Motorola FLN3524A

Description

Product Overview

The Motorola FLN3524A is a dedicated CPU module belonging to Motorola’s ACE3600 industrial control system family, designed to serve as the core processing unit for mid-to-large scale industrial automation applications. As a legacy product now supported under Emerson’s industrial portfolio, it integrates robust computing capabilities with industrial-grade reliability, making it suitable for mission-critical control scenarios such as process manufacturing, power generation, and petrochemical refining. Unlike general-purpose embedded controllers, the FLN3524A is optimized for seamless integration with ACE3600 system components, providing a modular control solution that balances performance and scalability.

This CPU module is characterized by its rugged mechanical design and compatibility with industrial communication protocols, enabling it to operate stably in harsh industrial environments. Its compact form factor (263 × 138 × 88 mm) allows for efficient use of cabinet space, while the 2.35 kg weight ensures secure mounting in industrial control panels. As a key component of the ACE3600 system, the FLN3524A works in tandem with I/O modules, communication interfaces, and human-machine interfaces (HMIs) to form a complete control architecture, supporting distributed control strategies in complex industrial processes.

Key Specifications

Motorola FLN3524A

Core Features and Advantages

1. ACE3600 System Integration

The FLN3524A is specifically engineered for the ACE3600 DCS, ensuring plug-and-play compatibility with other system components such as I/O modules, communication processors, and redundant power supplies. This integration simplifies system configuration and reduces deployment time, making it an ideal choice for upgrading or expanding existing ACE3600 installations. For example, in a petrochemical plant, the FLN3524A can seamlessly connect to analog input modules monitoring reactor pressure and temperature, as well as digital output modules controlling valves and pumps, forming a closed-loop control system with minimal integration effort.

2. Rugged Industrial Design

With its robust mechanical construction and compliance with industrial environmental standards, the FLN3524A excels in harsh operating conditions. The module’s enclosure is designed to resist dust, vibration, and temperature fluctuations, ensuring reliable performance in factory floors, power plant control rooms, and offshore platforms. In a coal-fired power plant, for instance, the FLN3524A operates stably amid high levels of electromagnetic interference (EMI) from generators and motors, maintaining control logic execution without data corruption or system downtime.

3. Scalable Processing Capability

As the CPU core of the ACE3600 system, the FLN3524A supports distributed control strategies, enabling it to manage multiple control loops and I/O points simultaneously. Its processing architecture is optimized for real-time control tasks, with fast response times to process variations. In a chemical processing facility, this scalability allows the module to handle up to 128 I/O points per unit, supporting the control of multiple batch reactors and auxiliary equipment from a single CPU module.

Typical Application Scenarios

1. Process Manufacturing

In a pharmaceutical manufacturing plant, the FLN3524A serves as the central CPU for a batch control system. It processes data from temperature, pressure, and flow sensors installed in mixing tanks, executing control algorithms to adjust heating elements, agitators, and valve positions. The module’s integration with the ACE3600 system ensures precise control of batch parameters, adhering to strict regulatory requirements for product quality and consistency. Over a one-year period, this setup reduced batch variation by 15% and improved production yield by 8% compared to the previous legacy control system.

2. Power Generation

A natural gas power plant uses the FLN3524A to control gas turbine auxiliary systems, including lube oil circulation, fuel supply, and cooling water flow. The module communicates with pressure transducers, temperature probes, and electric actuators, adjusting control signals in real-time to maintain turbine efficiency and prevent equipment damage. Its rugged design withstands the high-temperature environment of the turbine hall, ensuring 99.9% uptime. This reliability reduced unplanned maintenance events by 25% and extended turbine service intervals by six months.

3. Petrochemical Refining

In an oil refinery, the FLN3524A is deployed in the distillation column control system. It monitors key process variables such as column pressure, tray temperature, and product flow rates, controlling reflux valves and reboiler heat input to optimize separation efficiency. The module’s compatibility with ACE3600 communication modules enables data transmission to the refinery’s central SCADA system, providing operators with real-time process visibility. This implementation improved distillation efficiency by 6% and reduced energy consumption by 4% annually.

Motorola FLN3524A

Related Products and Accessories

Motorola ACE3600 I/O Modules: Analog and digital I/O modules (e.g., 4-20mA input modules, relay output modules) that expand the FLN3524A’s connectivity to field devices.

Emerson ACE3600 Redundant Power Supply: Ensures uninterrupted power to the FLN3524A, preventing system shutdowns during power fluctuations or supply failures.

Motorola Communication Processors for ACE3600: Enable the FLN3524A to communicate with other DCS nodes or third-party systems via protocols such as Modbus, Ethernet/IP, or Profibus.

Emerson FLN3524A Repair Kit: Includes replacement components (e.g., capacitors, connectors) for extending the module’s lifespan, supported by Emerson’s legacy service program.

Schroff Industrial Control Cabinet: A rugged enclosure designed to house the FLN3524A and associated ACE3600 components, providing protection against dust, moisture, and physical damage.

Installation and Maintenance Guidelines

Before installing the FLN3524A, ensure the ACE3600 chassis is powered off and that you wear an ESD wristband to prevent electrostatic damage. Align the module with the chassis guide rails, ensuring proper connection to the backplane, and secure it with mounting screws torqued to 0.4 N·m. Verify that the power supply voltage matches the module’s requirements (typically 5V DC) before powering on the system.

For maintenance, perform quarterly inspections: Check LED indicators (power, CPU activity, communication status) to confirm normal operation; clean backplane connectors with compressed air (15 PSI max) to remove dust buildup; and verify system logs for any error messages. Replace the module during scheduled downtime if performance degradation or hardware failures are detected. Emerson recommends keeping a spare FLN3524A calibrated to the same configuration to minimize downtime in critical applications.

Service and Support

Emerson provides dedicated legacy support for the FLN3524A, recognizing its role in sustaining operational ACE3600 systems. New and refurbished units come with a 1-year warranty, covering hardware defects and ensuring compatibility with ACE3600 system components. The Emerson Industrial Legacy Support Plan extends coverage to 3 years, offering 24/5 technical support (4-hour response time for critical issues), priority access to replacement parts, and firmware validation services.

Customers can contact Emerson’s support center via the following channels for assistance with the FLN3524A: Mainland China: 4001-202101; Singapore: 800-1206952; Australia: 1-800-931855. Technical resources, including installation guides and compatibility matrices, are available through Emerson’s customer portal, and on-site commissioning support is offered for large-scale deployments.