Hardware Module Description: Kongsberg Maritime Part No.330924

RCU502
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
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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P10 and P11 (RedNet connection) pin allocation...................................................28

P14 and P15 pin allocation (PROFIBUS DP connection) .....................................30
P19 and P20 pin allocation (RBUS connection) ....................................................30
P21 to P26 pin allocation (Link Channel connection) ...........................................31
X1 (Fan connection) ...............................................................................................32
X2 (Power connection)...........................................................................................32
X3 (DI, DO, WD)...................................................................................................33
X4 and X5 pin allocation (CAN connection) .........................................................34
FL1/GND (Module ground connection).................................................................34
FL2 (Floating module with HF ground connection) ..............................................35
MODULE INSTALLATION ................................................. 36
Ex Zone 2 installation requirements.......................................................................36
Installation procedure .............................................................................................37
MODULE REPLACEMENT .................................................. 38
Module replacement procedure ..............................................................................38
Fan replacement .....................................................................................................39
Spare parts ................................................................................................. 39
Replacement procedure ............................................................................... 39
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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
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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TN-S-DC Terra Neutral Separated Direct Current

UART Universal Asynchronous Receiver/Transmitter
WD Watchdog
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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.
Module functions and features

The RCU502 is a controller module for process control purposes. It is based on the
PowerPC™ Host Processor MPC8245 running at 400 MHz and with RAM memory
running at 133 MHz.
The main functions and features of the RCU502 are:
• 32-bit CPU running at 400 MHz
• VxWorks real-time operating system
• 64 MB RAM
• 32 MB Flash memory
• 4 general-purpose opto-isolated digital input channels
• 4 general-purpose opto-isolated digital output channels
• 1 Watchdog status opto-isolated digital output channel
• 6 Serial link interfaces dedicated for RSER modules. The RSER modules then
interfaces serial lines to 3rd party equipment
• Dual Process Net, Ethernet interfaces (10BASE-T/100BASE-TX) for interconnecting
operator stations and controllers
• Dual Field network (10BASE-T/100BASE-TX) for interfacing of field instruments
• Dual RedNet, Ethernet interfaces (100BASE-TX/1000BASE-T) for redundancy
configurations
• Dual RBUS interface for connection to RIO200 and RIO420 modules
• 2 CAN interfaces
• 2 PROFIBUS DP interfaces
• Built-in real-time clock
• Cooling fan alarm
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• High temperature alarm

• Over/under-voltage power alarms
• Dual supply voltage (24 VDC)
• Low power consumption (Max. 20 W)
• Built-in Test Equipment (BITE) for module monitoring during run-time
• Run status LED
• Eight test status LEDs
• Compliant to standards IEC 60945 and IACS E10
• SIL compliant according to IEC 61508
• Ex Zone 2 certified
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.
Figure 1 RCU502 interface block diagram
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The RCU502 provides alarm functions such as:

• Fan alarm
• Temperature alarm
• Voltage alarm
Controls, indicators and system connector

The RCU502 is provided with the NMI and RESET function controls/buttons located in
the upper right-hand corner of the module.
Figure 2 NMI and RESET buttons layout
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.
RCU condition monitoring

RCU502 system alarms
The RCU502 contains numerous system alarms that will be given to the operator when a
fault occurs. Detailed alarm description, possible consequences and corrective action
is given in the online AIM User Guide.
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Module function
Address switches (MAC 1, MAC 2, MAC 3)

The RCU502 has three hexadecimal switches MAC 1 (S7), MAC 2 (S6), MAC 3 (S5)
by which you can set the MAC address for NET A and NET B.
Figure 3 Address switches and Mode switch
MAC address format for NET A is: 02:41:4C:42:1X:XX

MAC address format for NET B is: 02:41:4C:42:2X:XX
where X:XX is MAC 1:MAC 2 MAC 3.
Example of address setting

The hexadecimal switch settings:
MAC 1 = 1, MAC 2 = 2, MAC 3 = 3
give the MAC addresses:
NET A: 02:41:4C:42:11:23
NET B: 02:41:4C:42:21:23
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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
Table 1 LED indicator information
LED name Colour Function

Run status Green Run
Green when the watchdog is enabled and is ON

(see section on page 19.
Red Error
Red when the watchdog is disabled or is OFF
Eight test status LEDs

The RCU502 has eight test status LEDs used for signalling test status conditions. The
LEDs ST0 to ST3 are used by the internal test programs.
The LEDs, ST4 to ST7 can be used by the application programs or for debug purposes.
E.g. ST3 is Flash test, ST4 is online and ST7 is scan task.
The eight LEDs are located in the upper left-hand corner of the module.
Figure 4 Test status LEDs layout
The following table shows the start-up sequence (1 = light, 0 = dark).
Table 2 Start-up LED status pattern
Phase ST3–ST0 Task running

