RPC420

Hardware Module Description

Kongsberg Maritime Part no. 317114

325654/A
February 2009
Document history
Document number: 325654
Rev. A February 2009 First version.

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: km.documentation@kongsberg.com

Kongsberg Maritime AS
P.O.Box 483 Telephone: +47 32 28 50 00
N-3601 Kongsberg, Telefax: +47 32 28 50 10
Norway Service: +47 815 35 355
www.kongsberg.com
 Hardware Module Description

Table of contents
Glossary....................................................................................................................5
1 OVERVIEW........................................................................ 7
2 FUNCTION ........................................................................ 8
2.1 Power supply ............................................................................................................8
2.2 RBUS interface.........................................................................................................9
2.3 Status LED ...............................................................................................................9
2.4 Module address (Slot No.)........................................................................................9
2.5 Digital output driver capability ..............................................................................10
2.6 Hardware types (HW types) overview ................................................................... 11
2.7 DI/DO – button and LED driver (HW type 0) .......................................................12
2.8 Current or voltage output for instruments (HW type 1) .........................................13
2.9 Sine/cosine potentiometer input (HW type 2) ........................................................14
2.10 Single potentiometer input (HW type 3) ................................................................15
2.11 Motor clutch control with HSD (HW type 4).........................................................16
2.12 Motor drive control (HW type 5) ...........................................................................17
2.13 Backlight Driver with HSD (HW type 6)...............................................................18
2.14 Dimmer input (HW type 7) ....................................................................................19
2.15 Electronic potentiometer output (HW type 8) ........................................................20
2.16 Multipurpose current/voltage driver & analog/digital input (HW type 9) .............21
2.17 Relay (HW type 10) ...............................................................................................21
2.18 Internal buzzer (HW type 11).................................................................................22
2.19 Sin input (HW type 12) ..........................................................................................22
2.20 Cos input (HW type 13) .........................................................................................23
2.21 Self diagnostics.......................................................................................................24
2.21.1 Module identification .................................................................................. 24
2.21.2 Status LED................................................................................................. 24
3 TECHNICAL SPECIFICATIONS ......................................... 25
4 CONFIGURATION ............................................................ 28
4.1 Module identification .............................................................................................28
4.2 J1 connector (button and LED inputs for lever panel) ...........................................29
4.3 J2 connector (utility panel).....................................................................................30
4.4 J3 connector (lever panel) ......................................................................................32
4.5 X1 connector (power supply in and out) ................................................................33
4.6 X3 connector (lever potentiometers) ......................................................................33
4.7 X4 connector (lever motors and clutches)..............................................................34
4.8 X5 connector (instruments) ....................................................................................34
4.9 X6 connector (panel controls) ................................................................................35

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Kongsberg RPC420

4.10 X7 connector (multipurpose and relay)..................................................................36

4.11 RBUS A (P1), RBUS B (P2) pin allocation ...........................................................37
4.12 DIP switches for selecting RBUS line-impedance.................................................38
4.13 SHIELD P1 and SHIELD P2 .................................................................................38
5 INSTALLATION ............................................................... 39
6 REPLACEMENT ................................................................ 40

4 325654/A
 Hardware Module Description

Glossary
AI Analogue Input
AO Analogue Output
AOB Analogue Output Bitcoded
COM Common
DI Digital Input
DO Digital Output
ESD Electrostatic Discharge
GND Ground (Module 0 V reference)
Hex Hexadecimal
HSD High Side Driver
IE Instrumentation Earth
I/O Input/Output
KM Kongsberg Maritime
LED Light Emitting Diode
LP Loop Power
Mbps Megabits per second
MUX Multiplexer
MTBF Mean Time Between Failure
NO Normal Open
NC Normal Closed
PE Protective Earth
PWM Pulse Width Modulation
RBUS Remote Serial Process Bus
RCU Remote Controller Unit
RIO Remote I/O
RPC420 Remote Panel Controller series 420
WD Watchdog

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Kongsberg RPC420

6 325654/A
 Overview

1 OVERVIEW
The RPC420 is an interface-module between panels on one side
and RCU(s) on the other side.
Features of the RPC420:
• Interface for levers
• Interface for LEDs
• Interface for buttons
• Interface for instruments (meters)
• Functions for dimming lamps and lamp test
• Interface for panel backlight
• Three internal buzzers and HSD for activating external buzzer
• Connection for redundant power supply
• Two serial process bus interfaces (RBUS A and RBUS B) for
redundant communication to the RCU(s)
• Galvanically isolated RBUS interfaces
• Plug-in connections for fast replacement
• Two-digit address-switch for setting the module address
• Status LED on the front showing status (running or offline)

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Kongsberg RPC420

2 FUNCTION
The RPC420 is a stand-alone panel-interface module. The
module comprises a piggyback design with two circuit boards
(see Component layout on page 28 for layout details).
The module is used for interfacing dedicated digital and analog
input and output signals from special control panels on one side
and communicating with one/two RCU(s) via single/dual serial
process bus (RBUS) on the other side.
The field connectors and terminal blocks on the module are
configured with I/O channels that match the demand from
different dedicated panel modules.

Figure 1 RPC420 block diagram

POWER SUPPLY

X1

P1
SIGNAL CONDITIONING
INTERFACE
RBUS A

COMMUNICATION

LOGIC FOR DI/DO

J1, J2 and J3
PROCESSOR

CIRCUITRY
X3, X4, X6 and X7
RBUS FIELD
P2 CABLING
INTERFACE
RBUS B

MODULE ADDRESS (CD090403a)

The RPC420 can be divided into the following main building

blocks:
• Power supply
• RBUS interfaces
• Communication processor
• I/O with signal conditioning circuitry

2.1 Power supply

The RPC420 is powered with 24 Vdc via the terminal block X1.
Two power supplies can be connected to allow power redundancy.
Diodes are provided to isolate the two power inputs from each
other. Both voltage inputs are monitored by the RPC420 module.

