RCU500 KONGSBERG Remote Controller Unit in stock

• Brand
  KONGSBERG
• Model
  RCU500
• Product Name
  Remote Controller Unit
• Dimensions
  230 mm × 132 mm × 72 mm
• Weight
  1.53 kg
• Place of Origin
  Norway
• HS Code
  85389000
• Operating Temperature
  -15 °C to +70 °C
• Storage Temperature
  -65 °C to +80 °C
• Power Supply
  19.2‑28.8 V DC
• Warranty
  12 month
• Status
  new and original

KONGSBERG RCU500

Input Specifications

Power Input

Nominal Supply Voltage: 24 V DC ±20%; operating voltage range: 19.2 V DC ~ 28.8 V DC

Maximum Power Consumption: 20 W

Typical Operating Current: 0.8 A @24 V DC; Max startup inrush current: 2.7 A

Digital Inputs

4-channel general-purpose opto-isolated digital inputs

Signal Level: 24 V DC; High-level input: 18-30 V DC; Low-level input: 0-5 V DC

Input current per channel: 6-12 mA; for external contact status, alarm and interlock signals

Serial & Bus Input Interfaces

12-channel non-isolated configurable serial ports (RS-232 / RS-422 / RS-485); signal level: 5 V logic

4-channel galvanically-isolated configurable serial ports (RS-232 / RS-422 / RS-485); isolation voltage: 500 V DC

1 dedicated RS-232 console diagnostic port; signal level: 5 V logic

Dual CAN-Bus: 1 Mbps redundant communication interface; nominal signal level: 5 V differential

Dual Profibus-DP: 12 Mbps, master/slave configurable; differential 5 V signal

SPBus (Serial Process Bus): Manchester-coded, up to 2 MHz, for connection to RIO400 remote I/O units

Dual 10/100 Mbps Ethernet ports for redundant LAN network access; standard Ethernet signal level

Output Specifications

Digital Outputs

4-channel opto-isolated general-purpose digital outputs, 24 V DC level

Output voltage: 24 V DC (sourced from system supply); maximum continuous current per channel: 0.5 A

Used for driving relays, indicator lamps and status alarm signals to external equipment

Communication Output Interfaces

All serial, CAN-Bus, Profibus, SPBus and Ethernet interfaces support bidirectional transmit-receive data exchange with field devices, remote I/O, operator stations and other system controllers, with respective standard differential/single-ended signal voltage and limited drive current.

System Auxiliary Output

Watchdog system-status open-collector output for hardware fault monitoring; rated 24 V DC, maximum sink current 100 mA

Internal fan-fault and overtemperature alarm status output via communication bus and front-panel LED indicators.

KONGSBERG RCU500 Commissioning Steps

Pre-commissioning Safety Notice

Complete all mechanical installation of the RCU500 module inside the control cabinet prior to commissioning operations. Wear ESD anti-static protective equipment during module handling and wiring work. Inspect cabinet ventilation conditions and confirm cooling fans operate normally. All wiring operations must be performed with the 24 V DC power supply fully disconnected. Improper wiring connection will cause permanent hardware damage to the controller.

Static Hardware Inspection & Wiring Verification

Check and confirm the RCU500 module is firmly and securely mounted in the cabinet. Measure the 24 V DC power supply circuit to ensure the operating voltage is within the standard range of 19.2–28.8 V DC, verify correct power polarity, and eliminate short-circuit risks at all power terminals. Inspect wiring integrity of all digital input and digital output channels for external alarm signals, safety interlock loops and relay drive circuits.

Check all communication cables including SPBus for RIO400 remote I/O connection, multi-type serial ports, CAN-Bus, Profibus-DP and dual Ethernet cables. Ensure all communication lines adopt shielded twisted-pair cables with standard single-point shielding grounding. Install 120 Ω terminal resistors at both ends of SPBus, CAN-Bus and Profibus-DP bus lines to ensure stable bus communication. Confirm the RS-232 diagnostic console port is properly reserved for local service debugging access.

