Hardware Module Description: Kongsberg Maritime Part No.330924
Hardware Module Description: Kongsberg Maritime Part No.330924
Hardware Module Description: Kongsberg Maritime Part No.330924
358190/F
June 2014 © Kongsberg Maritime AS
Document history
Document number: 358190
Rev. A December 2011 First version.
Updated sections 1.3, 2.1.1, 2.1.2, 2.1.3.1, 2.1.5 and 4.10 for
Rev. B May 2012
TÜV approval.
Rev. C February 2013 Life cycle predictions updated.
Rev. D April 2013 Interface policy towards 3rd party equipment has been corrected
from direct Serial Line interfaces to indirect Serial Link
communication through RSER
Rev. E March 2014 Corrected chapter 3 to “RBUS 9–pin male DSUB connector”.
Harmonized document in accordance with IECEx.
Rev. F June 2014 Updated document in accordance with ATEX.
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]
Kongsberg Maritime AS
www.kongsberg.com
Hardware Module Description
Table of contents
Glossary....................................................................................................................5
MODULE OVERVIEW.......................................................... 9
Document user..........................................................................................................9
Module functions and features .................................................................................9
Safety information ..................................................................................................10
MODULE FUNCTION ........................................................ 11
Controls, indicators and system connector.............................................................12
NMI push-button ........................................................................................ 12
RESET push-button .................................................................................... 12
RCU condition monitoring .......................................................................... 12
RCU502 system alarms .......................................................................... 12
Address switches (MAC 1, MAC 2, MAC 3) ................................................ 13
Example of address setting ..................................................................... 13
MODE switch............................................................................................. 14
LED indicators ........................................................................................... 14
Run status LED...................................................................................... 14
Eight test status LEDs ............................................................................ 15
RS232 console connector (P6) ..................................................................... 16
Power supply ..........................................................................................................16
Process Net interfaces ............................................................................................17
FieldNet interfaces .................................................................................................17
RedNet interfaces ...................................................................................................17
Serial link interfaces ...............................................................................................18
RBUS interfaces .....................................................................................................18
CAN interfaces .......................................................................................................19
PROFIBUS DP interfaces ......................................................................................19
Onboard I/O channels and Watchdog.....................................................................19
Self diagnostics.......................................................................................................19
Watchdog control........................................................................................ 19
Module grounding ..................................................................................................20
Safety functions ......................................................................................................20
TECHNICAL SPECIFICATIONS ......................................... 21
MODULE PIN AND CONNECTOR DESCRIPTION ................ 25
Module identification ............................................................................................25
Ex label...................................................................................................... 26
P6 pin allocation (Console connection)..................................................................26
P8 and P9 (Process Net connection) pin allocation................................................27
P30 and P31 (FieldNet connection) pin allocation.................................................28
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Kongsberg RCU502
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Hardware Module Description
Glossary
ADC Analog Digital Converter
BITE Built-In Test Equipment
CAN Controller Area Network
CPLD Complex Programmable Logic Device
CPU Central Processing Unit
DI Digital Input
DLL Delay locked loop
DO Digital Output
DSP Digital Signal Processor
ECC Error Correction Code
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
FPGA Field-Programmable Gate Array
GND Module 0 V reference
HF High Frequency
HW Hardware
I2c Inter Integrated Circuit
2–wire computer bus interface
IE Instrumentation Earth
IEEE Institute of Electrical and Electronics Engineers
I/O Input/Output
IRQ Interrupt request
KM Kongsberg Maritime
LAN Local Area Network
LED Light Emitting Diode
Link Channel Point to point serial line interface between RCU502 and
RSER200-4
MAC Media Access Control
MB Mega bit
MHz Mega Hertz
MTBF Mean Time Between Failure
NMI Non-Maskable Interrupt
PCI Peripheral Component Interconnect
Computer bus interface
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PE Protective Earth
PLD Programmable Logic Device
Process Net Process Network A and B based on Ethernet
10BASE-T/100BASE-TX
PROFIBUS Process Field Bus
PROFIBUS DP PROFIBUS DP is a device level bus that supports both analog and
discrete signals. PROFIBUS DP has widespread usage for such
items as remote I/O systems, motor control centres, and variable
speed drives. PROFIBUS DP communicates at speeds from 9.6
kbps to 12 Mbps over distances from 100 to 1,200 meters.