8 325654/A
 Function

To protect the power supply components and the module itself

from over voltage and over current, an automatic fuse F1 (2.25
A) is connected in series and a tranzorber are connected in
parallel on the input side. A fused 24 Vdc output terminal is
provided for powering external equipment.
Five voltages are made locally on the module for internal use:
1.2 Vdc, 1.6 Vdc, ±3.3 Vdc and 5 Vdc (VCC).

Figure 2 Power supply principles

24VLP_FUSED
X1

24V Fused
Voltage
monitoring
MUX
F1 5V
24V I Input
POWER
24V II Input STEP DOWN ± 3,3V/0,5A

1,6V
LDO
1,2V
(vs090400a)

2.2 RBUS interface

Two multidrop RS485 serial lines are used. RBUS A and RBUS
B are galvanic isolated from each other and from the I/O part of
the module. Bit rate is 2 Mbps.
Manchester Coding is used in order to avoid timing problems and
to reduce cabling cost.
The RBUS cable also supply power (24 V) to the isolated part
of the RS485 line.

2.3 Status LED

A status LED is located under the address wheel (LSD). It is
green when it is running in the host system and no error is
detected. It is red otherwise. See also Self diagnostics on page 24
for more details.

2.4 Module address (Slot No.)

Each module must be set to a unique address (Slot No.) that
identifies this module among the others connected to the RBUS.
The module address is represented by two decimal switches:
• MSD (most significant digit)
• LSD (least significant digit)

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Kongsberg RPC420

The total number of modules allowed connected to one RBUS

are 99 (slot number 1 through 99). The address setting (slot
number) range is consequently a number between 01 and 99.
The slot number is compared with the RBUS address set out from
the RCU. If they are equal, the module responds.

2.5 Digital output driver capability

The RPC420 uses High Side Drivers (HSDs) for driving the 24
Vdc digital power output loops and motor-control loops, see also:
• Motor clutch control with HSD (HW type 4) on page 16
• Motor drive control (HW type 5) on page 17
• Backlight Driver with HSD (HW type 6) on page 18
The HSDs are designed for both resistive and inductive loads
and offer short-circuit protection of the loop. At overload the
High Side Driver (HSD) is switched off by a built-in temperature
sensor. When the temperature falls below a certain limit, the
output is turned on again. Thus the HSD output will pulse with a
low frequency until the short circuit has been removed.

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 Function

2.6 Hardware types (HW types) overview

There are several hardware types. These are described in the
following sections.

55 CHANNELS 5 CHANNELS 1 CHANNEL 5 CHANNELS

HW0 HW1 HW2 HW3
+5V +24V +24V
0 – 20 mA
Current Io Hi
Current Gen. Current Current
Generator Generator Generator
Io ˜ 10 mA A AiHH Io ˜ 1.6 mA
Io ˜ 1.6 mA
D
Io AiH Io Io
A C
AiH Hi AiH Hi AiH Hi
D
Rv A A
C
D D
NAM C AiL C AiL Lo
DO
GND
Lo
Rv = 1kO 150O 150O
GND GND GND

BUTTON / LED CURR / VOLT OUTPUT SIN-COS SOURCE ++ POTMETER ++

2 CHANNELS 2 CHANNELS 4 CHANNELS 1 CHANNEL

HW4 +24V HW5 +24V HW6 HW7
+24V
DO DIR P AiH Hi
A SPEED DO J2/33 & X6/5
D AiHH Hi D A
BRAKE R D
C
GND GND DI Temp al. I N C AiL Lo J2/34 & X6/6
V
A E 150O
MOTOR-CLUTCH D Curr. GND GND
C

MOTOR-DRIVE HSD DIMMER-INPUT

1 CHANNEL 6 CHANNELS 3 CHANNELS

HW8 H X6/13 HW9 +24V-AO HW10
+24V
NC
Up/Down P
O R
NO
T
Increment M W X6/14 DO
E COMMON
T 0 – 20 mA
CS
E Current Io Hi DO
R Gen.
AiHH
L X6/15 A
GND
AiH
D
DIGITAL-POT. C AiL Lo
RELAY
Rv Rc

NAM
GND
Rv = 1kO CI
Rc = 150O
MULTI_PURPOSE

3 CHANNELS
HW11 1 CHANNEL 1 CHANNEL
VCC
HW12 HW13 HW15
AiH Hi AiH Hi Pure SW-channel
X3/3
A A (no hardware)
D D
C AiL Lo C AiL Lo X3/4 INTERNAL
BUZZER
R R R R
GND GND GND
R = 3M3 O R = 3M3 O (vs090416a)
INTERNAL
BUZZER SIN-INPUT COS-INPUT

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Kongsberg RPC420

2.7 DI/DO – button and LED driver (HW type 0)

This interface type is used both for DI and DO.
DI is typically used for reading a button and is read as an analog
voltage. DO is typically used for turning a LED on/off. The LED
can be PWM (pulse width modulated) using the DO. In both
cases a 10 mA constant current generator is used.
This interface type is implemented for the following channels:
SW channels HW channels
1, 2 ,3, 4, 5 to 34, 65 to 85 1, 2, 3, 4, 5 to 10 to 42, 55, 56, 61 and 64 to 73

Figure 3 Loop typical information

HW0 +5V

Current
Generator Monitor Mode LED
Io ˜ 10 mA
Io
0 1
A Hi 150ohm
D
AiH
C

DO 150ohm

GND

(vs090402b)

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 Function

2.8 Current or voltage output for instruments (HW

type 1)
This interface is used to drive meter instruments. Output can be
presented as current (0 to 20 mA) or voltage (0 to 10V). When
output voltage is selected, the voltage is generated by sending
a calibrated current (0 to 10 mA) through the internal voltage
resistor Rv (1 kOhm).
This interface type is implemented for the following channels:
SW channels HW channels
39 to 42 57 to 60

Figure 4 Loop typical information

HW1
0 – 20 mA
Current Volt
Current Io Hi
Gen.