Power-on Procedure & Built-in Self-test

Restore the 24 V DC cabinet power supply and observe the front-panel power LED indicator to ensure steady illumination. Allow 60–120 seconds for the controller to complete booting and built-in BIST self-test, which covers full detection of CPU, memory, cooling fan, internal temperature and all communication interfaces. Monitor the startup inrush current and confirm the operating current stabilizes at approximately 0.8 A after initialization.

If the fault indicator lights up, connect to the device via the RS-232 console or operator station to read self-test error codes and accurately locate hardware faults including fan failure, over-temperature abnormality and memory exceptions.

Basic Communication Parameter Configuration

Connect the service laptop to the dedicated RS-232 console port or service Ethernet port, and log in to the RCU500 configuration system. Set the controller station name, node address and dual redundant Ethernet IP addresses according to project specifications. Configure the working mode (RS-232/RS-422/RS-485), baud rate, data bits, stop bits and check parity for each serial channel.

Complete CAN-Bus baud rate configuration, Profibus-DP master/slave mode and station address setting. Match the SPBus communication rate with the connected RIO400 remote I/O modules. Download the project application program and customized configuration parameters to the RCU500 flash memory, save all parameters and complete local file backup and archiving.

Field I/O Signal Verification

Verify 4 opto-isolated digital input channels: apply 24 V DC high-level signals and open-contact low-level signals separately, and confirm that signal status changes are accurately and synchronously displayed on the operator station.

Test 4 digital output channels: manually trigger each output channel through the configuration tool, verify the corresponding relay and indicator lamp act normally, and measure the standard 24 V DC output voltage with the single-channel load current controlled within the maximum limit of 0.5 A.

Establish SPBus communication with RIO400 remote I/O units, fully verify all analog and remote digital signals collected by RIO400 can be normally transmitted to RCU500, and confirm no signal loss, delay or abnormal offset exists.

Redundancy Configuration & Switchover Test (Dual RCU Redundant System)

Ensure the primary and standby RCU500 controllers are loaded with identical application programs and configuration parameters. Set the heartbeat cycle, master-standby role definition and redundant link parameters. Simulate the power-off fault of the main controller, verify the system can achieve bumpless automatic switchover to the standby controller within the specified time without logic interruption or screen signal jitter.

Restore power to the main controller, and confirm the system automatically rebuilds the normal hot-standby redundant operating state.

System-level Logic & Interlock Function Test

Perform offline simulation tests without actual process load. Fully verify the completeness and accuracy of system control logic, alarm processing mechanism, interlock trigger conditions and safety protection functions in accordance with technical specifications. Check the watchdog hardware status output signal to confirm hardware fault alarms can be normally uploaded to external alarm equipment.

Verify bidirectional data interaction between RCU500, operator stations and third-party controllers via Ethernet, Profibus and serial interfaces, ensuring consistent data transmission and no obvious communication delay or packet loss.

Implement 24–72 hours of continuous field burn-in testing under actual operating conditions. Real-time monitor the controller’s CPU load, internal operating temperature, fan working status and overall communication quality. Ensure no repeated fault records or abnormal logs are generated in the system event database.

Record key commissioning data including power supply voltage, communication parameters, I/O signal test results and redundancy switchover performance in the official commissioning report. Export and archive the final complete configuration file, and complete project handover including fault code manuals and daily maintenance guidelines.

Common Troubleshooting Guidelines

No startup & power LED off: Check 24 V DC supply voltage, power polarity and terminal fastening condition.

SPBus communication failure: Inspect 120 Ω terminal resistors, cable shielding integrity and baud rate matching with RIO400 modules.

Over-temperature alarm: Check cabinet ventilation, fan operating status and dust accumulation at air inlets and outlets.

Frequent controller reset: Troubleshoot power supply voltage fluctuation and application program task dead-loop faults.

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