RAM Random Access Memory
RBUS Remote I/O Process Bus
RBUS interface RIO communication link based on multi-drop 2 Mbps RS485
with Manchester encoding
RBUS Power Electrical power supply to the RIO200 modules including field
channels
RCU500 Remote Controller Unit series 500
RCU501 Remote Controller Unit series 501
RCU502 Remote Controller Unit series 502
RedNet Redundancy Network based on Ethernet
100BASE-TX/1000BASE-T
RHUB200–5 RBUS hub module
RIO Remote I/O
RIO200 Kongsberg Maritime Remote I/O 200 module family
RIO420 Kongsberg Maritime Remote I/O 420 module family
RFI Radio Frequency Interference
RMP Remote Multi Purpose I/O module
ROM Real Only Memory
RS232 Electrical Interface standard for single ended serial data
communication.
RS422 Electrical Interface standard for single ended, differential,
balanced serial data communication.
RS485 Electrical Interface standard for differential, balanced, multipoint
serial data communication.
RSER200–4 Serial line interface module
SBC Single Board Computer
SRAM Static Random Access Memory
SDRAM Synchronous Dynamic Random Access Memory
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Hardware Module Description
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Kongsberg RCU502
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Module overview
Module overview
Document user
This document is intended to be used for HW engineering, hook-up and maintenance.
Physical interfaces and capabilities are described.
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Safety information
This unit has been developed in accordance with IEC 61508 ed. 2.
It can be used in safety functions for SIL 1,2 and 3, provided topologies and
calculations are fulfilled as required by the K-Safe documentation. The relevant K-Safe
documentation prepared for each safety project is based on the K-Safe Operator Manual
(KM document 343964) and the K-Safe Architecture Specification (KM document
331002).
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Module function
Module function
RCU502 is a high performance, general purpose, real-time process control computer for
use in a wide variety of KM system applications in both on- and offshore installations.
The processor core is an embedded Power PC™architecture. The unit is SIL qualified
and prepared for triple unit redundancy topologies.
Except for that the serial link 7 and 8 are replaced with field Ethernet, the unit is fully
backward compatible with the prior RCU501. It is also functionally compatible, but not
plug compatible, with RCU500.
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Kongsberg RCU502
NMI push-button
The NMI stops the executing programs in the RCU. Watchdog will be activated and
all output will turn to fail safe state. Now the RCU can be inspected by qualified KM
personnel. The RCU may be restarted by pushing the RESET button.
RESET push-button
Pushing the reset button will restart the RCU. Consequentially output will go to fail safe
state. After the reset is complete the application will be initiated automatically.
The reset button is used in order to reload the application.
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Module function
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Kongsberg RCU502
MODE switch
The RCU502 has a hexadecimal MODE switch (S4) (see Figure 3 on page 13), which is
used to set operational mode. It is used for flashing resident application programs to the
flash memory and for advanced servicing and debugging purposes.
The front MODE HEX switch controls the booting of code. The following HEX switch
settings can be used:
MODE HEX Function
switch setting
0 The RCU boots normally.
The switch shall almost always be in this position.
The other positions are for special purposes only to be operated
by KM qualified personnel only.
1 The RCU will only attempt to boot from the Process network.
2 The RCU will only attempt to boot from the Process network.
5 ECC is not started.
BIST is skipped which means that the RAM is not zero’ed.
The target shall enter the boot loop.
D ECC is not started.
BIST is skipped which means that the RAM is not zero’ed.
The target shall enter the boot monitor. (Auto boot is disabled)
F Application will not be started (initApplication() is not called.)
Note
The switch has to be set to 0 (zero) for normal operation (default setting).
LED indicators
Run status LED
The status LED is located on the front cover. It can be red or green - indicating run
or error status.
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Module function
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Power supply
One or two power supplies (24 VDC) can be connected to RCU502 using the dual
terminal block X2. Two independent power supplies (X2 A and B connection) are used
when power supply redundancy is required.
To protect the voltage regulators against overvoltage, a tranzorber is mounted across the
power terminals of X2. To protect the voltage regulators against overload, an automatic
resettable fuse is implemented on the input side. It is however mandatory to fit an
external fuse on the module power supply.
The internal voltages are monitored by the module.
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Module function
FieldNet interfaces
RCU502 is provided with two FieldNet interfaces, FieldNet 1 (P30) and FieldNet 2 (P31)
for Ethernet communication with the field instrumentation e.g. fire centrals etc.
Typical communication protocols may be e.g. Modbus TCP and PROFInet.
Note
Safety: For IEC 61508 functions only qualified I/O drivers shall be used.
RedNet interfaces
RCU502 is provided with two Ethernet based ports RedNet Next (P10) and RedNet
Previous (P11) for redundancy interconnection of the RCUs.
Two or three RCU502 can be interconnected in redundancy configurations.
Interconnecting cables used for RedNet must be provided with crossed RX and TX pairs.