A
AiHH
D
C Max
RL > 100K ohm
500 ohm
Rv
For good Vo accuracy, keep
NAM
GND RL as large as possible.
Rv = 1kohm

(vs090403b)

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Kongsberg RPC420

2.9 Sine/cosine potentiometer input (HW type 2)

The sine/cosine potentiometer require three SWchannels.
Channel 44 is the power source for the sine/cosine potmeter, and
will deliver a constant current (1.6mA) through the potentiometer
and to GND via the internal 150 ohm resistor. The voltages on
Hi and Lo is used to monitor the potmeter.
Maximum potentiometer resistant is 5000 ohm.
The sine/cosine voltages is read by SW channel 45 and 46 as
shown below.
This interface type is implemented for the following channel:
SW channel HW channel
44 43
45 44S
46 44C

Figure 5 Loop typical information

HW2 Sin/cos potmeter

+24V
+
Current
sin
Generator cos
Io ˜ 1.6 mA
X3/1 ?
Io
AiH Hi +
A
D E
C AiL Lo
150ohm X3/2
-
E
-
GND

Max resistance between

Sw Ch 45 (S/13)
X3/3 sin (+) and (-) = 5200ohm

X3/4 cos (vs090404b)

Sw Ch 46 (S/14)

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 Function

2.10 Single potentiometer input (HW type 3)

A constant current of approximately 1.6 mA is generated by this
circuitry. The current passes through the connected potentiometer
(Rp) and to GND via the internal 150 ohm resistor. The voltages
on Hi and Lo is used to calculate the external resistance (Rp)
and to monitor the potmeter.
Potmeter range 0 - 5702Ω.
This interface type is implemented for the following channels:
SW channels HW channels
43 and 47 to 50 63 and 45 to 48

Figure 6 Loop typical information

HW3
+24V

Current
Generator
Io ˜ 1.6 mA

Io
AiH Hi

A
AD
D
C
C Rp
AiL Lo

150O

GND

(vs090417a)

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Kongsberg RPC420

2.11 Motor clutch control with HSD (HW type 4)

The interface type is made for motor clutch control.
HW4 +24V Clutch operation is done by controlling the DO which activate
A
DO
AiHH Hi
or passivate the internal HSD accordingly.
D
C
GND GND This interface type is implemented for the following channels:
MOTOR-CLUTCH SW channels HW channels
(vs090406a)
52 and 54 51 and 50

Figure 7 Loop typical information

HW5 +24V A R

DIR P
SPEED

BRAKE DR M
Temp al. I N
DI VE

AD
C Curr.

HW4 +24V

DO

AD AiHH Hi Clutch
C

GND GND

(vs090406b)

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 Function

2.12 Motor drive control (HW type 5)

The interface type is made for motor control. The speed and
direction is controlled by the 16 bit AO-word as shown below.
DIR: selects rotation- direction CW or CCW.
SPEED: controls the motor speed.
BRAKE: the P and N terminal are shorted to GND when on.
Activated automatically when SPEED = 0.
This interface type is implemented for the following channels:
SW channels HW channels
51 and 53 49 and 50

Figure 8 Loop typical information

HW5 +24V
DIR P
SPEED D MOTOR-SPEED
BRAKE R M
DI Temp al. I N
V SPEED = 0
100% 100%
A E BRAKE = ON
D Curr.
C

HW4 +24V
DO
A
Hi CCW CW
D AiHH Clutch 0
AO (WORD)
C
GND GND -10 0 +10

(vs090407b)

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Kongsberg RPC420

2.13 Backlight Driver with HSD (HW type 6)

The HSD circuit is used for switching on and of +24V. Max
current = 1A. The output can be PWM, enabling dimming on
external lamps. Typical use will be, driver for “24V panel
backlight” with dimming facilities.
This interface type is implemented for the following channels:
SW channels HW channels
35 and 36, 95 and 96 62, 84, CHX1, CHX2

Figure 9 Loop typical information

HW6
+24V Example: Lamp

DO Imax = 1 A
HSD
Hi

GND GND

RLmin = 24 ohm
(vs090408b)

18 325654/A
 Function

2.14 Dimmer input (HW type 7)

In general this interface is capable of reading analog voltage
in the range 0 to 10V on Hi, or 0 to 20mA current on the
Lo-terminal.
In the application shown below an analog voltage in the range
1 to 5 volt is read on the Hi-terminal, which will indicate the
position on the external dimmer-potentiometer.
This interface type is implemented for the following channel:
SW channel HW channel
86 64

Figure 10 Loop typical information

1 – 5 volt +9V
HW7
AiH Hi + 10k
A -
D 10k - Potmeter
C AiL Lo J2/34 for dimming
150O
GND 2k7

(vs090409b)
External Hardware

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Kongsberg RPC420

2.15 Electronic potentiometer output (HW type 8)

The circuit is typically used for replacing a standard, manual,
low voltage and low current potentiometer.
The value is 1 kohm linear in 99 increments. The
voltage-difference on the potentiometer terminals H and L must
not exceed Vp volt. (see Technical specifications on page 25
for details).
Typical application: The potentiometer output is controlled by
dimmer input.
This interface type is implemented for the following channel:
SW channel HW channel
90 (readback POS from potmeter) POT

Figure 11 Loop typical information

Vp
Vp < 4V
1 CHANNEL
H
HW8
X6/13 15 …………...……………………...……………..…...… 10 6…...…...0
Up/Down
NU POS

Increment POT W
MET
ER
X6/14
CS

Potmeter Position (POS)

Range: 0 - 99
L

X6/15
DIGITAL-POT.
(vs090410b)

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 Function

2.16 Multipurpose current/voltage driver &

analog/digital input (HW type 9)
This is a multipurpose interface. The following input/output
HW9 +24V-AO options are available:
R • DO is 24 Vdc, 100mA max
DO • AO can be 0 to 20 mA or 0 to 10V
0 – 20 mA
Hi
Current Io
Gen. • AI can be 0 to 20 mA or 0 to 10V
AiHH
A
D
AiH This Hardware type can also bee used as digital input as shown
Lo
C AiL
below.
Rv Rc

NAM This interface type is implemented for the following channels:

GND
Rv = 1kO CI
Rc = 150O SW channels HW channels
MULTI_PURPOSE
(vs090411a)
56 to 61 74 and 79

