FOXBORO RH924UQ controller module

FOXBORO RH924UQ controller module

Product Overview

The FOXBORO RH924UQ controller module is a core computing and control unit launched by FOXBORO for high-end industrial automation control scenarios, and is a key component of its distributed control system (DCS) architecture. This module is based on a high-performance processor and integrates functions such as multi-channel signal processing, complex logic operations, real-time control algorithms, and high-speed communication. It is mainly used for centralized monitoring, precise operation, and closed-loop control of multivariate parameters in industrial production processes. It is the core hub connecting the on-site equipment layer and the upper monitoring layer.

With its modular design and powerful scalability, FOXBORO RH924UQ can adapt to various scenarios from single machine equipment control to large-scale joint plant collaborative control, and is widely used in industries such as petrochemicals, fine chemicals, power energy, metallurgy and building materials that require strict real-time and reliability control. It is compatible with mainstream DCS systems such as FOXBORO I/A Series, and can seamlessly integrate with various I/O modules, communication modules, and human-machine interfaces, providing core technical support for stable operation, efficiency improvement, and safety assurance in industrial production.

Specification parameters

core processor

Multi core industrial grade processor with a main frequency of 2.0GHz; Built in 4MB cache, supports multitasking parallel processing

storage capacity

Program memory: 16GB Flash; Data storage: 4GB DDR4 RAM; Support external SD card expansion (up to 32GB)

I/O interface capability

Supports up to 32 I/O module extensions; Digital I/O channels: up to 256 channels (configurable input/output); Analog I/O channels: up to 128 channels (4-20mA/0-10V)

control performance

Control cycle: minimum 1ms; supports 30+control algorithms such as PID/PID self-tuning, fuzzy control, predictive control, etc; Can simultaneously handle 64 independent control loops

communication parameters

Standard interfaces: 2 Gigabit Ethernet ports, 4 RS485 serial ports; Supported protocols: Profinet, Modbus TCP/RTU, EtherNet/IP, FOXBORO proprietary protocol; Communication speed: Gigabit Ethernet up to 1000Mbps

power supply parameters

Power supply voltage: 24V DC (redundant power supply optional); Voltage fluctuation range: 18-36V DC; Typical power consumption: ≤ 25W, maximum power consumption ≤ 40W

environmental parameters

Working temperature: 0 ° C to 60 ° C; Storage temperature: -40 ° C to 85 ° C; Relative humidity: 5% to 95% (no condensation); Anti vibration: Complies with IEC 60068-2-6 standard

Security and Authentication

Safety level: SIL 3; Explosion proof certification: Ex ia IIC T4 Ga (optional); Compliance certification: UL, CSA, ATEX, IECEx, CE

physical parameters

Dimensions (length x width x height): 180mm x 120mm x 40mm; Installation method: DIN rail installation; Shell material: Aluminum alloy die-casting

Performance characteristics

1. High performance computing and real-time control capabilities

Equipped with a multi-core industrial grade processor with a clock speed of up to 2.0GHz, coupled with 4MB cache and 4GB DDR4 RAM, it has powerful data processing and multitasking capabilities. The minimum control cycle can be as low as 1ms, and it can quickly respond to on-site signal changes and execute control instructions. Supports parallel operation of 64 independent control loops, compatible with various advanced algorithms such as PID self-tuning, fuzzy control, model predictive control, etc. It can be flexibly configured according to different process requirements to meet the control accuracy requirements of complex industrial scenarios.

2. Flexible scalability and system compatibility features

Adopting a modular architecture design, it supports up to 32 I/O module extensions and can flexibly match various I/O modules such as digital, analog, and special functions (such as pulses and thermocouples) according to on-site requirements, achieving on-demand configuration of I/O channels. Perfectly compatible with FOXBORO I/A Series distributed control systems, while supporting mainstream industrial communication protocols such as Profinet and EtherNet/IP, it can seamlessly integrate with third-party PLCs, SCADA systems, and intelligent instruments, reducing system integration difficulty and adapting to the automation upgrade needs of new and old factories.

