Description
Honeywell TC-RPCXX1
Technical Specifications
- Processor: 32-bit industrial control CPU
- User program memory: 64 KB
- Data memory: 32 KB
- Redundancy architecture: Dual-card hot standby synchronization
- Switchover response time: ≤5 ms, no output disturbance
- Supply power: 5 V DC from backplane
- Operating temperature: 0 °C to +60 °C
- Logic scan cycle: 1 ms per 1 KB program
Functional Features Dual-card real-time hot standby synchronization, primary and standby state, parameters and variables fully mirrored. Bumpless switchover, when primary card fails, standby card takes over immediately with output value fluctuation ≤0.1% full scale. Independent hardware watchdog timer, automatic fault switchover on program runaway. Front panel LEDs indicate primary mode, standby mode, sync link and fault status. Programs and parameters are stored in non-volatile memory, no re-download required after power restart. Supports online program modification; logic download does not interrupt running operation.
Application Scenarios Redundant control for critical petrochemical units High-reliability control for boiler drum level and main steam pressure in power plants Long-distance pipeline critical interlock loop control Legacy C200 system single-CPU redundant upgrade retrofits
Performance Parameters
- PID regulation accuracy: 0.05% full scale
- Sync data refresh rate: 0.5 ms
- Switchover output deviation: ≤0.1% full scale
- Data retention time: 10 years without power
- Mean time between failures: 1,000,000 hours
Material Composition FR4 high-speed PCB substrate 32-bit industrial processor chip Flash and RAM memory chips Synchronization logic FPGA Optocoupler isolation devices Gold-plated backplane edge fingers Metal shielded front panel
Structural Features Standard Eurocard dimensions, inserts into the controller dedicated processor slot. Front panel LEDs separately indicate primary mode, standby mode and sync fault. Internal equal-length differential sync traces ensure consistent signal delay between primary and standby cards. Isolation barrier separates control circuit and backplane communication circuit. Anti-keying notch prevents insertion into non-processor slots.
Working Principle After system power-up, the two processor cards complete primary/standby role election. One card enters primary control state running user logic, the other enters hot standby state. The primary processor collects I/O data, executes control logic, and issues output commands. The hot standby card receives all variables, parameters and intermediate state data in real time via the high-speed sync link, running identical logic without driving field outputs. The fault monitor circuit continuously checks primary processor heartbeat signals; when primary failure is confirmed, the hot standby card immediately takes over control output, with no process fluctuation.
Installation Requirements Install two processor cards in corresponding primary/standby slots. Connect sync flat cables between cards, lock all clips. Download identical firmware and user program to both cards. Confirm sync status LED shows normal lock after power-up. Trigger a forced primary fault during commissioning, verify bumpless switchover operation.
Usage Notes The two cards must run identical firmware revision; mismatched versions prevent sync handshake. Loose sync cable triggers unplanned switchover and process fluctuation. Never disconnect sync cables during operation; this disables redundancy function. Perform periodic forced switchover tests to confirm standby processor is ready to take over.
