Akerstroms REMOTUS CU9600 User manual

INSTALLATION INSTRUCTION REMOTUS 96XX 92 3161-000 Ver. C0 Page 1(3)
020320
S-780 45 BJÖRBO, PHONE [phone], FAX. [phone]
The following guide shall be used when installing Åkerströms Remotus CU9600 system, in
order to obtain a completely reliable operation. The installation shall be done by a competent
person.
1. MOUNTING
The permanent installation of the building must submit fuses which protect the equipment and
wiring from over-current and short-circuit. In detail the regular power supply of the equipment
and all relay-contacts must be fused.
All that fuses are used as separation devices. They must be easily accessible, must submit a
contact-gap of at least 3,0 mm and has to be placed in the line pole (L).
After the installation of the equipment, the installed cables must be bound together (e.g. by
using a cable binder) very close to the terminal blocks.
1.1 AERIAL PLACEMENT
The antenna for the receiver shall be placed as open as possible. Further information can be
found in drawing 90 8473-000.
Connector for MC 1
Connector for
Voltage supply
12-24VDC
Connector for
Profibus DP.
Aerial connector
Ground screw for
shield connection.
Connector for MC 2

INSTALLATION INSTRUCTION REMOTUS 96XX 92 3161-000 Ver. C0 Page 2(3)
020320
S-780 45 BJÖRBO, PHONE [phone], FAX. [phone]
1.2 CONNECTION CABLE
Connection cable for power supply and main contactor (MC):
The cable shall have a CONCENTRIC SHIELD e.g. ÖLFLEX or similar and with a cable
area of 0,75-1mm². We recommend grounding the cable the same way as the cable for
Profibus (according to the figure below).
Voltage supply: 24 VDC (11-35 VDC)
Power consumption: Max 9W
Connection cable for Profibus:
We recommend the following cable type (Type A).
Type A is in particular suitable for high data rate (>500kbit/s).
Technical specification:
Impedance: 35 up to 165 Ohm at frequencies from 3 to 20MHz
Cable capacitance: <30pF by each meter
Cable area: >0,34mm², similar to AWG 22
Cable type: Twisted pair. 1x2 or 2x2 or 2x4 wires
Resistance: <110 Ohm by each km.
Signal attenuation: Max. 9dB over entire length
Shield: Double shield i.e. shield cover and shield foil
Max Bus length: 200 m at 1500 kbit/s, up to 1,2 km at 93,75 kbit/s
Place the cable for PROFIBUS separated from the cable for power supply.
It is recommended to connect the shield on both sides low inductively with the protective
ground. Preferably the connection between shield and protective ground is made via the metal
cases. It should be noticed that this is not the optimal solution. In such a case it is better to
bare the cable shield at an appropriate point and to ground with a cable as short as possible to
the metallic structure of the cabinet. This could be achieved with a ground screw in front of
the CU96XX receiver.
If the machine parts NOT have the same ground potential, a equalization cable with great area
(e.g. 16mm²) most be connected between the parts and to the central protective ground.
Master Follower Follower
Equipotientiaial
rail
Equipotientiaial
rail Equipotientiaial
rail
Equipotientiaial cable
Data cable
Data cable

INSTALLATION INSTRUCTION REMOTUS 96XX 92 3161-000 Ver. C0 Page 3(3)
020320
S-780 45 BJÖRBO, PHONE [phone], FAX. [phone]
1.3 CONNECTION EXAMPLE FOR THE MAIN CONTACTOR
The maximum switching capacity of the relay contacts is 8A/250VAC at cosϕ=1.
Current loops that contains the relay contacts shall have a protection fuse rated 6 A.
1.3.1 Principal connection of the main contactor
PROFIBUS DP
The receiver functions as a Profibus DP slave and have the identity 0x0765. This is fixed and
corresponds to the unit function as a Profibus DP slave.
• 16 byte consistent data in. The last byte is a checksum total for the 15 preceding bytes.
• 16 byte consistent data out.
On the Profibus board there are two rotary switches on which you can adjust the Profibus DB
slave address. The default address is 55.
A diskette with TYPE-and GSD-files are included with each delivery.
Main contactor control from receiver
MC1 MC2
Possible ON-
function from PLC Main contactor
Receiver
Switch
Any modification to the equipment not expressively authorized by the party responsible for
compliance could void the user's authority to operate the equipment.
This device complies with Part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference, and (2) this device must accept any
interference received, including interference that may cause undesired operation.
FCC note:
The equipment user is required by the radio service rules to obtain a licence before operating the
equipment.