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Kongsberg RCU502
RBUS interfaces
The RCU502 has two galvanic isolated remote I/O process bus interfaces (RBUS
A and RBUS B) for single or redundant RBUS Link networks. The bus facilitates
communication between single or redundant controllers and I/O modules in the RIO200
and RIO420 systems. The RBUS is based on multidrop RS485 serial lines.
The two RBUS Link interfaces are available on the P19 and P20 connectors respectively.
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Module function
CAN interfaces
The RCU502 is provided with two CAN ports (CANBUS 1 and CANBUS 2), which are
available on the X4 and X5 connectors respectively. The CAN interfaces are designed
according to the requirements of Device Net.
Note
Safety: For IEC 61508 functions only qualified I/O drivers shall be used.
PROFIBUS DP interfaces
The RCU502 contains two PROFIBUS DP ports (PROFIBUS 1 and PROFIBUS 2),
which are available on the P14 and P15 connectors. There are no internal termination
resistors, consequently PROFIBUS plugs with resistors is mandatory.
Note
Safety: For IEC 61508 functions only qualified I/O drivers shall be used.
Self diagnostics
Extensive self-diagnostics are embedded into the design in order to detect faults.
Watchdog control
The RCU502 module have an embedded time controlled watchdog (WD) unit. This unit
is to assure that the module goes to a controlled fail-safe mode in case of an internal
computer malfunction. The WD unit is trigging (trig_1 and trig_2 on figure 9) two
(different) discrete logic devices. The logic devices will generate fail-safe (WD_out on
figure 9) if one or both the 'keep-alive' trig pulses are missing.
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Module grounding
Module ground is wired to system ground (IE or PE).
In a TN-S-DC system the module can be grounded to IE or PE using the fast-on terminal
FL1 and FL2 according to IEC 60364.
Earth fault detection may be done by using external devices.
Note
This is the recommended ground alternative due to high noise immunity, over-voltage
protection as well as EMC (ESD, RFI etc).
Safety functions
The RCU502 module is certified for use in IEC 61508 systems for SIL functions. The
guidelines and limitations given in the K-Safe documentation must be followed.
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Technical specifications
Technical specifications
Cage clamps
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RBUS:
Connector P19, P20: 2 x RBUS Link interface, available on two
shielded RJ45 modular jack connectors.
Serial line type RS485 multidrop
Signal code Manchester encoded (self-clocked)
Power supply voltage +18 - +32 VDC
Current consumption Max. 50 mA
Isolation voltage 500 V
Number of addresses 99
Connector 9 Pin DSUB female
Bit rate 2 Mbit/sec
Copper wire topology:
Insulation 500 V maximum (optocoupler)
Physical layer RS-485 multidrop
Cable attenuation < 6.5 dB/100 m @ 10 MHz (CAT 5)
Cable length Maximum 200 m between repeaters. Maximum 3
repeaters.
Fibre optics topology (w/additional fibre media
converter):
Fibre cable 62.5/125 μm, multi-mode
Connector ST
Maximum cable length 1000 m (point to point), 500 m if used in patch panel
topology.
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Technical specifications
Maximum 12 Mbps
Fan noise 32 dB
Fan size 60 mm x 60 mm x 28 mm
Fan MTBF 50,000 hours
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Table 16 Ex compliance
Failure rates per channel level See PSA RCU502 KM FMEA doc. no. 335925
Diagnostic Coverage See PSA RCU502 KM FMEA doc. no. 335925
Proof test interval recommendation Every 8760 hrs or as per SIL calculation for the specific
delivery project
Table 18 Recycling
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Module pin and connector description
Module identification
For any communication with Kongsberg Maritime regarding this module please refer to
the module name (RCU502) and information on the module identification label.
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Kongsberg RCU502
Ex label
Figure 12 Ex label
Ex label location
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Module pin and connector description
Note
Each connector housing of P8 and P9 is connected via a HF filter to module 0 V within
the module (see Figure 5 on page 17).
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Kongsberg RCU502
Note
Each connector housing of P30 and P31 is connected via a HF filter to module 0 V
within the module (see Figure 5 on page 17).
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Module pin and connector description
Note
Each connector housing of P10 and P11 is connected via a HF filter to module 0 V
within the module (see Figure 5 on page 17).
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Module pin and connector description
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X1 (Fan connection)
X1 (Fan connection) is a 3 pin male connector located within the lower hatch-covered
part of the module.
X2 (Power connection)
X2 (Power connection) is an 8-pole dual terminal block with screw terminals. The
connector is provided with two removable headers (terminal 1 to 4 and 5 to 8
respectively).
Cable cross section: 2.5 mm2
The connected power supply shall be a power that fulfills the requirements to "separated
or safety extra-low voltage" (SELV). Note that transorbers on the RCU will start to
drain current to ground at approximately 35 V and will shortcut at any voltage above
approximately 50 V.