HW Testing 0001 Test of bootPROM
checksum
0010 Test of RAM
0011 PCI Test
0100 Test of FLASH
0101 FPGA Test
0110 Serial Test
0111 Timer Test
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Table 2 Start-up LED status pattern (cont'd.)
Phase ST3–ST0 Task running

SW Booting 1000 Entered boot monitor
1001 Getting boot on net A
1001 flashing Booting on net A
1010 Getting boot on net B
1010 flashing Booting on net B
1011 flashing Started initializing the basic
SW
Application running 0000 Calling initApplication
and starting the application
code
RS232 console connector (P6)

The P6 connector is used for interfacing a data terminal to the RCU502 CPU during
advanced servicing and debugging.
The RCU502 Console connector P6 is an eight-pin unshielded RJ45 modular jack
connector with RS232-compatible signalling, designed to support hyper terminal (or
similar) protocol communication.
Note
Safety: There are restrictions with respect to use of this functionality in safety systems.
The safety will be de-guarded in debugging mode.
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
Figure 5 Power supply principles
Process Net interfaces

The Process Net interfaces, Net A and Net B, are available on P8 and P9 respectively.
The physical interface complies with IEEE 802.3 10BASE-T/100BASE-TX.
Typical communication is between RCUs and towards the operator stations (OS).
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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Figure 6 Dual RCU redundancy
Figure 7 Triple RCU redundancy
Serial link interfaces

The RCU502 is provided with 6 Link Channel interfaces (SER1 to SER6). They are
dedicated for interfacing with RSER modules. Every Link channel may interface four
separate serial channels via e.g. RSER200–4. Thus, the total number of 3rd party serial
line interfaces are 24 in this case.
• Each Link Channel is available on a RJ45 connector (P21 to P26).
• Each Link Channel connector has adjacent Tx and an Rx LEDs.
• Each Rx signal interface is galvanic isolated using an optocoupler.
• The bit rate is 1 Mbps.
Note
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
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
Onboard I/O channels and Watchdog

The four onboard DI channels, the four onboard DO channels and the one Watchdog
channel are all opto-isolated. The channels are available on the X3 connector. After reset
of the module the four DO channels are set to 0 i.e. no current in the optocouplers.
Note
Safety: The onboard I/O signals shall neither be used in IEC 61508 systems for SIL
functions nor for SIL monitoring functions.
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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Figure 8 Watchdog timer
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).
Figure 9 Module grounding in a TN-S-DC system according to IEC 60364
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
Table 3 Power Supply Requirements
Input voltage +24 VDC nominal (+18 - +32 VDC)

Nominal current consumption Max. 0.8 A
Maximum start-up current 3.8 A
Power consumption Max. 20 W
Heat dissipation Max. 20 W
Power connectors Screw terminal (slotted)
Cable cross section 2.5 mm2
Table 4 Central Processor and Memory Specifications
Processor type PowerPC™ Host Processor MPC8245

Processor clock frequency 400 MHz
RAM size and speed 64 MB DRAM at 132 MHz w/ECC
PROM 16 MB application Flash-file
Table 5 Watchdog Specifications
Watchdog time-out 0.1748 s to 5.594 s, programmable
Table 6 General Purpose I/O Channel Specifications
Digital output (DO) 4 general purpose digital opto-isolated outputs. Max.

30 mA
Digital input (DI) 1 opto-isolated watch dog (for external interface) Max.
30 mA
I/O connectors 4 opto-isolated inputs
Cage clamps
Cable cross section 0.75 mm2
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Table 7 Network Interface Specifications
Process Net interface P8, P9: 2 x Ethernet IEEE 802.3 type

10BASE-T/100BASE-TX interface, available
on two shielded RJ45 modular jack connectors.
FieldNet interface P30, P31: 2 x Ethernet IEEE 802.3 type
10BASE-T/100BASE-TX interface, available on two
shielded RJ45 modular jack connectors.
RedNet interface P10, P11: 2 x Ethernet IEEE 802.3 type
100BASE-TX/1000BASE-T interface, available on two
Table 8 Serial Link Interface Specifications
Channels P21 – P26: 6 serial links for RSER200–4 interface

distributed on 6 shielded RJ45 modular jack connectors.
Physical layer RS232, RS422, RS485 and NMEA 0183 multidrop via
RSER 200–4
Bit rate per channel Max. 115 kB/s
Table 9 Remote I/O Interface Specifications
RBUS:
Connector P19, P20: 2 x RBUS Link interface, available on two
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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Table 10 Fieldbus Interface Specifications
CAN interface X4, X5: 2 x CANopen/DeviceNet. Available on two

