Technical

Information STARDOM Technical Guide

TI 34P02A03-01E

Part-A Outline A

Part-B Autonomous Controller FCN/FCJ B

Part-C FCN/FCJ Installation C

Part-D NPAS POU Outline D

Part-E VDS (Versatile Data Server Software) E

Part-F General Specifications (GS) F

F1. STARDOM Overview Over-
view
F2. FCN/FCJ
FCx
F3. APPF
F4. VDS APPF

VDS

TI 34P02A03-01E
© Copyright Dec. 2007 (YK)
8th Edition July 31, 2014 (YK)
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Introduction
 About this manual
STARDOM control system provides
• High reliability
• Simple, high-quality engineering
• An open system that can be connected easily to other systems
• Reassuring support for long-term operation
This manual describes in detail the functions of the STARDOM control system.

 Contents of this manual

The contents of this manual are based on the style of hardware and the specifications of
software release at the time of this publication.
A function may be limited by the combination of an operating hardware and software.
Please check it on the following homepage.
http://STARDOM.jp
-> Members Page Yokogawa Plus
Network-based Control System (STARDOM)
Compatibility of STARDOM Component

 Intended readers of this manual

This manual has been prepared for individuals who conduct engineering and estimates
regarding STARDOM control system as an estimate guide for the model choice.

All Rights Reserved. Copyright © 2007, Yokogawa Electric Corporation TI 34P02A03-01E July 31, 2014-00
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STARDOM
Technical Guide
Part-A Outline
Part-A Outline
TI 34P02A03-01E 8th Edition

CONTENTS Part-A .......................................................................................................... i

A 1. STARDOM at a Glance ................................................................. A-1
A 2. Characteristics of STARDOM Control System ........................... A-3
A 2.1 Characteristic 1 [Reliability] ................................................................... A-4
A 2.2 Characteristic 2 [Ease of Engineering] ................................................. A-6
A 2.3 Characteristic 3 [Openness (Connectivity)] ......................................... A-8
A 2.4 Characteristic 4 [Long-term Stable Operation] .................................... A-9
A 3. STARDOM Control System Components ................................. A-10

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A1. STARDOM at a Glance

● Problems with PLC-based control system
At the end of 1994, Yokogawa Electric Corporation released the first PLC-based
control system “astnex” to Japanese market, and has since pioneered the way for a
new age of control system. PLC-based control system is being used in an
increasingly wide range of industries and fields, but at the same time, many issues
have become evident, including the following. A
• Linkage to other process control programs has increased, and whole systems are
becoming gradually more complexed.
• With the increase in scale and complexity of systems, it becomes difficult to
determine the cause.
• The price of hardware becomes lower, but the cost to create software constitutes
70% of the cost of ownership. Because of shortening new product cycle,
modification of software increases and quality control becomes difficult.

● The completion of STARDOM-based control system

Yokogawa has not merely added process control functions to a PLC, but looking on
engineering , operation and maintenance as a system on view point of process
control system vendor, and Yokogawa has completed “STARDOM control system”
which responds to those needs. STARDOM control system provides openness,
general versatility, and low implementation cost, and has been designed to make it
possible to decrease the long-term TCO (Total Cost of Ownership) in rapid changes in
business. In particular, in addition to enhancing process control functions, reliability,
openness, ease of engineering, and other functional aspects, an engineering support
and long-term stable operation mechanism are provided.

● STARDOM at a glance
STARDOM is a hybrid PLC which suits regulatory control and has PLC functionality of
high level of “openness” and “easy engineering” using IEC 61131-3 international PLC
language. STARDOM also implements DCS level “reliability” which achieves a high
operation rate, and “long-term operability.”

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● System configuration
STARDOM, the foundation of STARDOM control system, consists of independent
components for each function, such as control, operation, and monitoring, has an
ability of achieving flexible and scalable connection of these components through
network technology. The components and system configuration of STARDOM control
system are shown in the figure below.

Ethernet (Intranet)
Web-based HMI VDS

Ethernet (Dual-redundant control network )

Autonomous Controller PLC Autonomous Controller

Figure STARDOM Control System Configuration Diagram

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A2. Characteristics of STARDOM Control System

STARDOM Control System has the following characteristics.

 Reliability

● Easy Achievement and Operation of Highly Reliable System

• A robust controller with a highly reliable design inherited from DCS, including the A
use of ECC memory, etc.
• Easy redundant configuration of CPUs, control networks, power supplies, etc.
• Easy recovery from trouble without stopping process by failure module
replacement.

