Yokogawa OpreX ™ STARDOM FCN-RTU Remote Terminal Unit

Yokogawa OpreX ™  STARDOM FCN-RTU Remote Terminal Unit

Product core positioning and applicable scenarios

1. Core functional positioning

FCN-RTU, as a remote monitoring unit of Yokogawa STARDOM series, integrates four core capabilities of "remote data acquisition, distributed control, multi protocol communication, and low-power operation and maintenance", filling the gap of traditional RTUs in complex control and system compatibility. The specific functions cover:

Data acquisition: Supports analog (4-20mA, RTD/TC temperature), digital (24V DC switch signal), and pulse (flow counting, speed) acquisition, with a measurement accuracy of ± 0.1% FS, and supports channel level fault diagnosis (such as disconnection and short circuit detection);

Remote control: equipped with basic logic control (interlock protection, sequence control) and PID regulation functions, it can independently achieve localized control of remote stations (such as pump station pressure regulation, valve start stop), reducing dependence on the central system;

Narrow bandwidth adaptation: Supports narrow bandwidth communication such as GPRS/4G/LTE, satellite, microwave, etc. The data transmission adopts the "incremental upload+compression protocol" to reduce data consumption (such as compressing a single data upload to less than 1KB);

High reliability design: Key components (CPU, power supply, communication module) support redundant configuration, wide temperature range (-40~+70 ℃), anti-corrosion (G3 coating optional), anti vibration (5g/10-500Hz), suitable for unmanned harsh outdoor environments.

2. Typical Applicable Scenarios

Oil and gas industry: Station monitoring of long-distance oil and gas pipelines (such as oil pumps, valves, pressure transmitters), supporting interconnection with Yokogawa CENTUM VP DCS or SCADA systems to achieve leak detection and remote start stop;

In the field of new energy: monitoring of box transformers and combiner boxes in wind farms/photovoltaic power plants, uploading data on power generation, temperature, voltage, etc. through 4G/LTE, supporting on-site reactive power compensation control;

Water treatment and pipeline network: Pressure pump stations and flow meter monitoring for urban water supply pipelines, or remote aeration tank level regulation for sewage treatment plants, adapted to the low-power operation needs of remote sites;

Industrial distributed sites: cross plant equipment monitoring (such as tank farms in chemical plants and mineral processing equipment in mines), achieving centralized management of multiple sites through fiber optic or wireless bridging.

Key technical specifications and performance parameters

1. Hardware core specifications

Category core parameters (universal model, specific module slightly different)

CPU module model: F3CU01 (single CPU)/F3CU02 (redundant CPU); Processor: ARM Cortex-A9 dual core 1GHz; Memory: 1GB DDR3 RAM+4GB eMMC flash memory

Power module input: 12-48V DC (wide voltage adaptation, supports solar charging+battery backup); Output: 5V DC 3A (system power supply)+24V DC 2A (field device power supply), doubling the total output when configured redundantly

I/O module type analog input (AI): 4-20mA/1-5V (8-channel, isolated), RTD (platinum resistance, 8-channel), TC (thermocouple, 8-channel);

Analog output (AO): 4-20mA (4-channel, isolated);

Digital I/O (DI/DO): 24V DC 32 channel (DI)/16 channel (DO, relay output);

Pulse input: frequency 0-1kHz (4-channel, used for flow counting)

Expansion capability supports connecting remote I/O modules through RS-485 or dedicated expansion bus, with a maximum of 256 I/O points supported by a single RTU; Can cascade 8 expansion units, with a maximum transmission distance of 1km (twisted pair)/5km (fiber optic)

2. Communication and control performance

Communication interface:

Wireless communication: optional GPRS/4G/LTE modules (supporting dual card redundancy), satellite communication modules (such as Inmarsat BGAN);

Wired communication: 1 channel of 10/100Mbps Ethernet (supporting redundancy), 2 channels of RS-485 (Modbus RTU), 1 channel of RS-232 (debugging/local communication);

Protocol support: Modbus RTU/TCP, DNP3.0 (cascade/master), IEC 60870-5-101/104, MQTT (Internet of Things platform docking), supporting Yokogawa proprietary protocol (STARDOM Link).

Control performance: The control cycle is adjustable from 10ms-1s and supports 8 priority tasks; Built in PID control block (supporting automatic/manual switching, disturbance free switching), logic control block (such as AND/OR/NOT, delay), can achieve complex interlocking through programming.

3. Environmental and compliance characteristics

Environmental adaptability: working temperature -40~+70 ℃ (wide temperature), storage temperature -40~+85 ℃; Relative humidity of 5%~95% (non condensing, supporting condensing environment); Anti vibration level 5g (10-500Hz, IEC 60068-2-6), anti impact level 50g (1ms, IEC 60068-2-27);

Protection and certification: The enclosure protection level is IP40 (standard)/IP65 (outdoor type, optional), supporting G3 anti-corrosion coating (EN ISO 12944-5); Compliant with CE, UL 508, ATEX Zone 2 (Ex nA IIC T4), IECEx certification, suitable for hazardous areas and outdoor scenes.

