Yokogawa AFV30D-A41262/HKU Dual-channel redundant Field Control Unit (FCU)

Description

I. Product Overview

Yokogawa AFV30D-A41262/HKU is a duplex redundant Field Control Unit (FCU) matched with Yokogawa CENTUM VP DCS system, the core field controller of process automation system. Equipped with optional HKU hardware interface, it integrates high-speed operation, closed-loop process control, I/O signal acquisition, dual redundant communication and fault safety diagnosis functions. It realizes PID continuous regulation, sequence logic control and safety interlock protection for process parameters such as temperature, pressure, flow and liquid level, widely applied in petrochemical, thermal power, oil & gas, metallurgy and other process industries.

This model adopts full redundant architecture of dual controllers, dual power supplies and dual Vnet/IP buses, matches FIO distributed field I/O expansion mode, and is equipped with built-in battery backup for data power failure protection. It features millisecond-level control cycle and large-capacity program storage. Certified by CE, UL and TÜV, it can operate continuously 24/7 in industrial control cabinets with high temperature, dust and strong electromagnetic interference, serving as core spare parts for new DCS projects, control system expansion, faulty controller replacement and redundant architecture upgrading.

II. Hardware Structure and Composition

1. High-performance Redundant Main Control Operation Unit

Adopts VR5532 350MHz industrial processor with 128MB RAM, supporting local storage of control programs, historical parameters and event records. Dual hot-standby controllers synchronize data in real time and realize seamless switch within milliseconds during faults to ensure uninterrupted control logic. Built-in lithium battery power-off protection supports up to 72 hours of data retention after power failure, with a minimum charging time of 48 hours to avoid loss of programs and setting parameters caused by instantaneous grid power failure.

2. Dual Redundant Power Supply Loop Unit

Supports 220～240VAC dual independent AC redundant power input, with automatic switchover in case of single-circuit power failure, overload or short circuit. Integrated multi-level protections including overvoltage, undervoltage, overcurrent, surge and reverse connection, it effectively resists grid voltage fluctuation and instantaneous spike interference, preventing controller crash and process out-of-control caused by abnormal power supply.

3. Dual Redundant Vnet/IP Industrial Communication Unit

Two independent redundant Ethernet interfaces adopt Yokogawa dedicated Vnet/IP industrial bus protocol for data interaction with operation stations, engineering stations and ESB bus nodes. The ESB bus runs at 128Mbps, supporting up to 9 nodes with a maximum transmission distance of 10m, and can expand remote FIO cabinets up to 50km via optical fiber. Equipped with HKU dedicated interface, FCU fault dry contact signals can be externally output for remote fault alarm uploading to third-party monitoring systems.

4. FIO Field I/O Bus Expansion Unit

Adopts FIO distributed I/O architecture, which can expand multiple racks of analog and digital I/O modules, with 16-bit high-precision signal acquisition and millisecond-level digital signal scanning. Built-in channel-level electrical isolation prevents single-loop short circuit or electromagnetic interference from spreading to the main control unit, flexibly adapting to signal access of process detection, valve actuation and equipment interlock.

5. Hardware Diagnosis and Status Output Unit

Multiple LED indicators display power, main/standby controller, network communication and hardware fault status for rapid on-site fault location. Equipped with passive fault alarm contacts (30VDC, 0.3A rated), which can be connected to local audible and visual alarms or upper monitoring systems to realize dual local and remote fault warning.

III. Technical Specifications

(1) Electrical Parameters

Processor: VR5532 350MHz, RAM 128MB
Power Supply: 220～240VAC 50/60Hz, dual redundant input, typical power consumption 230VA
Control Cycle: Minimum 10ms high-speed closed-loop control, supporting PID, sequence control and interlock logic
Data Backup: Lithium battery backup, maximum 72h data retention, minimum 48h full charging time
Communication: Dual redundant Vnet/IP Ethernet, ESB bus 128Mbps; equipped with HKU fault contact dedicated interface
Fault Contact: Passive normally closed contact, rated 30VDC, 0.3A, open when hardware fault occurs
I/O Expansion: Compatible with FIO distributed field I/O modules, supporting multi-rack remote I/O extension

(2) Environmental Parameters

Operating Temperature: 0℃～+50℃; Storage & Transportation Temperature: -40℃～+85℃
Relative Humidity: 5%～90%RH, non-condensing, no corrosive gas or conductive dust
Ingress Protection: IP20, installed in indoor 19-inch ventilated control cabinets only

(3) Mechanical Parameters

Mounting: 19-inch standard rack installation, fixed with M5 screws
Net Weight: Approx. 8.0kg
Structure: Integrated duplex redundant anti-vibration rack housing
Process: PCB three-proof conformal coating for dust, moisture and corrosion resistance

IV. Product Functions and Features

Triple Full Redundant Architecture Ensures Uninterrupted Process Control

Dual controller, dual power supply and dual industrial Ethernet realize seamless fault switchover within milliseconds, avoiding unplanned plant shutdown and safety accidents caused by single-point hardware failure, fully meeting high safety operation specifications of high-risk process industries.

Integrated Rich Industrial Control Algorithm Library

Supports cascade PID, feedforward control, batch sequence control and safety interlock logic. Built-in digital filtering suppresses electromagnetic interference from frequency converters and high-voltage equipment, stabilizing process parameters and reducing frequent valve actuation.

Distributed FIO Remote I/O Long-distance Expansion

Optical fiber-based ESB bus realizes remote I/O deployment up to 50km, adapting to large-scale scattered measuring point layout, reducing cable construction cost and on-site electromagnetic interference; I/O modules support hot swapping without controller shutdown for maintenance.

HKU Dedicated Interface Realizes Cross-system Fault Alarm Linkage

Hardware fault signals can be output via independent passive contacts to third-party monitoring systems and local alarm devices, breaking the limitation of DCS internal alarm and realizing full-range equipment status monitoring for predictive maintenance.

Full-range Online Self-diagnosis and Traceable Event Recording

Real-time diagnosis covers main control, power supply, communication bus, backup battery and I/O loop, locating faults to unit level; massive historical events, alarm records and operation logs can be exported for accident analysis and safety compliance audit.

V. Application Scenarios

Continuous process control and safety interlock protection for thermal power, gas power plant boilers, steam turbines and auxiliary equipment in CENTUM VP DCS systems.
PID regulation and ESD emergency interlock control for reactors, distillation columns and heating furnaces in petrochemical, coal chemical and fine chemical plants.
Distributed automation control systems for oil & gas pipelines, LNG terminals, wastewater treatment, metallurgy and cement production lines.
Annual overhaul, faulty controller replacement and single-control system redundant upgrading of legacy Yokogawa CENTUM VP DCS systems.
New automation projects with scattered field measuring points adopting FIO remote I/O centralized acquisition and control mode.