RMP420S

Hardware Module Description

Kongsberg Maritime Part no. 319824

323935/B
February 2010
Document history
Document number: 323935
Rev. A September 2009 First version.
Missing Ex descriptions. / Added details on AIV and AIC,
Ex text added to the Overview, Technical Specifications,
Rev. B February 2010
Configuration and Installation chapters. Added Safety HW loop
typical information to Function chapter.

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: [email protected]

Ko n g s b e r g M a r it im e A S
P. O. Bo x 4 8 3 Te le p h o n e : + 4 7 3 2 2 8 5 0 0 0
N- 3 6 0 1 K o n g s b e r g , Te le fa x : + 4 7 3 2 2 8 5 0 1 0
No r w a y S e r v ic e : + 4 7 8 1 5 3 5 3 5 5
w w w .k o n g s b e r g .co m
 Hardware Module Description

Table of contents
Glossary....................................................................................................................4
1 OVERVIEW........................................................................ 7
2 FUNCTION ........................................................................ 9
2.1 Power supply and loop power ..................................................................................9
2.2 RBUS interface.......................................................................................................10
2.3 Status LED .............................................................................................................10
2.4 Module address....................................................................................................... 11
2.5 Analog inputs ......................................................................................................... 11
2.5.1 Differences between AIV and AIC modes of operation.................................. 13
2.6 Redundancy configuration......................................................................................14
2.7 Failure handling......................................................................................................15
2.8 Power ON/OFF.......................................................................................................15
2.9 Module grounding ..................................................................................................15
2.10 Self diagnostics.......................................................................................................16
2.10.1 Module identification code .......................................................................... 16
2.10.2 Monitoring using watchdog ......................................................................... 16
2.10.3 Status shown on front LED.......................................................................... 16
2.10.4 I/O loop status ............................................................................................ 16
2.10.5 Internal circuitry tests.................................................................................. 16
3 TECHNICAL SPECIFICATIONS ......................................... 17
4 CONFIGURATION ............................................................ 19
4.1 Module identification ............................................................................................20
4.2 Ex label...................................................................................................................20
4.3 RBUS A (P1), RBUS B (P2) pin allocation ...........................................................20
4.4 Local terminal (P3).................................................................................................21
4.5 X1, X2, X3, X4 terminal allocation .......................................................................22
4.6 FL1 and FL2 ...........................................................................................................24
4.7 PEA and PEB .........................................................................................................24
5 INSTALLATION ............................................................... 25
5.1 Ex Zone 2 installation requirements.......................................................................25
5.2 Installation procedure .............................................................................................25
6 REPLACEMENT ................................................................ 26

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Kongsberg RMP420S

Glossary
1oo2 “One out of two” voting redundancy configuration
ADC Analog to Digital Converter
AI Analog Input
AIC Analog Input Current
AIV Analog Input Voltage
AO Analog Output
BIST Built-In Self test
CPLD Complex Programmable Logic Device
DI Digitial Input
DO Digital Output
DSP Digital Signal Processor
EFI Earth Fault Indicator
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
FD Field Device
GB Ground Benign
GND Module 0 V reference
HW Hardware
HSD High Side Driver
IE Instrumentation Earth
I/O Input/Output
KM Kongsberg Maritime
LED Light Emitting Diode
LSD Least Significant Digit
MSD Most Significant Digit
MTBF Mean Time Between Failure
NS Naval Sheltered
PE Protective Earth
RAM Random Access Memory
RBUS Remote I/O Bus
RCU Remote Control Unit
RFI Radio Frequency Interference
RIO Remote I/O
RMP420S Remote Multi Purpose module series 420 and S

4 323935/B
 Hardware Module Description

RS485 RS-485 (Recommended Standard 485) is a standard for serial

binary data signals connecting between a DTE (Data Terminal
Equipment) and a DCE (Data Circuit-terminating Equipment).
SW Software
TN-S-DC Terra Neutral Separated Direct Current
DC supply network type with protective earth conductor.
WD Watchdog