 Engineering

● High-quality Rapid Response to Frequent Modifications

• Achieve short time delivery with high quality by combining high-quality software
parts of control program.
• Enhanced simulator and debugging functions
• Programs can be modified without stopping control.
• International Engineering work is also easy with development tools complying to
global standard “IEC 61131-3.”
• Easy set up Tools

 Openness (connectivity)

● Easy Links with Other Systems

• Linking between other systems is smooth through full-scale utilization of global
standard/industry standard technology.
• Linking to upper-level business systems is easy.
• High level of scalability with each type of field network support
• Linking with existing systems is also easy.

 Long-term Stable Operation

● Long-term Stable Operation of System

• It is easy to know the controller using the remote maintenance function status
even during control operation.
• Worry-free technical support during engineering phase through STARDOM
technical assistant
• Product maintenance contracts responding to the constantly evolving open
environment
Concrete examples of these characteristics are given as follows.

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A2.1 Characteristic 1 [Reliability]

In this era of a company's survival being significantly affected by accidents
and problems with quality, the reliability of production systems has become
vitally important. However, the common PLC-based redundant system is
expensive, and construction and maintenance are bothersome. Moreover,
accompanying the increased complexity and scale of systems, there is a
A tendency to face the trouble it which is hard to duplicate.

 Easy Redundancy and Maintenance

Redundant systems dramatically improve reliability. The common PLC redundant
system requires CPUs and base modules exclusively for redundancy, as well as
modules for communication with the upper level and with I/O. Even with small-scale
PLC redundant system, the amount of parts has increased and mounting panels have
become larger. It is also necessary to prepare spare parts. In addition, if, by chance,
the I/O or CPU malfunctions, a specialized tool (PC) must be connected. Careful and
serious thought was required when determining to use a PLC redundant system,
which can easily become a major undertaking.
With the STARDOM autonomous controller FCN, a redundant configuration can be
easily achieved by adding a single compact CPU (single/redundant dual purpose),
power supply module, etc., according to the required level of reliability. Further, it is
possible to configure a highly space-efficient, compact, and inexpensive redundant
system. The purchase of spare specialized redundant parts is not required. This
makes it possible to use redundancy easily to achieve a high level of reliability with
the right materials in the right place.
Moreover, maintenance tools are not required if the I/O or CPU module malfunctions.
Recovery is easy by removing the malfunctioning module and replacing it with a
working part.

Maintenance tools
are not required.

Figure Replacement When the CPU Malfunctions

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 Malfunction-suppressing Design
The memory devices used in many PLCs sometimes suffer transient memory errors
(non-permanent malfunction). In some cases, such transient errors cause controller
malfunctions that cannot be reproduced.
The autonomous controller STARDOM mounts ECC memory as a countermeasure
against transient memory errors which increase with the greater complexity and larger
scale of systems. This significantly reduces the possibility of malfunctions caused by
memory failure, making it possible to entrust it with control without worry. In addition,
the highly reliable design inherited from DCS is used throughout to reduce the rate of
hardware malfunction, allowing worry-free continuous operation. A

RAM
RAM X 1 Bit error
X1 Bit error ECC

CPU CPU

Abnormal Normal
X Output Output
PLC FCN/FCJ
Figure ECC memory

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A2.2 Characteristic 2 [Ease of Engineering]

Shortened product cycles have accelerated the frequency of remodeling
production facilities. So, demand of innovation of improving engineering
efficiency increases, and it is necessary to steadily remodel production
facilities in a short time with high quality. To solve this problem using PLC
considerable amount of attention and meticulousness is required for PLC
A program modification with actual device test, furthermore consistency of
PLC-side modification and PC-side modification. STARDOM solves these
problems in the following manner.

 Short Lead Times and High Quality through Structuring and

Component Basing
The shortcut to achieving both a short lead time and high quality is to use high-quality
“software parts” with clear specifications. Just as an electric circuit is made by
combining transistors, ICs, LSIs, VLSIs, and other parts with varying degrees of
integration, software parts also require low-level to highly functional parts.
STARDOM’s autonomous controller utilizes the global Standard IEC 61131-3 as the
engineering tool. On a foundation of the low-level parts stipulated in the standard, we
provide a wide range of parts, from PID control and other medium-scale parts to
large-scale parts which are combinations of these. Utilizing these manufacturer parts,
user parts matching the object of control can be manufactured and registered easily.
By creating control logic and moving to a component base (black box with a clear
interface) in this manner, highly maintainable system architecture becomes possible.
In other words, the created system is not dependent on specific individuals, even if
time passes, or if individuals not involved in the creation do the work, the structure
can be easily understood, and modifications and additions can be made. The
structure of this structuring and component basing is shown in the figure below. This
method of creation makes it possible to achieve both a short lead time and high
quality. It is also possible to obtain the benefits of utilization of international standards
when transferring technology to an overseas plant, etc.

