Description

Application Scenarios

At a petrochemical complex in South Korea,the primary FCS CPU in a critical reactor control loop failed during a turnaround startup,causing a temporary loss of temperature control.The plant’s CENTUM CS 3000 system used an older VC401-10 module nearing end-of-life.Engineers replaced it with a refurbished and tested YOKOGAWA VC401-10 unit from a certified supplier.The new module was pre-loaded with the control strategy and synchronized with the redundant pair within minutes.After reintegration,the FCS resumed full control with no data loss.The VC401-10’s built-in watchdog timer and V-Net redundancy ensured stable communication with the HIS and field I/O.Over the next six months,the system operated without a single control interruption—demonstrating the importance of reliable CPU modules in preventing costly process deviations.

Parameter

Main Parameters Value/Description

Product Model YOKOGAWA VC401-10

Manufacturer Yokogawa Electric Corporation

Product Category FCS CPU Module

Compatible System CENTUM CS 3000,CENTUM CS 1000

Processor 32-bit RISC CPU

Program Memory 1 MB(supports complex control strategies)

Control Execution Time~0.1 ms per 1,000 instructions(typical)

I/O Capacity Up to 640 I/O tags per FCS

Network Interface Dual V-Net ports(redundant fiber or coaxial)

Redundancy Support Yes–Synchronous hot-standby with automatic failover(<100ms)

Installation Method Front-loadable into AFV10S or AFV20S FCS chassis

Power Supply 24VDC from backplane(redundant power units)

Operating Temperature-20°C to+60°C

Environmental Rating Humidity:20–80%RH(non-condensing);Pollution Degree 2

Certifications IEC 61508 SIL 2,CE,UL,CSA

Diagnostics LED indicators(POWER,RUN,RDY,ERR,COM),V-Net status,alarm logging in HIS

Technical Principles and Innovative Values

Innovation Point 1:The YOKOGAWA VC401-10 delivers deterministic real-time control with predictable scan times,ensuring precise regulation of fast-critical loops such as reactor temperature,pressure,and flow control.

Innovation Point 2:It supports dual-redundant V-Net communication,providing a fault-tolerant network backbone between FCS,HIS,and other system nodes—critical for maintaining control during network disturbances.

Innovation Point 3:Designed for hot-standby redundancy,the VC401-10 allows one CPU to take over instantly if the primary fails,ensuring uninterrupted process operation and data integrity.

Innovation Point 4:The module is fully compatible with Yokogawa’s R3.07 and earlier control software,enabling seamless integration with existing control strategies,HMI graphics,and historical data systems.

Application Cases and Industry Value

A pharmaceutical manufacturing facility in Ireland upgraded its aging batch control system,which relied on CENTUM CS 3000 with original VC401-10 CPUs.To meet FDA 21 CFR Part 11 compliance and improve system reliability,the plant replaced all FCS CPUs with remanufactured YOKOGAWA VC401-10 modules tested to OEM specifications.The new CPUs featured updated firmware and enhanced diagnostic capabilities.The VC401-10’s deterministic performance reduced batch cycle time variation by 18%,improving product consistency.During a power fluctuation event,the redundant CPU pair switched over seamlessly,preventing a batch abort that would have cost over$250,000 in lost product.The project extended the DCS lifecycle by 10+years,proving the VC401-10’s value in protecting critical process investments.

Installation,Maintenance,and Full-Cycle Support

The YOKOGAWA VC401-10 installs into the FCS chassis(AFV10S/AFV20S)by sliding into the designated CPU slot.It connects to the backplane for power and internal communication with I/O modules.Dual V-Net cables link to the control network for redundancy.Configuration is performed via the Engineering Station using Instrument Function Builder(INTEWS)software.The control strategy is downloaded to both primary and standby CPUs in redundant setups.

Routine maintenance includes:

Visual inspection of LED status(POWER,RUN,RDY,ERR)

Monitoring V-Net communication health

Periodic backup of control logic and system configuration

The VC401-10 is hot-swappable—faulty units can be replaced without shutting down the FCS.Replacement typically takes under 10 minutes.

We provide complete lifecycle support for the YOKOGAWA VC401-10,including:

Compatibility verification and firmware validation

Pre-configured and tested replacement modules

On-site commissioning and system health checks

Obsolescence management and long-term supply planning

Whether you’re maintaining legacy CS 3000 systems or preparing for migration to CENTUM VP,our experts ensure reliable,certified components for your process control infrastructure.Contact us today for availability and technical assistance.

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