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Kongsberg RMP420S

6 323935/B
 Overview

1 OVERVIEW
The advanced remote I/O module RMP420S is approved
according to Safety Standard IEC 6150S Safety Integrity Level 3.
The module is designed to interface field I/O in both single and
redundant topologies. 32 AI field I/O channels are interfaced to
the host control computer via a remote I/O process bus interface
(RBUS).
Out of range monitoring is implemented on the module. If real
time in-range monitoring is mandatory for the application, this
shall be handled by the SIF (Safety Instrument Function) field
device (e.g. a SIL 2 safety function requires a SIL 2 qualified
sensor etc.).
The RMP420S is for safety use, and the RMP420 is for general
use.

Features of RMP420S:
• 32 solid-state configurable analog input current (AIC) and
analog input voltage (AIV) channels.
• Two remote I/O bus interfaces (RBUS A and RBUS B) for
redundant communication to the controller computer(s)
• High accuracy, 16 bits A/D and D/A converters
• I/O channels can be configured when system is running
• The remote I/O process bus interface circuitry is galvanic
isolated from other circuitry on the module.
• Easy installation and replacement:
– DIN-rail mounting
– Plug-in connections
– Two digit address switch
• Status LED on the front indicates running or error status
• Loop-check and debugging possible from operator station
• Short-circuit protected I/O loop current drivers
• RIO module and I/O loop, powered from the same source
• Embedded over-voltage protection, which safeguards the field
instruments
• Automatic Recovery Protection: Automatic restart of faulty
channel
• Automatic calibration in run-time to compensate for drift by
temperature change
• Fail-safe activation of outputs upon loss of communication
• Soft and hard fail-safe modes available on outputs (equal to
module reset and power ON status)

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Kongsberg RMP420S

• Extended built-in self test (BIST) features for controller

self-diagnostics and fault identification during start-up and
run-time
• Suitable for use in SIL applications:
– SIL 2 as single module configuration
– SIL 3 as redundant module configuration
• Fully grounded to PE or IE
• Ex Zone 2 type approved

8 323935/B
 Function

2 FUNCTION
Figure 1 Block diagram

The RMP420S provides a number of interfaces and functions.

The main function blocks are:
• Power supply
• RBUS interfaces
• Communication controller
• I/O with signal conditioning circuitry
• Self diagnostics

2.1 Power supply and loop power

24 VDC loop power to the RMP420S is provided via the terminal
blocks X1 to X4. The four power terminals are interconnected.
The module uses the loop power to make several internal voltages
(see illustration below). To protect the power supply components
against overvoltage a tranzorber is connected on the input side.
However, external fuses must be fitted on the power input to
limit input current.

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Kongsberg RMP420S

Figure 2 Power supply principles

2.2 RBUS interface

The bus design consists of multidrop RS485 serial lines.
RBUS A and RBUS B are galvanically isolated from each other
and from the I/O part of the module.
Manchester Coding is used in order to avoid timing problems
and reduce cabling cost.
The RBUS cable also supply power (+24 VDC) to the isolated
part of the RS485 line.
The RBUS’s 24 VDC power supply can be the same as the host
controller computer supply.
Note
For cable requirements see section 3 on page 17.

2.3 Status LED

The module is provided with a two-coloured LED for visual
status indication. The LED is located on the front of the module.
It is green when the system is running and no error is detected.
It is red otherwise.

Table 1 Status indicators on module front

LED Colour, state Function

name
Status Green, fixed Module has been configured and is ready to run.
Green - dark, Normal operation. Dark flashing for each scan, i.e.
flashing input/output messages are received.
Red, fixed Serious HW or SW error condition occurred.
Fail-safe is activated.
Red - Green, Illegal address switch setting (00).
flashing

10 323935/B
 Function

2.4 Module address

Each module must be set to a unique address number that
identifies this module among the others connected to the
same remote I/O process bus (RBUS). The address number is
represented by two decimal switches, MSD (most significant
digit) and LSD (least significant digit).
The address is compared with the RBUS address set out from the
host controller computer (RCU). If they are equal, the module
responds.
The total number of RIO modules on one RBUS is 99 (address
range 1 to 99).