Figure 12 Loop typical information

AR
HW9 Monitor mode
24VLP
0 1 2
DO
Io = 4 mA Io = 4 mA Io = 2 mA Loop equivalent
Current Io Hi
Gen.
Rw Rw Rw 820
AiH Rsw Rsw Rsw Rt
A 2,7K
D
C AiL Lo
Rv Rc Rw Rw Rw

NAM
GND Rt > 2175O Rt > 2175O 3200O < Rt < 4000O Switch open
Rv = 1kO CI
Rc = 150O
Rt < 2175O Rt < 50O 700O < Rt < 1150O Switch closed

DO = OFF, NAM = OFF, CI = ON (vs090411b)

Rw = wire resistance
Rsw = switch resistance
Rt = Rw + Rsw + Rw = 2*Rw + Rsw (for Monitor mode 0 and 1)

2.17 Relay (HW type 10)

The DO signal will go on or off , operating the relay. Max
3 CHANNELS rating: 6A / 250VAC.
HW10
+24V
NC This interface type is implemented for the following channels:
NO
SW channels HW channels
COMMON
62 to 64 80 to 82
DO

GND

RELAY
(vs090412a)

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Kongsberg RPC420

2.18 Internal buzzer (HW type 11)

The frequency is controlled by the RCU. Frequency range:
3 CHANNELS 10Hz to 658KHz.
HW11
This interface type is implemented for the following channels:
(vs090413a)
VCC

SW channels HW channels
87 to 89 Internal

BUZZER

GND

INTERNAL BUZZER

2.19 Sin input (HW type 12)

This is a high impedance voltage-input channel, dedicated to
1 CHANNEL read the wiper-position from the sine/cosine potentiometer.
HW12
Hi
This interface type is implemented for the following channels:
AiH X3/3
A
D SW channels HW channels Connector
C AiL Lo
45 44S X3
R R
GND
R = 3M3 O

SIN-INPUT
(vs090414a)

Figure 13 Loop typical information

HW2 Sin/cos potmeter MonitorMode1: for sin and cos input.

+24V
+
Current
sin Voltage (V)
Generator cos
Io ˜ 1.6 mA
Io X3/1 ? 10 RangeError
AiH Hi + [7] deltaV = 50
A X3/1 mV
D E
C AiL Lo
Valid Range Valid Range for sin and cos
[0] input-voltage
150ohm X3/2
-
E
-
X3/2 deltaV = 50
GND RangeError mV
0 [7]
Max resistance between
Sw Ch 45 (S/13)
X3/3 sin (+) and (-) = 5200ohm

X3/4 cos (vs090414b)

Sw Ch 46 (S/14)

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 Function

2.20 Cos input (HW type 13)

This is a high impedance voltage-input channel, dedicated to
1 CHANNEL read the wiper-position from the sine/cosine potentiometer.
HW13
Hi
This interface type is implemented for the following channels:
AiH
A
D SW channels HW channels Connector
C AiL Lo X3/4
46 44C
R R
GND
R = 3M3 ohm

COS-INPUT
(vs090415a)

Figure 14 Loop typical information

HW2 Sin/cos potmeter MonitorMode1: for sin and cos input.

+24V
+
Current
sin Voltage (V)
Generator cos
Io ˜ 1.6 mA
Io X3/1 ? 10 RangeError
AiH Hi + [7] deltaV = 50
A X3/1 mV
D E
C AiL Lo
Valid Range Valid Range for sin and cos
[0] input-voltage
150ohm X3/2
-
E
-
X3/2 deltaV = 50
GND RangeError mV
0 [7]
Max resistance between
Sw Ch 45 (S/13)
X3/3 sin (+) and (-) = 5200ohm

X3/4 cos (vs090414b)

Sw Ch 46 (S/14)

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Kongsberg RPC420

2.21 Self diagnostics

Extensive self-diagnostics are built into the RPC420 module to
detect internal faults. As an example, all internally generated
voltages are monitored, and the minimum and maximum values
are stored for later diagnostic.

2.21.1 Module identification

The module has been programmed with a unique identification
code (ID-code). This ID-code also identifies the type of module
installed, so that the system can supervise that correct module is
installed in the correct slot (address).

2.21.2 Status LED

A two-coloured LED (red /green) is visible on the front of the
module.

Table 1 Status indicators (LED) on module front

Colour, status Function

Green, fixed The module has been scanned by the host within the
FailSafe-timout time (IDF loc. 0x100B).
(scanned = Read Input or Write Output message from the
host (RCU)).
Green - dark, flashing Normal operation. Dark flashing for each scan, i.e.
input/output messages are received.
Red, fixed After power-up.
Soft Fail-safe is activated.
Hard Fail-safe is activated. (Serious HW or SW error
condition occurred).
Red - Green, flashing Illegal address switch setting (00).

24 325654/A
 Technical specifications

3 TECHNICAL SPECIFICATIONS
Power supply requirements
Input voltage 18 to 32 V
Current consumption Maximum 1.1 A (at 18 V)
Watch-dog
I/O Soft Fail-safe time-out Default value 6000 ms, programmable in the range
100 to 65535 ms (resolution 100 ms)
I/O Hard Fail-safe time-out Is activated if the internal FW fail to trigger the
watchdog within 60 ms
I/O channel specifications
Analog to Digital Converter (ADC) 16 bit, ± 10 V range
Linearity ± 0.01% FS
Gain ± 0.02% FS
Drift ± 20 ppm/°C
Offset ± 30 mV
Digital to Analog Converter (DAC) 16 bit, 0 to 10V range
Linearity 0.02% FS
Gain 0.03% FS
Drift ± 30 ppm/°C
Offset ± 30 mV
Hardware 0 (SW Channels 1 to 34 and 65 to 85)
LED driver - LED current: 10 mA typical, 15 mA maximum
Pulse width modulation (PWM)
Digital input - Loop current: 10 mA typical, 15 mA maximum
Hardware 1 (SW Channels 39 to 42)
Current output 0 - 20 mA
Voltage output 0 - 10 V, internal resistor 1 kohm
Hardware 2 (SW Channel 44)
Sin/Cos potentiometer input:
- Loop current 1.6 mA
- Potentiometer value 5702 ohm maximum
- Input resistor 150 ohm, 0.1%
Hardware 3 (SW Channels 47 to 50)
Potentiometer input:
- Loop current 1.6 mA maximum
- Potentiometer value 5702 ohm maximum
- Input resistor 150 ohm, 0.1%
Hardware 4, HSD (SW Channels 52 and 54)
Voltage output 0 / 24 V (24VLP_fused)