5-pole terminal blocks with screw terminals handling
2.5 mm2 wires
Maximum 1 Mbps. (DeviceNet not defined above 500

kbps)
PROFIBUS DP interface P14, P15: 2 x PROFIBUS interface, opto-isolated,
available on two 9 pin female D-sub connectors.
Maximum 12 Mbps
Table 11 Console Interface Specifications
Connector type RJ45 unshielded

Serial line type RS232
Bit rate 9600 bps, 8 bit data, 1 stop bit, none parity
Table 12 Fan Specifications
Fan noise 32 dB
Fan size 60 mm x 60 mm x 28 mm
Fan MTBF 50,000 hours
Table 13 Mechanical Specifications
Module size (W x H x D) 158 x 355 x 87 mm

Weight 1.34 kg
Mounting Screw locks on DIN-rail T35–15/7.5
Table 14 Environmental Specifications
Temperature operational -15 °C – +70 °C

Temperature storage -25 °C – +70 °C
Vibration Maximum 1.0 g
IP class IP 20
Compliant to standards IEC 60945 and IACS E10
Table 15 Life Cycle Predictions
Predicted failure rate according to SN29500 in 25 years

IEC60654–1 Class C environment (40 ºC)
Note that this figure includes data for Soft Error.
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Table 16 Ex compliance
Ex Certificate IECEx NEM 14.0008X and Nemko

14ATEX1504X
Ex code
Table 17 Safety IEC 61508
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
RoHS compliant Compliant to EU directive 2002/95: Restriction of the

use at certain hazardous substances in Electrical and
Electronic Equipment (RoHS).
Recycling Module recycling according to EU directive 2002/96:

Waste Electrical and Electronic Equipment (WEEE).
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Module pin and connector description
Module pin and connector

description
Figure 10 Layout of RCU502
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.
Figure 11 Module identification label (example)
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Ex label
Figure 12 Ex label
Ex label location
Figure 13 Location of Ex label on module
P6 pin allocation (Console connection)

P6 is an 8-pin RJ45, unshielded modular jack connector for RS232 serial line, console
connection.
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Figure 14 Front view of RJ45 with pin layout
Table 19 P6 pin allocation
Pin no. Signal name Function

1 Not connected
2 Not connected
3
4 0V 0 V GND
5 CPU_RS232_TX Transmit Data
6 CPU_RS232_RX Receive Data
7 Not connected
8
P8 and P9 (Process Net connection) pin

allocation
P8 and P9 are shielded RJ45, modular jack connectors that provide Process Net
connections (Net A (P8) and Net B (P9)) to the module.
Table 20 P8 and P9 pin allocation
Pin Signal name Function

1 TXP Positive transmit line
2 TXN Negative transmit line
3 RXP Positive receive line
4 Not connected
5
6 RXN Negative receive line
7 Not connected
8
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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P30 and P31 (FieldNet connection) pin

allocation
RCU502 provides two ports, FieldNet 1 (P30) and FieldNet 2 (P31), for Ethernet
communication with the field instrumentation. P30 and P31 are shielded RJ45 modular
jack connectors.

4 Not connected
5
7 Not connected
8
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).
P10 and P11 (RedNet connection) pin

allocation
RCU502 provides two ports, REDNET NEXT (P10) and REDNET PREV (P11), for
redundancy connection between RCU modules. P10 and P11 are shielded RJ45 modular
jack connectors.
Interconnecting cables used for RedNet must be provided with crossed RX and TX pairs.
See Figure 14 on page 27 for connector pin layout.

4 Not connected
5
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Table 22 P10 and P11 pin allocation (cont'd.)

7 Not connected
8
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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P14 and P15 pin allocation (PROFIBUS DP

connection)
RCU502 provides two PROFIBUS DP ports (PROFIBUS 1 (P14) and PROFIBUS 2
(P15)). P14 and P15 are 9-pin, female, D-sub connectors.
Figure 15 P14 and P15 pin layout and allocation
Pin no. Signal name P14 Signal name P15 Function

1 PR0_SCRN PR1_SCRN For cable screen connection *
2 Not connected
3 PR0_DATA_H PR1_DATA_H PROFIBUS Data, High terminal (RS485)
4 Not connected
5 PR0_GND PR1_GND PROFIBUS, signal reference *
6 PR0_VP PR1_VP PROFIBUS, 5 VDC (isolated)
7 Not connected
8 PR0_DATA_L PR1_DATA_L PROFIBUS Data, Low terminal (RS485)
9 PR0_GND PR1_GND PROFIBUS, signal reference *
* Common potential (PROFIBUS ground).