2.5 Analog inputs

The +24 VDC Loop Power terminals are interconnected between
terminal blocks X1 through X4, and the Loop Power Ground
terminals are interconnected in the same way. The zero voltage is
connected to common ground inside the module.
Inside the module all output terminals (CHnHi) have been
individually protected against over-voltage by power diodes
connected to the loop power terminal and the ground terminal
(embedded over-voltage protection).

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Kongsberg RMP420S

Figure 3 Signal loop types

Note
Regarding earth fault detection, if external I/O power topology is
implemented, KM supplied earth fault monitoring solution (EFI)
will not provide a fully functional earth fault monitoring.
For detailed I/O loop information see the appropriate KM
generic HW loop-typical drawing describing the specific I/O
loop.

12 323935/B
 Function

Note
This note is for KM internal use only:
The available HW loop typicals for Safety use are described at the
KM internal web publishing location KSWEB (http://ksweb/pck/).
This web location is available to all KM employees.
To open the description page, follow this procedure:
1 Open web page http://ksweb/pck/
2 Click IO Driver Information in the left pane
3 Click RBUS link in the table.
4 Click Design documents link under Content
5 Click RMP420S-32 ChannelCodeTable link in RIO Module
specific documents table
6 Click rmp420S-32_channel_codes_2 link in RMP420S Design
documents table.

See also section 3 on page 17 for interface information and

section 4.5 on page 22 for terminal allocation description at field
device.

2.5.1 Differences between AIV and AIC

modes of operation
The built-in Analog to Digital Converter (ADC) reads the
process-signal value from the field sensors as voltage.

AIV - Analogue Input Voltage

In AIV mode the field sensors feed voltage directly to the built
in ADC (Analogue to Digital Converter).

AIC - Analogue Input Current

In AIC mode the field sensors feed current through a measuring
resistor (RC)at the channel input, The voltage dropped across this
resistor feeds the built in ADC.

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Kongsberg RMP420S

2.6 Redundancy configuration

In a redundant 1oo2 I/O system, field equipment can only be
connected to RMP420S channels configured as Analog Input
Voltage (AIV) (see illustration below).

The figure represents a logical view of the connection. Physical

connection of the signals to the dual redundant RIO modules
may be done internally in the field equipment if supported, or by
cross termination within the RCU/RIO cabinets, i.e. the physical
connection can be a redundant connection as opposed to a single
connection.
Note
For detailed I/O loop information see the appropriate KM
generic HW loop-typical drawing describing the specific I/O
loop.

14 323935/B
 Function

2.7 Failure handling

The module is provided with a HW watchdog logic and DSP
failure output.
• If a serious HW error occurs in the module, all output channels
are set to high impedance.
• If the DSP stops, the communication interface outputs are set
to high impedance (no communication with the RCU(s) is
possible).

2.8 Power ON/OFF

At module power ON (before the communication with the RCU
is established) and at power OFF, all outputs will be set to high
impedance.

2.9 Module grounding

In a TN-S-DC system the module can be grounded to IE or PE
using the fast-on terminals FL1 and FL2 according to IEC 60364.
Earth fault detection can be done by using external devices. If so,
FL1 and FL2 shall not be connected to IE/PE.
Note
This is the recommended ground alternative due to high noise
immunity, over-voltage protection as well as EMC (ESD, RFI
etc).

Figure 4 Module grounding in a TN-S-DC system according to IEC 60364

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Kongsberg RMP420S

2.10 Self diagnostics

Extensive self diagnostics are built into the module to detect
faults related to it.

2.10.1 Module identification code

Every module has been programmed with a unique identification
code (ID-code). This ID-code also identifies the type of module
it is, so that the system can supervise that the correct type of
module is installed with the correct address.

2.10.2 Monitoring using watchdog

A watchdog (WD), controlled from the module SW, controls
whether the module will go to fail-safe.

2.10.3 Status shown on front LED

See section 2.3 on page 10 for details.