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Kongsberg RPC420

Hardware 5, motor drive (SW Channels 51 and

53)
Voltage output 0 / 24 V (pwm)
Hardware 6, HSD (SW Channels 35 and 36, 95
and 96)
Voltage input 0 / 24 V (24VLP_fused)
Current output 1 A maximum (HSD has internal temp protection)
Hardware 7, Dimmer input (SW Channel 86)
Voltage input on Hi 1 to 5 V
Current input resistor 150 ohm, 0.1%
Hardware 8, Digital Potmeter (SW Channel 90)
Potmeter range 0 to 1 kohm,
potmeter step 99 increments
Max potmeter voltage between H and L 4V
Hardware 9 (SW Channels 56 and 61)
Input current on Lo 0 to 20 (maximum 26,6 mA)
Input voltage on Hi 0 to 10 V
Potmeter range: 0 to 600 ohm
– Potmeter current 10,8 mA
Potmeter range: 0 to 1200 ohm
– Potmeter current 6,5 mA
Potmeter range: 0 to 12k ohm
– Potmeter current 0,7 mA
Potmeter range: 0 to 18k ohm
– Potmeter current 0,39 mA
Analog output current range: 0 to 20 mA
Analog output voltage range: 0 to 10 V (0 to 10mA via internal 1 kohm Rv
resistor)
Hardware 10 (SW channel 62 to 64)
Current / Voltage 6A / 250 V
Hardware 12 and 13 (SW channel)
Voltage input on Hi (Sin) 0 to 10 V
Voltage input on Lo (Cos) 0 to 10 V
RBUS specifications
Number of RBUS channels 2 x RBUS interface, available on the 9 pin male
D-sub connector P1 and P2.
Bit rate 2 Mbps
RBUS signal coding Manchester encoded (self-clocked)
Power supply voltage 18 to 32 Vdc

26 325654/A
 Technical specifications

Current consumption 50 mA maximum at 24 Vdc per RBUS

Isolation voltage 500 V (optocoupler)
Cable capacitance requirement ≤ 50 pF/m
Mechanical specifications
Module size 130 x 177 x 75 mm
Weight 0.6 kg
Mounting To a bracket with 5 bolts through spacer sleves
Environmental requirements
Operating temperature -15 °C - +70 °C
Storage temperature -25 °C - +70 °C
IP class IP00
Compliant to standards IEC 60945 and IACS E10
Life cycle specifications
MTBF calculated according to MIL-HDBK-217F 547 945 hours
(T = 25°C, env. = GB)
MTBF calculated according to MIL-HDBK-217F 147 945 hours
(T = 35°C, env. = NS)

325654/A 27
Kongsberg RPC420

4 CONFIGURATION
Caution
Electrostatic charges can damage components on the
card. Always wear a properly connected earthing strap
when handling unpacked cards. Place unpacked cards
only on a properly connected earthing mat or on a
shielding bag. Keep cards in their shielding bags when
not installed. Never store near electromagnetic or
electrostatic devices.

Figure 15 Component layout

F 0 1 F 0 1
E

E
1 13
B C D

B C D
2

2
3 4 5

3 4 5
X4
A

13
1
6

6
7 8 9 7 8 9

X7 X6

14
2
LSD MSD
1 9 1 9

15
3

16
4
9

9
1

17
5
10

10
2

18
6
11

11
3

19
7
12

12
4

20
8
13

13
5

21
9
14

14
6

22
10
15

15
FL1
7

11

23
16

16
8

12
8 16 16

24
P1
12 24

X1 X3 X5
1 7 1 7 6 1
7

7
1

24VLP- FUSED 6 3
RBUS A
8

8
2

24VLP-2 5 2 GND
9

9
3

9 5
24VLP-1
10

10
4

4 1
11

11
5

5
12

12
6

6 12 6 12 P2
J3
14
XXpin
pin 1
6

1 J2 RBUS B
9
40pin 5

1
J1 FL2
64pin
P6
1

(VS090401a)

4.1 Module identification

If you have to refer to the RPC420 module in any way, you should
refer to the module name (RPC420) and the Serial No. located in
the upper left corner (see Component layout on page 28).

28 325654/A
 CONFIGURATION

4.2 J1 connector (button and LED inputs for lever

panel)
J1 is a 64 pin flat-cable connector primarily implemented for
direct connection to a special button and LED matrix panel.
The connector pin-out is listed in the table below. For connector
pin layout see Component layout on page 28.
The J1-connector interfaces to Hardware types 0, 1 and 6 (see
function description).

Table 2 J1 terminal allocation

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
1 DI/DO Hi 2 GND Lever Panel DI-BUTTON 1 1 Type 0
Button 1
3 DI/DO Hi 4 GND Lever Panel DI-BUTTON 2 2 Type 0
Button 2
5 DI/DO Hi 6 GND Lever Panel DI-BUTTON 3 3 Type 0
Button 3
7 DI/DO Hi 8 GND Lever Panel DI-BUTTON 4 4 Type 0
Button 4
9 DI/DO Hi 10 GND Lever Panel DI-BUTTON 5 5 Type 0
Button 5
11 DI/DO Hi 12 GND Lever Panel DI-BUTTON 6 6 Type 0
Button 6
13 DI/DO Hi 14 GND Lever Panel DI-BUTTON 7 7 Type 0
Button 7
15 DI/DO Hi 16 GND Lever Panel DI-BUTTON 8 8 Type 0
Button 8
17 DI/DO Hi 18 GND Lever Panel DI-BUTTON 9 9 Type 0
Button 9
19 DI/DO Hi 20 GND Lever Panel DI-BUTTON 10 10 Type 0
Button 10
21 AO (0 to 22 not used Lever Panel AO Normal NA CHAO Type 1
5V) (Backlight 5H
dimm)
23 DO 24 GND Alarm DO-NORMAL 35 62 Type 6
normal buzzer
25 DI/DO Hi 26 GND Lever Panel AOB-LED 13 13 Type 0
Lamp D1
27 DI/DO Hi 28 GND Lever Panel AOB-LED 14 14 Type 0
Lamp D2
29 DI/DO Hi 30 GND Lever Panel AOB-LED 15 15 Type 0
Lamp D3
31 DI/DO Hi 32 GND Lever Panel AOB-LED 16 16 Type 0
Lamp D4
33 DI/DO Hi 34 GND Lever Panel AOB-LED 17 17 Type 0
Lamp D5

325654/A 29
Kongsberg RPC420

Table 2 J1 terminal allocation (cont’d.)