Figure Structuring, Component Basing

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 Improved Quality through a Powerful Debugging Function

Particular note for the debugging environment to conduct reliable function verification
is given to target-less debugging using a simulator (running a virtual controller on a
PC) and to wireless debugging. In the case of wireless debugging, virtual wiring of
the controller I/O and a simulated input program are possible, and combination can be
made not only with the target controller, but with a simulator as well. Use as a simple
control target for loopback wire connection, first-order lag, etc., is possible, and
debugging of control logic without an actual I/O can be conducted. These debugging
functions are shown in the figure below.
A

Target-less Debugging

Wireless Debugging
Simulated Input

Figure Debugging Functions

 Online Download Function

After debugging, the program can be updated without stopping devices or machines
by using the online download function. This function makes it possible to use a
simple operation to modify/download control logic while the controller is running. In
this case, it is not necessary to pay attention to redundancy, and modification of
control programs, changes to I/O allocation, etc, can be conducted while maintaining
continuity without terminating control.
In this manner, STARDOM control system makes it possible to rapidly implement
frequent modifications with high quality, for each step of control programming,
debugging, and downloading.

 Compatibility with SCADA HMI Software

Besides ease of controller side engineering, it is important for the results of controller-
side engineering to be aligned firmly with HMI/SCADA-side engineering. With
STARDOM, reliable alignment can be done simply by importing the results of
controller engineering to the SCADA software VDS. This makes it possible to conduct
worry-free modifications.

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A2.3 Characteristic 3 [Openness (Connectivity)]

There has been an increase in requests to integrate different type controllers of
existing equipment, and to link business systems with production systems, to
strengthen cost management and shorten lead times. STARDOM fully utilizes
international standards and de facto standards, and is able to respond flexibly to their
needs.
The openness and connectivity of STARDOM control system is shown in the figure
below.
A
Operation/ Scheduler MES Business
Monitoring System
HMI Client

Oracle
SQLserver

Intranet
OLE DB

OPC Server

Ethernet
Ethernet

FA-M3 Ethernet, RS, etc. Ethernet, RS, etc.

MELSEC

PLC PLC/DCS PLC/DCS

of each company of each company
Autonomous Controller
FA-M3 (Ethernet,RS) YEWMAC (Ethernet) JW (Ethernet,RS)
Field Field Field MELSEC (Ethernet,RS, MEWNET-FP (Ethernet,RS)
CC-Link MELSECNETⅡ KZ-A300/A500 (RS)
Device Device Device MELSECNET/10) TOYOPUC (Ethernet)
FOUNDATION Fieldbus Device, Hart Device, SYSMAC (Ethernet, RS, MICREX-SX (Ethernet)

Existing Modbus Device, CANopen Device,

PROFIBUS-DP Device,
ControllerLink SYSMACLINK,
Compo Bus/D)
Logix5550 (Ethernet)
FL-NET (FL-NET)

Equipment Electrical Power Monitor, SYSMAC (PLC) MICREX-F (RS)

HIDIC-S10 (Ethernet)

Figure The Openness and Connectivity of STARDOM Control System

 HMI/SCADA Side Linking Function

SCADA-side connections include the upper-level side, such as the business system,
and the lower-level side, such as by the equipment controller. On the upper-level
side, connection can be made easily to the business system or MES and other
applications through the OPC server function or OLE DB. Schedulers are also
available, making it possible to construct highly compatible, high-level applications. In
the case of the lower-level side, the OPC client function and drivers for the PLC of
each company are fully enhanced. A discretionary controller connection function is
also available, making it possible to connect unique custom controllers. In this
manner, overall control of every controller is possible.

 Controller-side Linking Function

In the same manner as the autonomous controller side, the communications function
is fully enhanced, and each manufacturer's PLC, field devices, electrical power
monitors, etc., can be connected. By transmitting information of connected devices
over the Internet or by e-mail, remote operation unifying the utility is enabled. In
addition, an OPC server connection function is available to allow combination with a
variety of HMI/SCADA software. Moreover, one characteristic function is the ability to
run Java applications on the controller, allowing information processing, gathering,
and transmission. Using this function allows the creation of a variety of Web-based
applications, including operation/maintenance screens that do not require dedicated
software on PC.