3. High reliability and redundant guarantee design

Support 24V DC redundant power supply configuration. When the main power supply circuit fails, the backup power supply can automatically switch within 10ms to ensure the continuous and stable operation of the controller and avoid production shutdown caused by power interruption. The core circuit adopts a dual isolation design, with overcurrent, overvoltage, short circuit, and surge protection functions, which can effectively resist electromagnetic interference and power grid fluctuations in industrial sites. The average time between failures (MTBF) exceeds 200000 hours. Compliant with SIL 3 safety level standards, it can be used for safety interlock systems to reduce industrial production risks.

4. High speed communication and data exchange capability

Standard configuration includes 2 Gigabit Ethernet ports and 4 RS485 serial ports, supporting simultaneous operation of multiple protocols. The Gigabit Ethernet port enables high-speed data exchange between the controller, upper system, and other control units, with a communication speed of up to 1000Mbps, ensuring fast transmission of real-time control data and production monitoring data. Support data breakpoint continuation and traffic control functions, which can ensure that critical data is not lost in case of network congestion or temporary interruption, quickly synchronize data after restoring connection, and maintain system data consistency.

5. Convenient debugging and operation management

Support parameter configuration, program writing, and online debugging through FOXBORO dedicated configuration software (such as Control Builder). The software has a rich algorithm library and functional modules built-in, and can quickly build control logic through drag and drop, reducing programming difficulty. The module comes with LED status indicator lights, which can visually display power, operation, communication, and fault status. It also supports outputting fault diagnosis codes through the communication port. Operation and maintenance personnel can quickly locate the cause of faults with the help of configuration software or handheld terminals, shorten fault handling time, and improve operation and maintenance efficiency.

Working principle

The FOXBORO RH924UQ controller module has the core workflow of "signal acquisition data operation control output communication interaction", and achieves closed-loop control of industrial processes through collaborative work with extended I/O modules and upper level systems. The specific working principle is as follows:

1. Signal acquisition stage

The controller establishes a data connection with the extended I/O module through the backplane bus. The I/O module is responsible for collecting various signals from on-site sensors, transmitters, and actuators. The digital input module collects discrete signals such as device start stop status and limit switches; The analog input module collects 4-20mA/0-10V signals with continuous changes in temperature, pressure, flow rate, etc; The special function module collects thermocouple millivolt signals or pulse signals, etc. The collected raw signals are filtered, isolated, and AD converted internally by the I/O module, and then transmitted to the core computing unit of the controller through the backplane bus.

2. Data operation and logical processing stage

After receiving the digital signals transmitted by the I/O module, the core processor performs logical operations according to the preset control program and algorithm. The processor adopts a multitasking scheduling mechanism to simultaneously handle the computational requirements of multiple control loops: it compares the collected process parameters with the set values issued by the upper system, calculates the control deviation through PID and other control algorithms, and generates corresponding control commands according to algorithm rules. During the computation process, the processor reads the parameter configuration and logical relationships stored internally in real time to ensure the accuracy and real-time performance of the computation results.

3. Control instruction output stage

The control instructions generated by the operation are processed by the processor and transmitted to the corresponding I/O output modules through the backplane bus: the digital output module outputs switch signals to control the start and stop of equipment such as contactors and solenoid valves; The analog output module outputs 4-20mA/0-10V signals to drive actuators such as regulating valves and frequency converters, achieving precise adjustment of industrial process parameters. At the same time, the output module collects real-time feedback signals from the actuator and sends them back to the controller to form a closed-loop control, ensuring that the control effect meets expectations.

4. Communication interaction and status monitoring stage

The controller interacts with the upper SCADA system or human-machine interface (HMI) through a gigabit Ethernet port to upload process parameters, equipment operating status, and fault information collected on site to the upper system. At the same time, it receives control parameters (such as set values, start stop instructions) and program update instructions issued by the upper system. Communicate with on-site intelligent instruments or third-party devices through RS485 serial port to achieve bidirectional data exchange. The controller monitors its own operating status and the working status of the I/O module in real time. When an abnormality is detected, it immediately triggers an alarm mechanism and outputs a fault code, which facilitates timely handling by operation and maintenance personnel.