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
35 DI/DO Hi 36 GND Lever Panel AOB-LED 18 18 Type 0
Lamp D6
37 DI/DO Hi 38 GND Lever Panel AOB-LED 19 19 Type 0
Lamp D7
39 DI/DO Hi 40 GND Lever Panel AOB-LED 20 20 Type 0
Lamp D8
41 DI/DO Hi 42 GND Lever Panel AOB-LED 21 21 Type 0
Lamp D9
43 DI/DO Hi 44 GND Lever Panel AOB-LED 22 22 Type 0
Lamp D10
45 DI/DO Hi 46 GND Lever Panel AOB-LED 23 23 Type 0
Lamp D11
47 DI/DO Hi 48 GND Lever Panel AOB-LED 24 24 Type 0
Lamp D12
49 DI/DO Hi 50 GND Lever Panel AOB-LED 25 25 Type 0
Lamp D13
51 DI/DO Hi 52 GND Lever Panel AOB-LED 26 26 Type 0
Lamp D14
53 DI/DO Hi 54 GND Lever Panel AOB-LED 27 27 Type 0
Lamp D15
55 DI/DO Hi 56 GND Lever Panel AOB-LED 28 28 Type 0
Lamp D16
57 DI/DO Hi 58 GND Lever Panel AOB-LED 29 29 Type 0
Lamp D17
59 DI/DO Hi 60 GND Lever Panel AOB-LED 30 30 Type 0
Lamp D18
61 EXT_LEDP 62 EXT_LEDN Operation
Lamp
63 not used 64 GND

4.3 J2 connector (utility panel)

J2 is a 40 pin flat-cable connector primarily implemented for
direct connection to a special button and LED matrix panel
called “Utility Panel”.
The connector pin-out is listed in the table below. For connector
pin layout see Component layout on page 28.
The J2-connector interfaces to Hardware type 0 (see function
description).

30 325654/A
 CONFIGURATION

Table 3 J2 terminal allocation

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
1 DI/DO Hi 2 GND Utility Panel DI-BUTTON 65 31 Type 0
Button S1
3 DI/DO Hi 4 GND Utility Panel DI-BUTTON 66 32 Type 0
Button S2
5 DI/DO Hi 6 GND Utility Panel DI-BUTTON 67 33 Type 0
Button S3
7 DI/DO Hi 8 GND Utility Panel DI-BUTTON 68 34 Type 0
Button S4
9 DI/DO Hi 10 GND Utility Panel DI-BUTTON 69 35 Type 0
Button S5
11 DI/DO Hi 12 GND Utility Panel DI-BUTTON 70 36 Type 0
Button S6
13 DI/DO Hi Utility Panel AOB-LED 74 37 Type 0
Lamp D1
14 DI/DO Hi Utility Panel AOB-LED 85 66 Type 0
Lamp D12
15 DI/DO Hi 16 GND Utility Panel AOB-LED 75 38 Type 0
Lamp D2
17 DI/DO Hi Utility Panel AOB-LED 76 39 Type 0
Lamp D3
18 DI/DO Hi Utility Panel AOB-LED 84 65 Type 0
Lamp D11
19 DI/DO Hi 20 GND Utility Panel AOB-LED 77 40 Type 0
Lamp D4
21 DI/DO Hi 22 GND Utility Panel AOB-LED 78 41 Type 0
Lamp D5
23 DI/DO Hi 24 GND Utility Panel AOB-LED 79 42 Type 0
Lamp D6
25 DI/DO Hi 26 GND Utility Panel AOB-LED 80 11 Type 0
Lamp D7
27 DI/DO Hi 28 GND Utility Panel AOB-LED 81 12 Type 0
Lamp D8
29 DI/DO Hi 30 GND Utility Panel AOB-LED 82 55 Type 0
Lamp D9
31 DI/DO Hi 32 GND Utility Panel AOB-LED 83 56 Type 0
Lamp D10
33 DI/DO Hi 34 GND Dimmer AI (controls 86 64 Type 0
LED
intensity.
Handled by
FW).
35 DI/DO Hi 36 GND Utility Panel DI-BUTTON 72 CHX3 Type 0
Button S8
(Lamp test
input)

325654/A 31
Kongsberg RPC420

Table 3 J2 terminal allocation (cont’d.)

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
37 DI/DO Hi 38 GND Utility Panel DI-BUTTON 71 61 Type 0
Button S7
(Alarm
buzzer
silence)
39 DI/DO 40 GND Utility Panel DI-BUTTON 73 67 Type 0
High Button S9

4.4 J3 connector (lever panel)

J3 is a 14 pin flat-cable connector primarily implemented for
direct connection to a special button and LED matrix panel called
“Lever Panel”.
The connector pin-out is listed in the table below. For connector
pin layout see Component layout on page 28.
The J3-connector interfaces to Hardware type is 0 (see function
description).

Table 4 J3 terminal allocation

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
1 DI/DO Hi 2 GND Lever Panel DI-BUTTON 11 72 Type 0
Button 11
3 DI/DO Hi 4 GND Lever Panel DI-BUTTON 12 73 Type 0
Button 12
5 DI/DO Hi 6 GND Lever Panel AOB-LED 31 68 Type 0
Lamp D19
7 DI/DO Hi 8 GND Lever Panel AOB-LED 32 69 Type 0
lamp D20
9 DI/DO Hi 10 GND Lever Panel AOB-LED 33 70 Type 0
lamp D21
11 DI/DO Hi 12 GND Lever Panel AOB-LED 34 71 Type 0
lamp D22
13 not used 14 not used not used

32 325654/A
 CONFIGURATION

4.5 X1 connector (power supply in and out)

X1 is a 6 pin terminal block for connection of input power and
supply voltage to e.g. a lever panel.
The terminal-block pin-out is listed in the table below. For
connector pin layout see Component layout on page 28.

