Autonomous Controller (FCN-500)

Reliability

For steady operations, high reliability is an essential requirement in the systems that controls and acquires data from various devices and processes and which interlink with other controllers in the control domain. The STARDOM autonomous controllers FCN-500 have rugged and highly reliable software and hardware, and as an optional feature support dual-redundant configurations for mission-critical applications.

Never Interrupts Your Process

High reliability is essential for the systems that control your critical processes. The dual redundant capability of the field control node (FCN) autonomous controller ensures that these processes continue without interruption even when a damaged module is replaced.

• CPU unit, power supply unit, FOUNDATION™ fieldbus module, extension unit bus, and control network can all be dual redundant.
• Automatic switchover to stand-by CPU
• Automatic data transfer from control side to replaced stand-by CPU
• Hot-swappable modules including CPU and I/O modules
• Fault-tolerant design (including ECC memory)

Durable Hardware

FCN-500 has a highly durable design. In addition to features such as fan-less cooling, there are no IC chips on the backplane, preventing mechanical failures. Furthermore, the use of error check and correct (ECC) memory prevents software failures.

Advanced Self Diagnosis

Rich diagnostic functions make it possible to keep track of CPU temperature, SRAM memory status, and I/O module status. In addition to the diagnostic functions that are performed by the CPU, the analog input modules have embedded self-diagnostic functions that can detect disconnected wires and short-circuits by continuously monitoring the loop status.

Network

STARDOM capability of establishing connections to a various network types results in big cost reduction for the customers. Networkability of STARDOM autonomous controllers FCN-500 designed for the hazardous area shows absolute advantage in the various applications requiring remote monitoring and operation.

TCP/IP-based Redundant Network

A TCP/IP based network enables a seamless connection with control and information networks using COTS network components, and also allows the easy adaption of controllers for use with narrow bandwidth network infrastructure including public telephone lines, GSM/GPRS, satellite, and radio. The use of a redundant network configuration and data buffering guard against the loss of valuable data in the event of a disruption in network communications.

More Networks

4 ports model is available for FCN-500. By utilizing this model, field network or engineering PC are connected while securing redundant control networks.

Field Network Supported

Engineering

FCN-500 controller applications are written in programming languages compliant with the IEC 61131-3 international standard, so users do not need to learn manufacturer-specific programming languages and can start engineering immediately.

IEC 61131-3 Compliant Programming Languages

Concise applications can be developed by choosing the most suitable programming language for each application or the preference of the user from five IEC 61131-3 compliant languages including Function Block Diagram, Ladder Diagram, and Sequential Function Chart. Loop control and sequence control can be coded within the same environment, further improving engineering efficiency.

Reuse of Programs

Engineering efficiency is improved by reusing the programmed and verified applications by using the following methods.

- Encapsulation

IEC 61131-3 compliant program allows your know-how to be encapsulated into reusable POU (Program Organization Units.) These POUs can be protected against user modification.

- Network Template

Network Template, which is a code frame programmed by FBD, LD, ST or IL, makes reuse of program easier. Network Template is inserted into any applications and modified corresponding to applications.

Efficient Debugging

- Software Wiring to Aid Debugging

Virtual wiring to input/output modules can be defined in the software, and so loop checks and testing of ladder sequences can be performed without actual inputs to the FCN-500 from a calibrator or test switches.

- Simulator Functions for Efficient Development

The simulator functions simulate the control applications of the FCN-100 on a PC. Since this function does not require FCN-500 hardware, control applications can be developed simultaneously by two or more engineers. Alternatively, applications can be developed and debugged separately from applications running on FCN-500.

Maintenance

Quick troubleshooting is the key to increasing the availability of the systems. From trouble shooting to the replacement of modules, STARDOM helps people on site perform simple maintenance procedures without requiring dedicated tools.

Minimize the spare parts in your inventory

Since the same CPU modules are used for both of single and redundant configurations, you only need to keep a small number of CPUs in your inventory.

Troubleshooting on site

The system and system logs can be backed up onto a SD card in FCN-500 using the rotary switch. It does not require any PCs or dedicated terminals on site.
Alternatively, expert engineers in the central control room can remotely check the CPU status on Web pages on the FCN-500.

Online Download

Your application can be modified without interfering your process. By using online download functions on Logic Designer, application running on dual redundant CPUs are automatically synchronized and variables on the applications can be inherited.

Quick start after replacing I/O

- Non-stop operation for redundant CPU

All program copy (APC) synchronizes the control side and stand-by side CPUs without using any PC tools.

- Quick start after replacing I/O

Thanks to hot swappable I/O module features, I/O definitions are automatically downloaded to I/O modules without use of PC tools. While replacing I/O modules, rewiring cables are not required.

Integration

A TCP/IP based network enables a seamless connection with control and information networks using COTS network components, and also allow the easy adaption of controllers for use with narrow bandwidth network infrastructure including public telephone lines, GSM/GPRS, satellite, and radio.

Yokogawa System Integration

STARDOM controllers act as Yokogawa DCS controllers via gateway. From a single window on the Yokogawa DCS HMI, operators enjoy seamless and transparent access to all the utilities on these different systems, with complete consolidation of all alarms.

Image Zoom

Configurations

I/O unit extension bus (E2bus) with 3 types of base module enable various system configurations.

Extension units as remote I/O

The I/O modules can be remotely distributed. The maximum transmission distance between two units is 100 m. The total transmission distance is up to 800 m (with 8 extension units in 1 line).
Moreover, by converting the copper cable to fiber optic cable, the total distance can be extended up to 5 km.

Flexible Arrangement

• Long, short, and compact base module are selectable depending on the installation space
• 2 lines of daisy-chain connection

Network Reference

STARDOM capability of establishing connections to a various network types results in big cost reduction for the customers. Networkability of STARDOM autonomous controllers designed for the hazardous area shows absolute advantage in the various applications requiring remote monitoring and operation.

Suitable Network Architecture for COTS Network Infrastructure

STARDOM autonomous controllers are suitable for the geographically distributed area since software architecture is highly independent and control network easily adapts to the COTS network infrastructure.

Network Installation Records for Various Networks

Customers have already installed STARDOM autonomous controllers to a wide range of applications under various network infrastructures.