCD MD24 383050
Outline Drawing, Display 27" LCD MD27 354260
Layout Drawing, KM05 OS-650 WS Mk2, El. Mech. DP/IAS, DeepLine 370987
Outline Drawing, Display MD22, Desktop & Ceiling Bracket 357881
Outline Drawing, Display MD24, Desktop & Ceiling Bracket 364666
Outline Drawing, Display MD27, Desktop & Ceiling Bracket 364667
Outline Drawing, MP8200, KM1000 Mounting Kit 365290
Power and Wiring Diagram, KM05 K-Chief OS WS Mk2, Deep Line/Built-in, 370975
KM05
Power and Wiring Diagram, KM05 Slimline/Deepline/Built-in WS Mk2, 370984
Standard El. Mech
See also Common Kit Drawings list.

Common Kit Drawings

Power and Wiring Diagram, Alarm Output, K-Chief OS-650/Built-in 312699
Layout Drawing, CANBus to Ethernet, K-Chief OS-650/Built-in 313313
Layout Drawing, Dual Power Input OS-650/BI 357786
Power and Wiring Diagram, CANBus to Ethernet, K-Chief OS-650/Built-in 313299
Power and Wiring Diagram, Dual Power Input, OS/BI with Inverter 357744
Power and Wiring Diagram, Fibre Net, K-Chief OS-650/Built-in 313300
Power and Wiring Diagram, Network Distribution Net A/B, K-Chief 313301
OS-650/Built-in
Power and Wiring Diagram, Network Distribution Net C, K-Chief 313302
OS-650/Built-in
Power and Wiring Diagram, Single EAS Network 378199
Power and Wiring Diagram, Redundant EAS Network 378200

56 371472/E
COP05 OS-555 Built-in WS Mk2

57 371472/E
©2013 Kongsberg Maritime