Table 5 X1 terminal allocation

Pin no. Name Function Pin no. Name Function

1 GND Power supply_1, 4 24VLP-1 Power supply_1,
0 Vdc terminal 24 Vdc terminal
2 GND Power supply_2, 5 24VLP-2 Power supply_2,
0 Vdc terminal 24 Vdc terminal
3 GND 0 Vdc terminal for 6 24VLP-FUSED Fused 24 Vdc terminal
power to external load for power to external
(e.g. lever panel) equipment (e.g. lever
panel)

4.6 X3 connector (lever potentiometers)

X3 is a 12 pin terminal block dedicated for connection to lever
potentiometers.
The terminal-block pin-out is listed in the table below. For
connector pin layout see Component layout on page 28.
Hardware types are 2, 3, 12 and 13 (see function description).

Table 6 X3 terminal allocation

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
1 AI Hi 2 AI Lo Lever AI 44 43 Type 2
potentiometer
Sin/Cos
source
3 AI Hi Lever AI 45 44S Type 12
potentiometer
Sin Wiper
4 AI Lo Lever AI 46 44C Type 13
potentiometer
Cos Wiper
5 AI Hi 6 AI Lo Lever AI 47 45 Type 3
potentiometer
7 AI Hi 8 AI Lo Lever AI 48 46 Type 3
potentiometer
9 AI Hi 10 AI Lo Lever AI 49 47 Type 3
potentiometer
11 AI Hi 12 AI Lo Lever AI 50 48 Type 3
potentiometer

325654/A 33
Kongsberg RPC420

4.7 X4 connector (lever motors and clutches)

X4 is a 24 pin terminal block dedicated for connection to lever
motors and clutches.
The terminal-block pin-out is listed in the table below. For
connector pin layout see Component layout on page 28.
Hardware types are 4, 5, 6 and 9 (see function description).

Table 7 X4 terminal allocation

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
1 AO Hi 2 Lo Lever motor AO +/- 24V 51 49 Type 5
#1 (speed) PWM
3 DO Hi 4 GND Lever motor DO HSD 52 51 Type 4
#1 (clutch)
5 AO Hi 6 Lo Lever motor AO +/- 24V 53 50 Type 5
#2 (speed) PWM
7 DO Hi 8 GND Lever motor DO HSD 54 52 Type 4
#2 (clutch)
9 not used
10 DO Hi 11 GND Command DO- 36 84 Type 6
transfer NORMAL
buzzer ON
12 not used
13 Hi 14 GND CAS Silence Multi 56 74 Type 9
Input Purpose
15 Lo
16 Hi 17 GND Spare Multi 57 75 Type 9
Purpose
18 Lo
19 Hi 20 GND Spare Multi 58 76 Type 9
Purpose
21 Lo
22 Hi 23 GND Spare Multi 59 77 Type 9
Purpose
24 Low

4.8 X5 connector (instruments)

X5 is a 12 pin terminal block for mainly connection to
current-loop driven meters.
The terminal-block pin-out is listed in the table below. For
connector pin layout see Component layout on page 28.
Hardware types are 1 and 3 (see function description).

34 325654/A
 CONFIGURATION

Table 8 X5 terminal allocation

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
1 Hi 2 GND Instrument #1 AO 39 57 Type 1
(0-20mA)
3 Hi 4 GND Instrument #2 AO 40 58 Type 1
(0-20mA)
5 Hi 6 GND Instrument #3 AO 41 59 Type 1
(0-20mA)
7 Hi 8 GND Instrument #4 AO 42 60 Type 1
(0-20mA)
9 Hi (J1/21) 10 GND Lever Panel Dimming – CHAO Type 1
5H
11 Hi 12 Lo Multi AI 43 63 Type 3
position (Potmeter)
switch

4.9 X6 connector (panel controls)

X6 is a 16 pin terminal block for connection to a control panel.
The terminal-block pin-out is listed in the table below. For
connector pin layout see Component layout on page 28.
Hardware types are 0, 6, 7 and 8 (see function description).

Table 9 X6 terminal allocation

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
1 Hi 2 GND Utility Panel DI-BUTTON 71 61 Type 0
Button S7
(Alarm
buzzer
silence)
3 Hi 4 GND Alarm DO- 35 62 Type 6
Buzzer ON NORMAL
5 Hi 6 GND Dimmer AI (Controls 86 64 Type 7
LED
intensity.
Handled by
FW).
7 Hi 8 GND Utility Panel DI-BUTTON 72 CHX3 Type 0
Button S8
(Lamp Test
Input)
9 Hi 10 GND Backlight-LED Dimming 95 CHX1 Type 6
(PWM)
11 Hi 12 GND Backlight-24V Dimming 96 CHX2 Type 6
(PWM)

325654/A 35
Kongsberg RPC420

Table 9 X6 terminal allocation (cont’d.)

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
13 H 14 W Digital LT_AOB_ 90 POT
Potmeter DIGITAL_ Type 8
15 L POTMETER_
HW8
16 not used

4.10 X7 connector (multipurpose and relay)

X6 is a 16 pin terminal block for multipurpose use and relay.
The terminal-block pin-out is listed in the table below. For
connector pin layout see Component layout on page 28.
Hardware types are 9 and 10 (see function description).