Note
Connector housing of P14 and P15 are connected to individual PROFIBUS ground
(see Figure 5 on page 17).
P19 and P20 pin allocation (RBUS

connection)
RCU502 is provided with two RBUS connectors: RBUS A (P19) and RBUS B (P20).
P19 and P20 are shielded RJ45 modular jack connectors.
Cable shield to be grounded in cabinet PE.
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1 DATA_H RS485 serial line high terminal
2 DATA_L RS485 serial line low terminal
3 Not connected
4 0 VDC 0 V individual RBUS ground

5
6 Not connected
7 24 V +24 VDC, interface input supply voltage
8 0 VDC 0 V individual RBUS ground
P21 to P26 pin allocation (Link Channel

connection)
RCU502 is provided with 6 Link Channel connectors SER1 (P21) to SER 6 (P26). P21
to P26 are shielded RJ45 modular jack connectors.
The Link Channel interface to RSER has to use a straight (not crossed) cable with all
8 pins in use.
Table 25 P21 to P26 pin allocation

1 TXn-P Link Channel #n Transmit, Positive terminal
2 TXn-N Link Channel #n Transmit, Negative terminal
3 RXn_P Link Channel #n Receive, Positive terminal
4 RTSn_P 1 Link Channel #n Request To Send, Positive output terminal
5 RTSn_N1 Link Channel #n Request To Send, Negative output terminal
6 RXn_N Link Channel #n Receive, Negative terminal
7 Not connected
8 0V 0 V, signal reference terminal
where n = 1 for P21, 2 for P22, ...., 6 for P26

1 – RTS is here an output signal used for flow control between RCU and RSER. It is
signalling to the RSER that the RCU is ready to receive.
Note
Each connector housing of P21 to P26 is connected to common ground (see Figure 5
on page 17).
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Kongsberg RCU502
X1 (Fan connection)
X1 (Fan connection) is a 3 pin male connector located within the lower hatch-covered
part of the module.
Table 26 X1 pin allocation
Pin no. Pin name Function

1 Pulse Fan running feedback signal
2 0 VDC Supply voltage 0 V reference
3 +24 VDC Fan supply voltage
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.
Figure 16 X2 terminal layout
Table 27 X2 terminal allocation
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
32 358190/F
Table 27 X2 terminal allocation (cont'd.)
Terminal
number Terminal name Function
7 0 VDC Supply voltage B, 0 V terminal
8
X3 (DI, DO, WD)

X3 is a dual-row 18-pole terminal block with spring-lock terminals. It is provided with a
removable header.
Figure 17 X3 terminal layout and allocation
Table 28 X3 terminal allocation
Terminal
number Signal name Function
1 WDO_H Watchdog Out (opto collector)
2 DOH1 DO1 (opto collector)
3 DOL1 DO1 (opto emitter)
10 WDO_L Watchdog Out (opto emitter)
11 DIH1 DI1 (opto anode)
12 DIL1 DI1 (opto cathode)
358190/F 33
Kongsberg RCU502
Table 28 X3 terminal allocation (cont'd.)
Terminal
number Signal name Function
X4 and X5 pin allocation (CAN connection)

RCU502 is provided with two CAN ports CANBUS 1 (X4) and CANBUS 2 (X5). X4
and X5 are 5-pole terminal blocks with spring loaded terminals. The terminal blocks
have removable header.
Figure 18 X4 and X5 terminal layout
Table 29 X4 and X5 terminal allocation
Terminal Signal name X4 Signal name X5 Function

number
1 VNEG_C0 VNEG_C1 Bus power reference (0 V)
2 CANL_C0 CANL_C1 Bus low signal
3 SHIELD_C0 SHIELD_C1 Shield (AC termination) *
4 CANH_C0 CANH_C1 Bus high signal
5 Not connected
* Ground via HF filter to module 0 V.
FL1/GND (Module ground connection)

The FASTON terminal FL1/GND is ground reference (0 V) for the RCU502 module.
The module is grounded by wiring this terminal to an earth bar.
34 358190/F
FL2 (Floating module with HF ground

connection)
The FASTON terminal FL2 is HF (high frequency) ground reference (0 V) for the
RCU502 module. The module is HF grounded by wiring this terminal to an earth bar.
358190/F 35
Kongsberg RCU502
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.
Ex Zone 2 installation requirements