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A2.4 Characteristic 4 [Long-term Stable Operation]

The speed of evolution of COTS products, low cost and system flexibility come into
conflict with long-term stable system. However, long-term stable operation of
STARDOM control system is supported by providing system configuration support,
hardware product maintenance after the start of system operation.

 Engineering Support
Technical support during engineering phase is worry-free by STARDOM technical A
assistance. Yokogawa offices in each region and Yokogawa head quarter cooperate
to provide prompt support to resolve customer's difficulty of engineering work.

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A3. STARDOM Control System Components

STARDOM control system is composed of the following component product
groups which are open and have a high level of independence, based on
network technology. These provide superior function even as standalone
products, but by using them in combination as a system, they can be even
more effective, from the standpoint of reliability and ease of engineering.
A

Ethernet (Intranet)
Web-based HMI VDS

Ethernet (Dual-redundant control network )

Autonomous Controller PLC Autonomous Controller

Figure STARDOM Control System Configuration Diagram

Ethernet (Control network)

Low Power Autonomous Controller

Figure STARDOM Low Power Autonomous Controller FCN-RTU

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 Autonomous Controller FCN/FCJ

FCN/FCJ is an autonomous controller. FCN/FCJ has not only feature of PLC such as
analog or sequence control but also feature of industrial PC such as infromation
processing or transmission.
There are three types of controllers: all-in-one type FCJ (Field Control Junction),
modular type FCN (Field Control Node) which makes redundant configurations
possible, and low power modular type FCN-RTU (Remote Terminal Unit).
A
SEE ALSO
For more information about the Autonomous Controller FCN/FCJ, refer to Part-B, “Autonomous
Controller FCN/FCJ.”

 Web-based HMI/SCADA Software VDS

VDS (Versatile Data Server Software, hereafter “VDS”) is HMI/SCADA (Supervisory
Control and Data Acquisition) software which uses "VDS Viewer" (Java application)
for display, allows access of the site through a network using a general-purpose PC,
and makes it possible to monitor the operation of the site through a graphic screen.

SEE ALSO
For more information about the VDS, refer to Part-E, “VDS (Versatile Data Server Software).”

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 RS-232-C Communication Cable

The pin assignments of the CPU module is shown below.

● Pin Assignments of FCJ’s Serial Ports

Table Connector Pin Assignment (D-sub 9-pin, male) Figure Pin Position (Front View)
Pin No Signal Function
name
1 CD Data channel receiving carrier detection
2 RD Receiving data 5
9
3 SD Transmission data 4
8
4 ER Data terminal ready 3
5 SG Signal ground
7
2
6 DR Data set ready 6
1
7 RS Transmission request
8 CS Transmission enabled
9 - Not used

C
IMPORTANT
FCJ’s serial ports are D-SUB 9 pins (male). Connectors are fastened using inch
screw threads (No.4-40 UNC).

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Revision Information
Document name : STARDOM Technical Guide
Document No. : TI 34P02A03-01E

Dec. 2007/First Edition

• New publication
Sep. 2008/Second Edition
• Support for VDS/ASTMAC R6.01
• Supoprt for FCN/FCJ R2.01
• Error corrections
Oct. 2009/Third Edition
• Supoprt for FCN-RTU
• Supoprt for NFBU050 for FCN use
• Support for VDS/ASTMAC R6.20
• Supoprt for FCN/FCJ R2.20
• Error corrections
Aug. 2010/Fourth Edition
• Support for VDS/ASTMAC R6.30
• Support MELSEC L Series Ethernet
• Supoprt for FCN/FCJ R3.01
• Abolish Control Loop Definition Funtion
• Error corrections
Jun. 2011/Fifth Edition
• Support for VDS/ASTMAC R7.01
• Supoprt for FCN/FCJ R3.10
• Supoprt for Windows 7
• Addition of VDS Viewer
• Addition of Communication Cables
• Error corrections
Aug. 2012/Sixth Edition
• Support for VDS/ASTMAC R7.10
• Supoprt for FCN/FCJ R3.20
• Addition of communication modules (NFLC121, NFLP121)
• Error corrections
Jun. 2013/Seventh Edition
• Support for VDS R7.20
• Supoprt for FCN/FCJ R3.30
• Error corrections

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July 2014/Eighth Edition
• Support for VDS R7.30
• Supoprt for FCN/FCJ R3.40
• Support for Windows 7 SP1 (64-bit)
• Windows XP was deleted.
• Update of compliant standards.

 For Questions and More Information

If you have any questions, you can send an E-mail to the following address.
E-mail:stardom_info@cs.jp.yokogawa.com
 Written by: Yokogawa Electric Corporation
 Published by: Yokogawa Electric Corporation
2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, Japan

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