FCN-500: Dual redundant configurable PLC/RTU
High reliability and high speed are essential for the systems that control your critical processes. The dual redundant model of the field control node (FCN) autonomous controller ensures that these processes continue without interruption even when a module is replaced.
Exclusive features for FCN-500
- Modular type PLC/RTU
- Wider operation temperature (-20 to 70 °C*)
- Dual redundant configuration for CPU unit, power supply unit, and control networks
- 4 network ports model available
- Improved file system stability in case of power failure
- PC-less maintenance capability using SD card
- Online changeable battery
- I/O expansion capability
*Depending on I/O modules
OpreX is the comprehensive brand for Yokogawa’s industrial automation (IA) and control business. The OpreX name stands for excellence in the technologies and solutions that Yokogawa cultivates through the co-creation of value with its customers, and encompasses the entire range of Yokogawa’s IA products, services, and solutions. This brand comprises the following five categories: OpreX Transformation, OpreX Control, OpreX Measurement, OpreX Execution, and OpreX Lifecycle. One of the product groups that make up the OpreX Control category is the OpreX Control and Safety System family, which includes the ProSafe-RS. With its various OpreX Control solutions, Yokogawa is able to quickly effect changes for its customers that lead to a transformation in such areas as management and operations, and provides highly reliable control technology that ensures high efficiency, high quality, and safe and stable plant operations.
With the OpreX brand, Yokogawa will deliver integrated solutions that address specific needs and support its customers in their efforts to transform and grow their businesses.
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)
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.
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.
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
|Upper-level systems||Ethernet||VDS (TCP/IP), FAST/TOOLS (TCP/IP, DNP3, Modbus TCP), HIS (Vnet/IP via gateway)
Other vendor SCADA systems (OPC, DNP3, Modbus TCP)
|Serial (RS-232, RS-422/485)||FAST/TOOLS (Modbus RTU/ASCII), Other vendor SCADA systems (Modbus RTU/ASCII, DNP3)|
|Other devices||Ethernet||FA-M3 (driver available), MELSEC (driver available), others (Modbus TCP)|
|Serial (RS-232, RS-422/485)||FA-M3 (driver available), MELSEC (driver available), others (Modbus RTU/ASCII)|
|Fieldbus||FOUNDATION™ fieldbus||FOUNDATION fieldbus devices|
|ISA100||ISA100 wireless devices|
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.
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.
- 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.
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.
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.
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.
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.
- Long, short, and compact base module are selectable depending on the installation space
- 2 lines of daisy-chain connection
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.
|Network Type||Application Name|
||Power meter reading (Power)
Heat and CO2 custody transfer system (Power)
Water pipeline leak management system (Water)
Automatic custody transfer system for cryogenic gas by truck delivery (Chemical)
Water dispensing bays control (Mining)
Environmental monitoring (Others)
|VSAT (Satellite)||Pipeline operation (Oil & Gas)
Wellhead monitoring (Oil & Gas)
|Radio Link||Gas development management system (Oil & Gas)
Oil platform - offshore CO2 metering (Oil & Gas)
Tram data (signals, points, location, etc) logging (Others)
Power metering and distribution control (Power)
Control system in the wells cellulose production line (Paper)
|Wired||ADSL+VPN||Oil collecting station (Oil & Gas)
Co-generation utility monitoring (Oil & Gas)
Cryogenic gas control and custody transfer (LNG)
Water pipeline leak management system (Water)
Water treatment plant monitoring and controlling pumps (Water)
|PSTN||Cryogenic gas control and custody transfer (LNG)
Water gate valve control (Water)
Water pipeline leak management system (Water)
|ISDN||Co-generation utility monitoring (Oil & Gas)|
|Leased Line||Gas district cooling - chilled water monitoring (Oil & Gas)|
- Reduced cabling costs by using a commodity GPRS network infrastructure
- Additional reduction in system cost by making full use of existing components
- Reduction in cost of software by using all web-based technology
- Long-term service contract — no need to worry about a suspension of maintenance services
- The STARDOM network-based control system and FA-M3 range-free controllers play an important role in smoothing out the supply of this power to the grid
- STARDOM and FA-M3 ensure smooth supply of power to grid by wind farm equipped with large-capacity NAS batteries
- FCN Autonomous Controller Functions (FCN-500) (442 KB)
- FCN Autonomous Controller Hardware (FCN-500) (1.7 MB)
- Turbomachinery Controller Overview (FCN-500/FCN-RTU) (312 KB)
- Analog I/O Modules (263 KB)
- Digital I/O Modules (361 KB)
- Turbomachinery I/O Module (412 KB)
- Field Connection Specifications (585 KB)
- Serial Communication Module (174 KB)
- Terminal Block (145 KB)
- Application Portfolios for FCN/FCJ (FCN-500/FCN-RTU) (846 KB)
- DNP3 Communication Portfolio (FCN-500/FCN-RTU) (765 KB)
- STARDOM FOUNDATION fieldbus Communication (377 KB)
- FCN/FCJ Duolet Application Development Kit (157 KB)
- MIL Connector Terminal Blocks, MIL Connector Cables (422 KB)
- FCN/FCJ Simulator (124 KB)
- FCN/FCJ OPC Server for Windows (210 KB)
- Foundation Fieldbus Communication Module (171 KB)
- Duplexed Network Program for FCN/FCJ OPC Server (126 KB)
- PROFIBUS-DP Communication Module (328 KB)
- CANopen Communication Module (296 KB)
- Gas Flow Calculation Portfolio (FCN-500) (201 KB)
- Liquid Flow Calculation Portfolio (119 KB)
- HART Communication Functions (190 KB)
- Logic Designer (362 KB)
On April 18th 2018, YOKOGAWA has released the new unit extension module: “E2 bus interface module” for the STARDOM autonomous controller “FCN-500”. Excellent Scalability and Excellent Reliability, FCN-500 has evolved with “Excellence × 2”.
Providing an introduction to the features of STARDOM autonomous controller ‘FCN’. “Faster, Stronger, Smarter”, the FCN-500 STARDOM controller strengthens your core competencies with field proven reliability.
New CPU module for the STARDOM autonomous controller 'FCN' is unveiled. “Faster, Stronger, Smarter” controller will strengthen your competencies.
Yokogawa presents a demonstration of how the combination of Stardom FCN-RTU and FAST/TOOLS SCADA can be combined to provide a powerful control and data collection system where in the event of a network disconnection or computer outage - Stardom internally buffers data that would otherwise be lost and on reconnection or restoration of the SCADA Server FAST/TOOLS is able to back-fill missing data in its trend.
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