2.10.4 I/O loop status

The input signals or the read-back of output signals can be
examined for out-of-range values, and faults can be detected.
The signal loop type selected decides what signal type and range
can be detected (see section 2.5 on page 11).

2.10.5 Internal circuitry tests

2.10.5.1 Running diagnostics

The Analog to Digital Converter (ADC) is continuously tested
by read-back of an internal reference voltage (2.5 VDC).

2.10.5.2 Temperature
There are two temperature-based functions in the module.
• Temperature can be continuously monitored by the system
software.
• Temperature based shut-down, controlled by the module itself
and at fixed shut-down temperature.

16 323935/B
 Technical Specifications

3 TECHNICAL SPECIFICATIONS
Table 2 Technical specifications

Power supply requirements and specifications

Input voltage 24 VDC +30% -25%
Current consumption Idle current ≈ 0.35 A + loop current maximum 32
A (maximum 1 A per channel)
Heat dissipation 10 W typical
Surge energy (inrush energy at power on of module) 0.6 J (joule) for 1 ms
Power rise time at power ON Maximum 20 ms/V monotonic slope
I/O channel common
X1 - X4 connectors Screw terminals 2.5 mm2 Phoenix COMBICON
MDSTBV 5.08 mm
Overvoltage Maximum Input supply voltage + 0.5 VDC
without damage
Loop Power Capability
Loop voltage Input supply voltage
Front end device Short circuit proof High Side Driver
Loop output Maximum 1 A, minimum 10 mA
Loop driver trip current Approximately 1.4 A at 20°C (reset by command)
Loop driver OFF leakage current Maximum 100 µA at 24 VDC supply voltage
Channel 1 - 32 specifications
Voltage input 0 - 4 V, 0 - 10 V
Current input 0 - 20 mA
Input resistor to ground 150 ohm, ± 0.1 %
Automatic protection 26 mA
Measurement accuracy ±0.15 % of full scale
Offset ±30 mV
Analog to Digital Converter ADC
Voltage ranges 0 - 4 V and 0 - 10 V
Resolution 16 bit
Accuracy (correlated with linearity, offset, gain and ±0.15 % of full scale
temperature drift parameters listed below)
Linearity ±0.01 % of full scale
Offset ±30 mV
Gain ±0.02 % of full scale
Temperature drift ±20 ppm/°C
RBUS
Number of addresses 99
Number of channels 2
Power supply 24 VDC ±20 % (maximum 50 mA)

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Kongsberg RMP420S

Table 2 Technical specifications (cont’d.)

Connector 9 Pin DSUB female

Bit rate 2 Mbit/sec
Signal code Manchester encoded (self-clocked)
Copper wire technology:
Insulation 500 V (optocoupler)
Physical layer RS-485 multidrop
Cable attenuation < 6.5 dB/100 m at 10 MHz (CAT 5)
Cable length Maximum 200 m between repeaters. Maximum
3 repeaters.
Fibre optics technology:
Insulation Galvanic
Fibre cable 62.5/125 μm, multi-mode
Connector ST
Maximum cable length 1000 m (point to point), 500 m if fitted in patch
panel topology
Hard fail safe
Watch-dog response Minimum 65 ms
Internal test error (DSP) Instantly set
Soft fail safe (down counter)
Programmed down-counter, time range 100 ms - 65 s (default 6 s)
Mechanical specifications
Module size (W x H x D) 158 x 355 x 87 mm
Weight 1.35 kg
Mounting Screw locks on DIN-rail T35–15/7.5
Compatibility
EMC directive CE mark compliant. Conform to 2004/108/EC
Atex directive 94/9/EC
EN directive 60079 for Electrical apparatus for explosive gas Ex nA II T4
atmospheres
Ex-protection specifications II 3G EEx nA II T4 Ta: 55°C
Safety directive SIL 3 approved according to IEC 61508
Environmental requirements
Operating temperature -15°C – +70°C
Storage temperature -25°C – +70°C
IP class IP 20
Life cycle specifications (predicted data)
Predicted failure rate (T = 25°C, env. = GB) (60% confident 38.5 years
based on chip suppliers data)
Predicted failure rate (T = 35°C, env. = NS) (Environmental 10.4 years
de-rating based on Rome Laboratory tool-kit)

18 323935/B
 Configuration

4 CONFIGURATION
Figure 5 Component layout

323935/B 19
Kongsberg RMP420S

4.1 Module identification

For any communication in writing with Kongsberg Maritime on

this module you should refer to the module name (RMP420S)
and the information on the module identification label.