Table 10 X7 terminal allocation

SW HW HW
Pin no. Function Pin no. Function Device Loop type Ch Ch type
1 Hi 2 GND Spare 60 78 Type 9
3 Lo
4 Hi 5 GND Spare 61 79 Type 9
6 Lo
7 COM 8 NO Lamp Test DO Relay 62 80 Type 10
Output
9 NC
10 COM 11 NO CAS Alarm DO Relay 63 81 Type 10
Output
12 NC
13 COM 14 NO Spare DO Relay 64 82 Type 10
15 NC
16 not used

36 325654/A
 CONFIGURATION

4.11 RBUS A (P1), RBUS B (P2) pin allocation

RBUS A and RBUS B are 9-pin female DSUB connectors. They
connect the module to the multi-drop serial bus cables.
The connector pin-out is listed in the table below. For connector
pin layout see Component layout on page 28.

Table 11 RBUS A and RBUS B pin allocation

Pin no. RBUS A RBUS B Function

1 ADATA_H BDATA_H RS485 serial line H
2 ADATA_L BDATA_L RS485 serial line L
3 A24VGND B24VGND 24V ground for RS485 transmitter /receiver
4 not used not used
5 A24V B24V +24V for isolated RS485 transmitter /receiver
6 A5V B5V Isolated +5V for the RBUS line (internally
generated +5V for RBUS receive/transmit circuits)
7 A24VGND B24VGND 24V ground for RS485 transmitter /receiver
8 not used not used
9 not used not used

325654/A 37
Kongsberg RPC420

4.12 DIP switches for selecting RBUS

line-impedance
There are two DIP switches on the RPC420. One for RBUS A
and one for RBUS B.
At the end of a RBUS-line, the dip switches enable the user to
select the line-impedance to 100 (revolved cabled) or 120 (CAT7
cable) ohm, to avoid reflections on the RBUS-line.
Note
Normally the line-impedance is done outside the module by the
BusTerm-module.

RBUS A RBUS B
SW1–A: 100 ohm SW1–B: 100 ohm
SW2_A: 120 ohm SW2–B: 120 ohm

Figure 16 DIP Switches

Shield (P1)

ON
1 100 ohm

2 120 ohm

Dip switches

Shield (P2)

(Cd090404b)

4.13 SHIELD P1 and SHIELD P2

Two fast-on terminals SHIELD P1 and SHIELD P2 are
respectively connected to the two RBUS connectors P1 and P2
(9-pin D-sub) inner cable shields. The SHIELD P1 and SHIELD
P2 are normally wired to IE or to system ground (PE). RBUS
outer shield is normally connected to PE.
For location of the shields, see figure above (DIP Switches).

38 325654/A
 Installation

5 INSTALLATION
Caution
Electrostatic charges can damage components on the
card. Notice the following precautions: Always wear
a properly connected earthing strap when handling
unpacked cards. Place unpacked cards only on a
properly connected earthing mat or on a shielding bag.
Keep cards in their shielding bags when not installed.
Never store near electromagnetic or electrostatic
devices.

1 Label the module.

2 Set correct address to the module by rotating the two decimal
switches (addresses 1 to 99).
3 Fix the module to the appropriate bracket by fastening the
four corner screws using a flat-bit screwdriver.
4 Connect wires to the FAST-ON receptacles SHIELD P1 and
SHIELD P2 as appropriate.
5 Connect power wires to the terminal block X1.
6 Connect field wires to the terminals on X3, X4, X5, X6 and
X7.
7 Connect the three flat-cables to the connectors J1, J2 and J3.
8 Connect the RBUS cables to the connectors P1 (RBUS A)
and P2 (RBUS B), and fasten the connectors by using the
screws.
9 Switch on the power to the module.
10 Check the module’s panel function by pressing the lamp test
button of the corresponding button panel, if a such panel
is connected.
11 Verify the RUN lamp turns to green when connected in a
running host system.
12 Verify proper module operation by using the set of functions
of the connected panels in a running system.

325654/A 39
Kongsberg RPC420

6 REPLACEMENT
Caution
Electrostatic charges can damage components on the
card. Notice the following precautions: Always wear
a properly connected earthing strap when handling
unpacked cards. Place unpacked cards only on a
properly connected earthing mat or on a shielding bag.
Keep cards in their shielding bags when not installed.
Never store near electromagnetic or electrostatic
devices.

1 Switch off the power to the module.

2 Remove the RBUS cables by loosen the fasting bolts for
connectors P1 and P2, and pull the connectors out.
3 Disconnect the flatcables in J1, J2 and J3 by using the
connector ejectors, one at each end of the connector.
4 Disconnect the field wires from the terminal blocks X3, X4,
X5, X6 and X7 by loosen the end bolts, split and remove
the block header.
5 Disconnect the power wires from the terminal block X1 by
loosen the four end bolts, split and remove the block header.
6 Remove wires from the FAST-ONs SHIELD P1 and
SHIELD P2 by pulling them out (grip the connector and
not the wire).
7 Remove the four corner screws that fixes the module to the
bracket by using a flat-bit screwdriver.
8 Remove the module and mark it with the fault symptoms.
9 Label the new module.
10 Set correct address to the module by rotating the two decimal
switches to the same values as of the old module.
11 Fix the module to the bracket by fastening the four screws,
one at each corner, using a flat-bit screwdriver.
12 Connect the wires to the SHIELD P1 and SHIELD P2 as
appropriate.
13 Reconnect the connector header to the terminal block X1
and fasten the four fixing bolts.
14 Reconnect the connector headers to the terminal blocks X3,
X4, X5, X6 and X7 and fasten the corresponding fixing
bolts.
15 Reconnect the flat-cables to the connectors J1, J2 and J3 by
pushing them into the sockets.

40 325654/A
 Replacement

16 Reconnect the RBUS cables to the connectors P1 (RBUS A)

and P2 (RBUS B), and fasten the connectors by using the
corresponding fastening bolts.
17 Switch on the power circuit to the module.
18 Check the module’s panel function by pressing the lamp test
button of the corresponding button panel, if a such panel
is connected.
19 Verify that the Status-LED turns to green when connected in
a running host system.
20 Verify proper module operation by using the set of functions
of the connected panels in a running system.

325654/A 41
 ©2009 Kongsberg Maritime

Kongsberg Maritime AS
P.O.Box 483 Telephone: +47 32 28 50 00
N-3601 Kongsberg, Telefax: +47 32 28 50 10
Norway Service: +47 815 35 355
www.kongsberg.com