Terminal
number Terminal name Function
1 +24 VDC Supply voltage A, positive terminal
2
3 0 VDC Supply voltage A, 0 V terminal
4
5 +24 VDC Supply voltage B, positive terminal
6
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Module pin and connector description
Terminal
number Terminal name Function
7 0 VDC Supply voltage B, 0 V terminal
8
Terminal
number Signal name Function
1 WDO_H Watchdog Out (opto collector)
2 DOH1 DO1 (opto collector)
3 DOL1 DO1 (opto emitter)
4 DOH2 DO2 (opto collector)
5 DOL2 DO2 (opto emitter)
6 DOH3 DO3 (opto collector)
7 DOL3 DO3 (opto emitter)
8 DOH4 DO4 (opto collector)
9 DOL4 DO4 (opto emitter)
10 WDO_L Watchdog Out (opto emitter)
11 DIH1 DI1 (opto anode)
12 DIL1 DI1 (opto cathode)
13 DIH2 DI2 (opto anode)
14 DIL2 DI2 (opto cathode)
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Terminal
number Signal name Function
15 DIH3 DI3 (opto anode)
16 DIL3 DI3 (opto cathode)
17 DIH4 DI4 (opto anode)
18 DIL4 DI4 (opto cathode)
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Module pin and connector description
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Module installation
Note
As long as the module is attached vertically on a DIN rail the fan fitted on the lower end
of the unit will provide sufficient flow of air through the unit.
WARNING
Do not open enclosure when an explosive atmosphere is present,
Hot work permit required.
Actions such as:
• connecting/disconnecting wires and/or cables
• operating buttons/switches
are not allowed when the module is energized.
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Module installation
Installation procedure
1 Label the module.
2 Set correct MAC address to the module by rotating the three decimal switches to
values as appropriate.
3 Verify that the MODE switch is set to 0.
4 Fix the module to the rail by fasten the module attachment screws , one at the top
and one at the bottom of the unit.
5 Connect the earth terminations to the FASTON connectors FL1 and FL2 as
appropriate.
Note
All screw terminals must be fastened to a torque of 0.4-0.5 Nm
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Kongsberg RCU502
Module replacement
1 Turn off the power to the module by tripping the corresponding circuit-breaker(s)
or terminal block(s) with fuse.
2 Remove all cables attached to the module including the earth terminations to the
fast-ons (see Note).
Note
The connectors X2 to X5 can be split by firstly release the attachment screws and
then split the header from the connector body using a thin bladed screwdriver.
3 Remove the module from the rail by loosen the bottom and top attachment screws.
4 Unpack the spare (new) RCU502.
5 From the new module remove all connector headers being in use.
6 Label the new module as the one being replaced.
7 Set correct MAC address to the module by rotating the three decimal switches
to the same value as for the replaced.
8 Verify that the MODE switch is set to 0.
9 Fix the module to the rail by fasten the attachment screws at the top and bottom.
10 Connect the earth terminations to the FASTON connectors FL1 and FL2 as
appropriate.
11 Refit the connector headers to X2 to X5 as appropriate by using a screwdriver.
12 Reconnect all cables to the module as appropriate.
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Module replacement
Note
All screw terminals must be fastened to a torque of 0.4-0.5 Nm
13 Check that all cable plugs and screw terminal wires are properly fixed to avoid
any loose connection.
14 Turn ON power.
15 Verify that the Run/Error LED shows red and later green after software program
has been loaded and is running.
16 Verify by the system user interfaces that the module is working OK.
17 For the replaced module: Re-attach all Space Connectors from the replaced module.
Make a short defective performance description of why the module was replaced.
18 Ensure that KM Service desk or the Project Manger (as applicable) is informed
about replaced modules and new module serial numbers.
Fan replacement
Spare parts
Spare fan Kongsberg Maritime part no: 600686
Replacement procedure
1 Turn off the power to the module by tripping the corresponding circuit breaker(s).
2 Remove the lower part of the hatch by loosen the fixing screw.
3 Grip the fan and gently pull it out (no hooks need to be bent).
4 Disconnect the fan plug from the X1 connector by gently pushing down and pulling
the lock peg out.
5 Examine the new fan (see Note).
Note
The new fan body shall have a gasket located on the top side to avoid a loose
assembly.
Be aware of determining correct fan orientation. Blowing direction must be into the
module. See arrow marks on the fan for your guidance.
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10 Verify that the fan is running in a proper way and that the air direction is correct
(see Note above).
11 Verify that the Run/Error LED shows red and later green after software program
has been loaded and is running.
12 Verify by the system user interfaces that the module is working OK.
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©2014 Kongsberg Maritime