System architecture and extension logic

1. Hardware architecture and redundancy design

FCN-RTU adopts a layered architecture of "main unit+expansion unit+remote I/O", balancing flexibility and reliability:

Main unit: including CPU module, power module, basic I/O module and communication module, supporting DIN rail installation (size: 140 × 100 × 220mm, weight about 2.5kg), suitable for small control cabinets or outdoor cabinets;

Expansion Unit: Connected to the main unit via RS-485 or fiber optic cables, providing additional I/O interfaces (such as AI/AO/DI/DO modules). A single main unit can cascade up to 8 expansion units, suitable for centralized monitoring of multiple devices;

Redundant configuration: The CPU, power supply, and wireless communication module can be redundant with a redundancy switching time of less than 100ms. The communication link supports "wireless+wired" dual backup (such as 4G and fiber optic redundancy) to avoid disconnection caused by a single link failure.

2. Typical System Topology Example

plaintext

[Center SCADA/DCS] ←→ [Communication Network (4G/Satellite/Fiber Optic)] ←→ [FCN-RTU Main Unit (Redundant CPU+Power Supply)]

↓ (RS-485/fiber optic)

[Extension Unit 1 (AI/TC Module)] ←→ [Pipeline Pressure/Temperature Sensor]

↓

[Expansion Unit 2 (DI/DO Module)] ← → [Pump Station Motor/Valve actuator]

↓

[Expansion Unit 3 (Pulse Module)] ←→ [Flow Meter (Pulse Output)]

Engineering development and operation characteristics

1. Programming and configuration tools

FCN-RTU is equipped with Yokogawa STARDOM Engineering Tool kit, which complies with IEC 61131-3 standard and reduces the development threshold:

Control Designer: a control program development tool that supports FBD (Function Block Diagram), LD (Ladder Diagram), and ST (Structured Text) programming, and provides industry-specific function block libraries (such as oil and gas pipeline leak detection blocks and flow accumulation blocks);

System Configurator: a hardware configuration and communication parameter setting tool that visualizes the mapping of logical I/O and physical modules. It supports one click configuration of communication protocol parameters (such as DNP3.0) without the need to manually write drivers;

Offline Simulator: an offline simulation tool that can simulate on-site signals (such as pressure fluctuations and valve failures) on a PC, verify the correctness of control logic, and shorten on-site debugging time.

2. Operations and diagnostic capabilities

Low power operation and maintenance: supports "sleep wake" mode (such as sleep when there is no data, timed wake-up upload), and can achieve continuous 72 hour operation without sunlight in the scenario of solar+battery power supply;

Status monitoring and alarm: The main unit is equipped with an LCD display screen (128 × 64 pixels) and LED indicator lights, which display the real-time operating status (power, communication, I/O faults); Support local button operation (fixed value modification, log query), or export fault logs through USB interface;

Remote operation and maintenance: Remote diagnosis can be achieved through a web interface or Yokogawa PRM (Plant Resource Manager) system, supporting I/O channel calibration, firmware online upgrade, configuration file backup/recovery, and reducing on-site operation and maintenance frequency.

Key modules and selection information

1. Core module model and function

Module Type Model Example Core Functions

CPU module F3CU01 single CPU configuration, 1 Ethernet+2 RS-485, supports Modbus/DNP3 protocol

F3CU02 redundant CPU configuration, 2 Ethernet (redundant)+2 RS-485, suitable for high reliability scenarios

Power module F3PU01 12-48V DC input, single output (5V+24V), supports battery charging management

F3PU02 redundant power module, dual independent outputs, supports fault self detection

Analog input module F3AI08 8-channel 4-20mA input, channel isolation, accuracy ± 0.1% FS, supports HART protocol (optional)

F3AR08 8-channel RTD input (platinum resistance 100 Ω), supporting wire breakage detection and cold end compensation

Communication module F3CM4G 4G/LTE wireless module, dual card redundancy, supports global frequency bands (1.8/2.1GHz)

F3CMSAT satellite communication module, compatible with Inmarsat BGAN network, supports communication in remote areas without base stations

Expansion module F3EX01 expansion bus interface module, realizing RS-485/fiber optic connection between the main unit and the expansion unit

2. Key dimensions for selection

I/O requirements: Determine the number of AI/AO/DI/DO points based on the type of on-site equipment (sensors/actuators), and select the number of basic I/O modules and expansion units for the main unit;

Communication environment: Satellite communication module is selected for areas without base stations, 4G/LTE module is selected for areas with mobile signals (dual card redundancy priority), and fiber optic+wireless backup is optional for fixed stations;

Environmental conditions: Choose IP65 protection and G3 coating for outdoor or harsh environments, support wide temperature range (-40 ℃) for low-temperature scenarios, and select ATEX certified models for hazardous areas;

Reliability requirements: Key stations (such as oil and gas pipelines) are equipped with CPU, power, and communication redundancy, while non key stations (such as ordinary pump stations) can be configured separately to reduce costs.