KONGSBERG RCU500 Controller Manual

4.2 Electromagnetic Compatibility and Standards

RCU500 is designed according to the following standards:

IEC 61131-2: General requirements for programmable controllers

IEC 60945: Maritime navigation and wireless communication equipment

IACS E10: Uniform Requirements for Ship Electrical Equipment by the International Association of Classification Societies

IEC 61508: Functional Safety (SIL Level)

And meet EMC standards: EN 61000-6-2 (industrial immunity), EN 61000-6-4 (industrial emission), and EN 60945.

4.3 Classification Society Certification

The goal of RCU500 is to obtain type certification from DNV (Det Norske Veritas), ABS (American Bureau of Shipping), and T Ü V Rheinland (for IEC 61508). When selecting the project, it is necessary to confirm the latest certification status.

Software Compatibility and Development

RCU500 is binary compatible with RCU400H and SBC500 software. This means that real-time applications compiled for these old platforms can run directly on RCU500 without modification. This greatly simplifies the system upgrade process.

The supported operating systems are usually KONGSBERG's proprietary real-time kernel or commercial RTOS such as VxWorks. The application can be written in C/C++and access hardware interfaces (serial port, CAN, Profibus, Ethernet, etc.) through the API provided by KONGSBERG SPBus、 Digital I/O, etc.).

Typical application scenarios

6.1 Dynamic positioning system

The Dynamic Positioning (DP) system requires the controller to process data from sensors such as satellite positioning (GPS, GLONASS), gyrocompass, wind sensors, and Motion Reference Unit (MRU) at high frequencies, and calculate thruster commands to maintain the ship's position. The 400 MHz processor, multiple serial ports, and dual Ethernet of RCU500 fully meet the computing and communication requirements of DP2/DP3 levels. The redundant RCU configuration and hot swap function ensure that even if the main controller fails, the ship's positioning will not be lost.

6.2 Ship Integrated Control System

The propulsion, power management, ballast water, fuel, alarm monitoring, etc. of modern ships all need to be centrally managed through controllers. The Profibus and CAN interfaces of RCU500 can be connected to the engine control unit and generator protection device; Serial port connection to various ship instruments; Ethernet connects the operation station and remote access. SPBus extends RIO 400 remote I/O to connect on-site signals (switches, sensors) to the controller.

6.3 Process Control System

RCU500 can be used to control process equipment such as separators, compressors, and pump sets on onshore or offshore oil platforms. Dual redundant Profibus connects DCS or PLC, SPBus connects on-site I/O, and redundant Ethernet connects historical and operator stations.

6.4 Safety Instrumented System

When designed according to IEC 61508, RCU500 can be used to achieve safety functions such as emergency shutdown and fire protection. Built in self-test and watchdog are important parts of diagnostic coverage. It should be noted that the SIL level depends on the overall system design, and the T Ü V certification of RCU500 helps simplify project certification.

Fault diagnosis and maintenance

7.1 Status LED Indication

The status LED on the front panel provides quick diagnostic information (specific colors and flashing patterns need to refer to the product manual, but typical functions include):

Power: Normal power supply (green)

Run: System running (flashing green)

Fault: Hardware or software malfunction (red)

Watchdog: Watchdog triggered or system reset (yellow/red)

Link/ACT: Ethernet Connection and Activity

7.2 Common Troubleshooting

Problem 1: RCU500 cannot start, power LED does not light up

Check if the 24V input voltage is within the range of 19.2-28.8V.

Check if the terminal connections are secure and if the polarity is correct.

Measure whether the internal fuse (if any) is blown.

Question 2: RCU500 Periodic Reset

It may be that the watchdog is not feeding the dog properly. Check for dead loops or task blocking in the application.

Check if the power supply fluctuates too much (such as voltage drops caused by faults).

View the error report of the operation station and locate the specific BIST failure item.

Problem 3: SPBus is unable to communicate with RIO 400

Confirm that both ends of the bus have been terminated (120 Ω).

Check if the cable is too long or interfered with (using shielded twisted pair).

Use an oscilloscope to check the amplitude of the SPBus signal (RS-485 differential signal usually ± 2V or above).

Confirm that the SPBus frequency configuration is compatible with RIO 400.

Problem 4: Redundancy switching failure

Check if the redundant configuration parameters of the two RCU500 are consistent (such as primary and backup roles, heartbeat interval).

Verify the physical connection and communication status of redundant dedicated links (such as serial ports or Ethernet).

Simulate a power outage in the main unit and observe whether the backup unit is connected within the expected time.

Question 5: High temperature alarm

Check if the built-in cooling fan is running (listen to the sound or manually measure the air volume).