PRODUCT DESCRIPTION REMOTUS CU9600 92 3159-980 Rev. F Page 1(16)
Datum: 02.10.24
780 45 BJÖRBO, TEL. + 46 241 25 000, TELEFAX. [phone]
Written by: Bengt Edström, Henrik Hedlund
Approved by: Tomas Bustad
Date: 02.10.24
R A D I O L I N K S Y S T E M
R E M O T U S C U 9 6 0 0
R E C E I V E R
for serial communication and fieldbuses

PRODUCT DESCRIPTION REMOTUS CU9600 92 3159-980 Rev. F Page 2(16)
Datum: 02.10.24
780 45 BJÖRBO, TEL. + 46 241 25 000, TELEFAX. [phone]
CONTENTS
1. SPECIFICATION
2. CONSTRUCTION
3. FUNCTION DESCRIPTION
3.1 Security
3.1.1 DUAL channel approach.
3.1.2 Check of output devices.
3.1.3 Under voltage protection.
3.1.4 Over voltage protection.
3.1.5 Watch-dog
3.1.6 Test of all system code (FLASH EPROM).
3.1.7 Test of safety relevant code (FLASH EPROM).
3.1.8 Test of PLC-program (FLASH EPROM)
3.1.9 Test of data memory (RAM).
3.1.10 CPU-test
3.1.11 Software reset.
3.1.12 Main contactor
3.1.13 Emergency stop
3.1.14 Disturbed message
3.2 System configuration
3.2.1 Unit address
3.2.2 Selection of persistent functions
3.2.3 Manipulator decoding
3.2.4 Disconnect delay, brake lifter
3.2.5 Multi-operator and multi-crane operation
3.2.6 Settings for Profibus DP
3.3 Indications
3.4 Two-way communikation (duplex)
3.5 Communication with other equipment
3.6 Dipswitches
3.7 Test mode
3.7.1 Runtime information
3.8 Monitor
4. MESSAGE CHECK
5. CONNECTIONS
Appendix.
1 Description of the PLC system (90 8075-000).
2 Description of the MONITOR (90 8069-000).

PRODUCT DESCRIPTION REMOTUS CU9600 92 3159-980 Rev. F Page 3(16)
Datum: 02.10.24
780 45 BJÖRBO, TEL. + 46 241 25 000, TELEFAX. [phone]
1. SPECIFICATION
oPart of the family REMOTUS 9000 and are therefore compatible with other units.
oConnects as a slave to fieldbus PROFIBUS DP. Max 16 byte out (120 functions
include checksum) and 16 byte in.
• Designed to fulfil security category 3 or category 5 (according to EN 954-1) by using
• way of double microprocessor-channels (redundancy).
oDouble security circuits (3 MC-relays).
oBuild-in powerful PLC-system.
o14 bits address, which permits 16 384 different addresses.
oSelectable decoding of manipulators.
oAdvanced multi-operator and multi-crane operator thanks to built-in PLC.
oOne serial asynchronous communication channel for communication with scales,
position transmitters etc.
oBuilt-in monitor for test-and parameter settings.
oIndications for different functions in the system (status, outputs).
oStatistics functions programmable with built-in PLC.
oUser-defined log function stores history.

PRODUCT DESCRIPTION REMOTUS CU9600 92 3159-980 Rev. F Page 4(16)
Datum: 02.10.24
780 45 BJÖRBO, TEL. + 46 241 25 000, TELEFAX. [phone]
Radio frequency: 405-470 MHz. Other frequencies of request.
Channel separation: 25 kHz option 20 kHz or 12,5 kHz
Power output: 50/500 mW
Sensitivity (9600 baud): -100 dBm
Transfer speed: 9600 baud (4800 with 12,5 kHz)
Link turnaround time: 10 mS
Transmission principle: FSK
Radio fullfills: I-ETS 300 220
Fieldbus: PROFIBUS DP slave
ID = 765
Address = 55 (00-99)
16 (8) bytes consistent data input. The latest byte is a
checksum for the 15 previous.
16 (8) bytes consistent data output.
Extra communication channel: Serial asynchronous RS232/RS485
Voltage supply: 24 VDC (11-35 VDC)
Power consumption: Max 9 W
Working temperature: -25°C -+55°C
Storage temperature: -40°C -+85°C
MC-relays: 2 pc 250 VAC, 16 A resistive load
MC-relays fuses 2 pc 250 VAC, 10 A
Aluminium cabinet for mounting on a symmetric DIN rail EN50 022.
Dimensions: 125x135x135 (bxhxd)
Weight: 1 kg

PRODUCT DESCRIPTION REMOTUS CU9600 92 3159-980 Rev. F Page 5(16)
Datum: 02.10.24
780 45 BJÖRBO, TEL. + 46 241 25 000, TELEFAX. [phone]
2. CONSTRUCTION
REMOTUS CU 9600 receiver consists of power supply-unit, RADIO/MODEM-unit, CPU-unit,
SP/HK-unit and fieldbus unit.
Outputs for functions as relays or analogue signals will be missing. Instead we transmit such
signals via a fieldbus to an available control unit (type PLC). A “fieldbus card“ which contents
the components which are specific for fieldbus Profibus DP, are mounting on the fieldbus-card.
For security reason there are relay outputs for emergency shutdown.
To reach the highest security level (5) the CPU-unit must be mounting with two identically
CPU:s with data/program-memory, indications, voltage supply etc.
The standard cabinet is of “aluminium“ and designed for mounting on DIN-rail.
The receiver is designed to be mounted together with a PLC in the same cabinet suitable for the
present environment.
Dipswitches
CPU-A
CPU-B
RADIO
Fieldbus
RS232
MC2
Power supply 24 V
MC1