External environmental conditions, the choice of enclosure, placement of modules,
components and total heat dissipation in the cabinet will affect the end application
temperature. These conditions must always be taken into account. When the module is
installed in hazardous area Zone 2, the following requirements must be met:
• The modules must be built into a cabinet which complies with requirements of
IEC60079-0 & IEC60079-15 (e.g. cabinet with min. IP54 rating required).
• The modules must be used in an area of not more than pollution degree 2.
• The maximum surface temperature must not exceeded 70 °C when use in an
ambient Ta of 55 °C taken into account the least favorable mounting condition and
environmental influences.
• Connecting/disconnecting wires or cables and operating buttons / switches are not
allowed when the module is energized unless area is known to be non-hazardous.
• All screw terminals on module are 2.5 mm2 and must be fastened to a torque of
0.4-0.5 Nm.
36 358190/F
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
6 Connect the power wires to the screw terminals on X2 connector as appropriate

by using a screw driver.
Note
Safety: For safety systems refer to the K-Safe guidelines.
7 If relevant, connect the DI, DO and Watchdog wires to X3 as appropriate by using a

screw driver.
8 If relevant, connect the CAN-bus wires to X4 and X5 as appropriate by using a
screw driver.
9 Connect all cable plugs to the connectors as appropriate.
10 Check that all cable plugs and screw terminal wires are properly fixed to avoid
any loose connection.
11 Turn ON power.
12 Verify that the Run/Error LED shows red and later green after software program
has been loaded and is running.
13 Verify by the system user interfaces that the module is working OK.
358190/F 37
Kongsberg RCU502
Module replacement
Module replacement procedure

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.
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.
38 358190/F
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.
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.
6 Insert the fan plug into the X1 connector.

7 Slide the spare fan into the guides. The wires should be to the left (seen from the
module's lower end).
8 Refit the lower hatch part and fasten the screw.
9 Turn on the power circuit(s) to the module.
358190/F 39
Kongsberg RCU502
10 Verify that the fan is running in a proper way and that the air direction is correct
(see Note above).
40 358190/F
Kongsberg RCU502
41 358190/F
©2014 Kongsberg Maritime

Hardware Module Description: Kongsberg Maritime Part No.330924

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RCU502

Hardware Module Description

Kongsberg Maritime Part no.330924

P10 and P11 (RedNet connection) pin allocation...................................................28

TN-S-DC Terra Neutral Separated Direct Current

Module functions and features

• High temperature alarm

Figure 1 RCU502 interface block diagram

The RCU502 provides alarm functions such as:

Controls, indicators and system connector

Figure 2 NMI and RESET buttons layout

RCU condition monitoring

Address switches (MAC 1, MAC 2, MAC 3)

Figure 3 Address switches and Mode switch

MAC address format for NET A is: 02:41:4C:42:1X:XX

Example of address setting

Table 1 LED indicator information

LED name Colour Function

Green when the watchdog is enabled and is ON

Red when the watchdog is disabled or is OFF

Eight test status LEDs

Figure 4 Test status LEDs layout

The following table shows the start-up sequence (1 = light, 0 = dark).

Table 2 Start-up LED status pattern

Phase ST3–ST0 Task running

Table 2 Start-up LED status pattern (cont'd.)

Phase ST3–ST0 Task running

RS232 console connector (P6)

Figure 5 Power supply principles

Process Net interfaces

Figure 6 Dual RCU redundancy

Figure 7 Triple RCU redundancy

Serial link interfaces

Onboard I/O channels and Watchdog

Figure 8 Watchdog timer

Figure 9 Module grounding in a TN-S-DC system according to IEC 60364

Table 3 Power Supply Requirements

Input voltage +24 VDC nominal (+18 - +32 VDC)

Cable cross section 2.5 mm2

Table 4 Central Processor and Memory Specifications

Processor type PowerPC™ Host Processor MPC8245

Table 5 Watchdog Specifications

Watchdog time-out 0.1748 s to 5.594 s, programmable

Table 6 General Purpose I/O Channel Specifications

Digital output (DO) 4 general purpose digital opto-isolated outputs. Max.

Cable cross section 0.75 mm2

Table 7 Network Interface Specifications

Process Net interface P8, P9: 2 x Ethernet IEEE 802.3 type

Table 8 Serial Link Interface Specifications

Channels P21 – P26: 6 serial links for RSER200–4 interface

Table 9 Remote I/O Interface Specifications

Table 10 Fieldbus Interface Specifications

CAN interface X4, X5: 2 x CANopen/DeviceNet. Available on two

Maximum 1 Mbps. (DeviceNet not defined above 500

Table 11 Console Interface Specifications

Connector type RJ45 unshielded

Table 12 Fan Specifications

Table 13 Mechanical Specifications

Module size (W x H x D) 158 x 355 x 87 mm