4.2 Ex label

The Ex label contains two lines of information:

• Nemko 07ATEX3090X is the type approval certificate
number.
• II 3G EEx nA II T4 Ta: 55ºC are the Ex requirements satisfied
by the module.

4.3 RBUS A (P1), RBUS B (P2) pin allocation

RBUS A and RBUS B are 9-pin male D-sub connectors.

Figure 6 RBUS A and B connector pin layout

Table 3 RBUS A and RBUS B pin allocation

Pin no. RBUS A RBUS B Function

1 A_DATA_H B_DATA_H RS485 serial line H
2 A_DATA_L B_DATA_L RS485 serial line L
3 A_0V B_0V 0 V, ground reference for isolated RS485
transmitter/receiver

20 323935/B
 Configuration

Table 3 RBUS A and RBUS B pin allocation (cont’d.)

Pin no. RBUS A RBUS B Function

4 Not used (NC = Not Connected)
5 A_24V B_24V +24 VDC for isolated RS485 transmitter/receiver
6 A_5V B_5V Termination voltage
7 A_0V B_0V 0 V, ground reference for isolated RS485
transmitter/receiver
8 Not used (NC = Not Connected)
9

4.4 Local terminal (P3)

Local terminal is an 8-pin female RJ45 connector. It is not in use.

323935/B 21
Kongsberg RMP420S

4.5 X1, X2, X3, X4 terminal allocation

Each Xn terminal group consists of two terminal blocks, one for
terminal 1 through 13 and one for terminal 14 through 26. All
field signals are connected via the four terminal groups (X1 to
X4). Each terminal group handles eight I/O channels.

Figure 7 X1 to X4 with channel and terminal layout and names

22 323935/B
 Configuration

Table 4 X1, X2, X3, X4 terminal allocation

Term no. X1 term. group X2 term. group X3 term. group X4 term. group
1 CH1Hi CH9Hi CH17Hi CH25Hi
2 CH1GND CH9GND CH17GND CH25GND
3 CH1Lo CH9Lo CH17Lo CH25Lo
4 CH2Hi CH10Hi CH18Hi CH26Hi
5 CH2GND CH10GND CH18GND CH26GND
6 CH2Lo CH10Lo CH18Lo CH26Lo
7 CH3Hi CH11Hi CH19Hi CH27Hi
8 CH3GND CH11GND CH19GND CH27GND
9 CH3Lo CH11Lo CH19Lo CH27Lo
10 CH4Hi CH12Hi CH20Hi CH28Hi
11 CH4GND CH12GND CH20GND CH28GND
12 CH4Lo CH12Lo CH20Lo CH28Lo
13 0 V 0 V 0 V 0 V
14 CH5Hi CH13Hi CH21Hi CH29Hi
15 CH5GND CH13GND CH21GND CH29GND
16 CH5Lo CH13Lo CH21Lo CH29Lo
17 CH6Hi CH14Hi CH22Hi CH30Hi
18 CH6GND CH14GND CH22GND CH30GND
19 CH6Lo CH14Lo CH22Lo CH30Lo
20 CH7Hi CH15Hi CH23Hi CH31H
21 CH7GND CH15GND CH23GND CH31GND
22 CH7Lo CH15Lo CH23Lo CH31L
23 CH8Hi CH16Hi CH24Hi CH32H
24 CH8GND CH16GND CH24GND CH32GND
25 CH8Lo CH16Lo CH24Lo CH32L
26 +24 V +24 V +24 V +24 V

Table 5 X1, X2, X3, X4 terminal description

Name Function
CHnHi Channel #n high – loop drive terminal
CHnLo Channel #n low – loop return terminal
CHnGND Channel #n 0V – signal ground reference for channel #n
0V Module power 0 V – power voltage reference
+24 V Module power +24 VDC – loop power

323935/B 23
Kongsberg RMP420S

4.6 FL1 and FL2

Two fast-on terminals FL1 and FL2 are connected to 0 V of the
RIO module.