PRODUCT DESCRIPTION REMOTUS CU9600 92 3159-980 Rev. F Page 6(16)
Datum: 02.10.24
780 45 BJÖRBO, TEL. + 46 241 25 000, TELEFAX. [phone]
3. FUNCTIONAL DESCRIPTION
The REMOTUS CU 9600 receiver has been designed to be a very compact unit.
The receiver is fully compatible with REMOTUS 9000 family. It is thus possible to use any
REMOTUS 9000 transmitter with a REMOTUS CU 9600 receiver. Functional flexibility is
obtained with a built-in PLC system and fieldbus connection to superior PLC.
The software consists of four main parts:
Radio communications module:
This receives and checks messages from the transmitter. It also executes the safety checks. The
logic for closing and opening the main contactor and decoding is handled by this module. A
number of variants are programmed in for this purpose, which are chosen during "configuration".
PLC module:
This module is functionally positioned between the above module and the outputs. The functions
can therefore be "processed" before they are outputted. The processing can consist of placing
functions on certain outputs, delaying, combining, sequencing, duplicating etc. Micro-mode can
be programmed in the PLC module. PLC programs are written separately on an ordinary
personal computer. The result is downloaded into the onboard FLASH-EPROM.
Fieldbus-module:
This module handles the communication with the fieldbus. Output from the PLC-module
transmits out to the control module for the fieldbus. Data from the fieldbus takes also in and
transmits as in data to the PLC-module.
Monitor module:
This module can be used to read and write anywhere in the PLC memory. This is particularly
useful for testing PLC programs and for fault tracing. The monitor is also used to set the serial
communication channel (see section 3.7) and to handle logging (see section 3.6) and statistic (see
section 3.5). For logging, it is necessary to select which variables are to be logged. To use the
monitor, it is first necessary to give a "password". A simple hand terminal is adequate for
communication with the monitor. It is connected to the front of the CPU-board. If only one CPU-
board is installed the prompt on the monitor is “R9000>”.If two CPU-board are installed the
prompt on the monitor is "R9000A>" for CPU:A and ”R9000B>” for CPU:B.

PRODUCT DESCRIPTION REMOTUS CU9600 92 3159-980 Rev. F Page 7(16)
Datum: 02.10.24
780 45 BJÖRBO, TEL. + 46 241 25 000, TELEFAX. [phone]
3.1 Safety
The safety level of this receiver is normally category 3. Category 5 is available during design
with dual CPU-board which works in parallel channels design and a large number of safety tests.
3.1.1 DUAL channel approach.
With only one CPU-board (category 3) the MC-relays activates via two separate control signals.
With two CPU-boards (category 5) the MC relays activates differentiate of both
microprocessors-channels i.e. both must be agreed for activate the MC-relays. Output data from
the both channels are compared of respective CPU before it transmits out via the fieldbus.
3.1.2 Check of output devices.
Test of driver outputs:
One side of the relay-coil is driven by cpu-A through a positive driver (source) and the other side
is driven by cpu-B through a negative driver (sink). When the main contactor is deactivated all
source drivers is monitored for not being in high state by cpu-A and all sink drivers is monitored
for not being in low state by cpu-B. In case of failure the main contactor is prevented to be
activated by the respective cpu. The respective cpu:s also clears the outputs which transmits to
the fieldbus.
3.1.3 Under voltage protection.
This consists of one device for each channel. The trip voltage is 4,65 V.
o Fault -> hardware reset.
3.1.4 Over voltage protection.
This consists of one device (MAX921) for each channel. The trip voltage is set to 5,5 V.
o Fault -> hardware reset.
3.1.5 Watch-dog.
A watchdog timer is used to monitor microprocessor function. This watchdog must be constantly
"patted" or it will "bite". "Patting" is the task of the microprocessor, which sends pulses regularly
to the watchdog. If the time between pulses is too long, the dog will "bite", which results in a
hardware reset.
There are one device for each CPU-board. It monitors a separate signal from the CPU.
o Fault -> hardware reset (indicated on a led).
The watch-dog is only maintained if an exact number of program-modules has been executed
during a ”software-cycle”.
The signal feeding the respective watch-dog is also fed to the opposite cpu which enables the
cpu:s to monitor each other. This is done all the time the receiver is running.
o Fault after the fault-tolerance-time -> All outputs cleared and main contactor off.
CPU-A
WDT-A
CPU-A CPU-B
WDT-A WDT-B
1 CPU-board 2 CPU-board