KONGSBERG RCU500 Controller Manual

2.6 Fieldbus Interface

Dual CAN bus: Supports CAN 2.0A/B, with a speed of up to 1 Mbps. Each CAN interface can be independently configured and is commonly used to connect engine control modules, battery management systems, etc.

Dual Profibus: With a speed of 12 Mbps, it can be configured as a DP master or slave. Profibus is still widely used in process automation, and dual interfaces can achieve redundant buses.

SPBus (Serial Process Bus): Dedicated to connecting RIO 400 series remote I/O units. SPBus adopts RS-485 multipoint topology, Manchester coding (self clock), the highest frequency is 2 MHz, and 500V optocoupler isolation is provided through 9-pin male DSUB connector. SPBus allows multiple RIO 400 modules to be mounted on the same bus, thereby expanding the number of I/O points.

2.7 Dual Ethernet interface

Two 100 Mb Ethernet interfaces support redundant LAN configuration. In typical ship or platform control systems, network redundancy is necessary: two interfaces are connected to independent network switches, and when one network path fails, RCU500 can automatically switch to the other interface. Ethernet is used for communication with operation stations, other controllers, remote diagnostic systems, and ship management systems.

2.8 Redundant Operations and Hot Replacement

RCU500 is designed for redundant operation: two RCU500s can be configured in primary/backup mode. The main controller executes control logic and synchronizes the status to the backup unit through heartbeat signals or dedicated redundant buses. When the main unit fails, the backup unit automatically takes over.

Hot Replacement is a key feature: in a redundant system, a faulty RCU500 can be physically unplugged and replaced with a new unit without the system being powered on. After the new unit is powered on, it automatically synchronizes its configuration and status with the current main unit, and then enters standby mode. This feature significantly reduces the mean time to repair (MTTR) and improves system availability.

Installation and Wiring Guide

3.1 Mechanical Installation

RCU500 is installed using DIN standard rails (35mm top cap rails) and is suitable for horizontal or vertical placement inside control cabinets. The installation steps are as follows:

Hook the lower slot onto the lower edge of the DIN rail.

Push RCU500 towards the cabinet direction, so that the upper retaining spring is engaged with the upper edge of the guide rail.

Confirm that the lock is in place.

Due to its weight of only 1.35kg, a single device does not require additional support. But the heat dissipation distance between devices should be considered (at least 50mm ventilation space above and below).

3.2 Electrical Connections

power supply

Input voltage: 24 VDC ± 20% (i.e. 19.2 V~28.8 V), directly compatible with typical ship and industrial power sources.

Maximum power consumption: 20 W (approximately 0.83A @ 24V).

Connector: pluggable screw terminal, with a maximum wire cross-sectional area of 1.5mm ² (approximately 16 AWG).

Polarity protection: There is a reverse polarity protection diode inside.

It is recommended to use shielded twisted pair cables for wiring, with the shielding layer grounded at a single point on the power end.

SPBus interface:

Connect the 9-pin DSUB male connector to the RIO 400 bus. It is recommended to use a dedicated shielded cable, and the last device on the bus should be terminated with a 120 Ω resistor.

CAN and Profibus:

Using a standard 9-pin DSUB connector (pin allocation reference specific document). For redundant CAN/Profibus, connect them to different interfaces separately.

Digital I/O:

Connect through screw terminals. Digital input can accept 10-30V DC dry contacts or level signals; The collector of the digital output is open circuited, and the maximum driving current is about 100mA. An external relay or indicator light needs to be connected with a freewheeling diode.

Serial port:

Connect the corresponding pins according to the required protocol (RS-232/422/485). For RS-485, pay attention to the correct wiring of A/B terminals; For RS-422, use full duplex four wire.

3.3 Grounding and Shielding

All communication cable shielding layers should be grounded on the RCU500 side (through the DSUB enclosure or terminal grounding). The power ground (GND) should be connected to the protective ground of the cabinet, but it is necessary to avoid ground circulation. RCU500 has high-frequency decoupling capacitors inside, but it is recommended to install ferrite magnetic rings externally to suppress conducted interference.

Environmental specifications and certification

4.1 Working environment

Temperature: 0 ° C to 70 ° C (operation), -25 ° C to 70 ° C (storage). For installation inside the cabinet, it is necessary to ensure good ventilation. If the ambient temperature is close to the upper limit, the built-in cooling fan should work normally.

Humidity: Maximum relative humidity of 98%, no condensation.

Heat dissipation: Maximum 20 W, passive heat dissipation supplemented by cooling fan (with alarm output in case of built-in fan failure).

Protection level: IP20, only suitable for dry and dust-free control room environments.