4.7 PEA and PEB

PEA and PEB are two fast-on terminals respectively connected
to the two RBUS connectors P1 and P2 (9-pin D-sub) inner cable
shields. They are normally connected to IE or to system ground
(PE). RBUS cable outer shield is normally connected to PE.

24 323935/B
 Installation

5 INSTALLATION
Note
The module is mounted vertically on a DIN-rail. The module’s
top and bottom can be mounted with no spacing to any cabinet
top, bottom, DIN-rail modules etc.

5.1 Ex Zone 2 installation requirements

The choice of enclosure, placement of modules, components and
free volume inside enclosure will affect the temperature.
When the module is used in Ex Zone 2, the following
requirements must be met:
• The RIO module shall be mounted in an enclosure which
complies with the requirement of clause 26.3 of EN 60079-15
and fulfil IP 54, or alternatively is mounted in an EEx
e-enclosure.
• Maximum surface temperature shall not exceed temperature
class T4 corrected for the maximum ambient temperature at
service (Ta: 55°C) within the safety margin of 5°K.
• Maximum ambient temperature inside enclosure shall not
exceed 75°C.

5.2 Installation procedure

1 Label the module.
2 Set correct module address by rotating the two decimal
switches to correct values (see section 2.4 on page 11).
3 Fix the module to the rail by fastening the screw on top
and bottom.
4 Connect wires to the fast-on terminals FL1 and FL2, PEA
and PEB as appropriate.
5 Connect all field wires and power wires to the appropriate
screw terminals on X1 to X4.
6 Connect the RBUS cables to the RBUS A and RBUS B
connectors and fasten the connectors by using the plug’s
end bolts.
7 Turn on the power supply to the module.
8 Verify from the operator station that the module is working
OK.

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Kongsberg RMP420S

6 REPLACEMENT
1 Turn off the power circuit that supplies the RIO module to
be replaced.
2 Disconnect field wiring and power wiring by unscrewing the
end-bolts and pulling off the eight snap-on terminal blocks
for X1 to X4.
3 Disconnect the RBUS A and RBUS B connectors by loosen
the end bolts and unplug.
4 Disconnect wires to the fast-on terminals FL1 and FL2, PEA
and PEB as appropriate.
5 Loosen the top and bottom screws that fasten the module to
be replaced and remove it.
6 Unscrew the end-bolts and pull off the snap-on terminal
blocks X1 to X4 of the new RIO module.
7 Label the new module.
8 Set correct module address by rotating the two decimal
switches to correct values (see section 2.4 on page 11).
9 Fix the module to the rail by fastening the screws on top
and bottom.
10 Connect wires to the fast-on terminals FL1 and FL2, PEA
and PEB as appropriate.
11 Reconnect all field wires and power wires to the appropriate
connector X1 to X4 by snapping on the eight connector
headers and fastening them by using the end bolts.
12 Plug the RBUS cable plugs to the RBUS A and RBUS B
connectors and fasten the plug’s end bolts.
13 Turn on the power supply to the module.
14 Verify from the operator station that the module is working
OK.

26 323935/B
 Replacement

323935/B 27
 ©2010 Kongsberg Maritime

Ko n g s b e r g M a r it im e A S
P. O. Bo x 4 8 3 Te le p h o n e : + 4 7 3 2 2 8 5 0 0 0
N- 3 6 0 1 K o n g s b e r g , Te le fa x : + 4 7 3 2 2 8 5 0 1 0
No r w a y S e r v ic e : + 4 7 8 1 5 3 5 3 5 5
w w w .k o n g s b e r g .co m