Foxboro™ DCS

Field Control Processor 270 (FCP270)

User’s Guide

*B0700AR*,*N*

B0700AR Rev N
July 2020

https://www.se.com
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Contents
Figures................................................................................................................................... vii

Tables..................................................................................................................................... ix

Safety Information ................................................................................................................. xi

Preface................................................................................................................................. xiii
Revision Information ............................................................................................................. xiii
Schneider Electric Products Mentioned in this Document ..................................................... xiii
Related Documents ................................................................................................................ xiv
Global Customer Support ....................................................................................................... xv
We Welcome Your Comments ................................................................................................ xv

1. Introduction ...................................................................................................................... 1
Overview ................................................................................................................................... 1
Features ..................................................................................................................................... 2
Fault-Tolerance ......................................................................................................................... 4
Traditional Redundant Systems ............................................................................................ 4
FCP270 Fault-tolerant Operation ........................................................................................ 4
Self-Hosting and Non-Self-Hosting Modes ............................................................................... 4
Self-Hosting Feature, Available with 200 Series FBMs Only ................................................ 5
On-Line Image Update ............................................................................................................. 6
FCP270 Network Configuration .............................................................................................. 6
Network Path Switching ...................................................................................................... 6
Splitter/Combiner ................................................................................................................ 6
Fieldbus Expansion Module 100 (FEM100) ........................................................................ 9
I/O Communications ................................................................................................................ 9
Dual Baud Functionality .................................................................................................... 10
Communication to 200 Series Fieldbus Modules ............................................................... 12
Communication to Y-Module (100 Series) Fieldbus Modules ............................................ 15
Communication to Migration Modules .............................................................................. 15
Time Synchronization ............................................................................................................. 15
Overview ............................................................................................................................ 15
Internal Source Time Synchronization .......................................................................... 16
External Source Time Synchronization .......................................................................... 16
FCP270 Sizing Constraints ..................................................................................................... 16
FCP270 Supported Block Processing Cycles ...................................................................... 16

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B0700AR – Rev N Contents

2. Installing the Field Control Processor 270 ...................................................................... 19

System Definition ................................................................................................................... 19
Installing a Single or Primary FCP270 Module ....................................................................... 20
Enabling the FCP270 Self-Hosting Option ........................................................................ 24
Initializing the FCP270 with Self-Hosting Enabled ....................................................... 24
Disabling Self-Hosting .................................................................................................. 24
Verifying Self-Hosting Information Using SMDH ........................................................ 25
Verifying Self-Hosting Information Using Station Block Display .................................. 25
Auto-Checkpoint While Enabling/Disabling Self-Hosting ............................................ 26
Installing a Shadow FCP270 Module ...................................................................................... 27
Cabling a Single (Non-Fault-Tolerant) FCP270 Module ........................................................ 29
Cabling a Fault-Tolerant FCP270 Module Pair ...................................................................... 30
Boot-Up Sequence .................................................................................................................. 34
Case 1 – Rebooting a Commissioned FCP270 ................................................................... 35
Case 2 – Connecting an FCP270 with the Same Letterbug ................................................ 35
Case 3 – Connecting an FCP270 with a New Letterbug .................................................... 36
Case 4 – Connecting a Shadow Module with Same Software Image ................................... 36
Case 5 – Connecting a Shadow Module with Different Software Image ............................. 38
Fault Tolerance Behavior in Self-Hosting FCP270 .................................................................. 39
Cabling Y-Module FBMs to an FCP270 Baseplate ................................................................. 40
Remote Fieldbus Extension, Cable Connections ................................................................ 41
Decommissioning an FCP270 Module ................................................................................... 47

3. Configuration Information.............................................................................................. 49
System Definition ................................................................................................................... 49
System Definition Procedure .............................................................................................. 50
System Configuration ............................................................................................................. 50
Available Foxboro DCS Control Blocks ............................................................................. 51
System Configuration with Dual Baud Functionality ......................................................... 51

4. System Management ....................................................................................................... 53

Operating Status ..................................................................................................................... 53
System Management Displays for the FCP270 ........................................................................ 53
Equipment Information Display for FCP270 ..................................................................... 54
Configuration Information Display for FCP270 ................................................................ 58
Equipment Change Display for FCP270 ............................................................................ 59
Reboot Station Procedure .............................................................................................. 62
Image Update Procedure for a Non-Fault-Tolerant FCP270 ......................................... 63
Image Update Procedure for a Fault-Tolerant FCP270 ................................................. 63
Messages Following Checkpoint Operation in Self-Hosting FCP270 ............................ 64
Checkpoint Invalidation in Self-Hosting FCP270 ......................................................... 67
System Management Displays – Primary ECB (FBM0) .......................................................... 69
Equipment Information Display for Primary ECB (FBM0) ............................................... 69

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Contents B0700AR – Rev N

Equipment Change Display for Primary ECB (FBM0) ...................................................... 73

Overview of Fieldbus Switching Mode .......................................................................... 75
Using the Fieldbus Switching Options .......................................................................... 75
Overview of the General Download ............................................................................... 76
Downloading all FBM Images ....................................................................................... 76
On-Line Diagnostics (PIO) Display for Primary ECB (FBM0) .......................................... 76

5. Troubleshooting.............................................................................................................. 79
LED Indicators, Reset Button, and Infrared Ports ................................................................... 79
Operational Status LED Indicators .................................................................................... 81
FCP270 Troubleshooting ....................................................................................................... 81
Using the Operational Status LEDs .................................................................................... 82
Red off, Green off .......................................................................................................... 82
Red on, Green off .......................................................................................................... 83
Red on, Green on .......................................................................................................... 84
Cycling Red, Red/Green ................................................................................................ 84
Red off, Green on .......................................................................................................... 84
Using the Ethernet Tx and Rx/Link Status LEDs ............................................................... 84
Using the Fieldbus Tx and RX Status LEDs ....................................................................... 85
Fault-Tolerant FCP270 Troubleshooting Addenda ............................................................ 85
Replacing a Non-Operational Module ........................................................................... 86
Available Memory Detected Error Messages ....................................................................... 86
Memory Dumps and Last Gasp Messages ............................................................................... 86
Last Gasp Messages ............................................................................................................ 87
Memory Dumps ................................................................................................................. 87
Diagnostics ............................................................................................................................. 89
Start-Up Diagnostics .......................................................................................................... 89
Detected Error Recovery Local Diagnostics ........................................................................ 89
Detected Error Recovery Cooperative Diagnostics .............................................................. 89

Appendix A. Upgrade Diagrams .......................................................................................... 91

Appendix B. FEM100 and FBI100 Connection Diagrams ................................................ 101

Glossary.............................................................................................................................. 105

Index .................................................................................................................................. 109

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B0700AR – Rev N Contents

vi
Figures
1-1. Typical FCP270 Network Configuration (Simplified) .................................................. 8
1-2. FBI200 Connections to 200 Series and 100 Series FBMs on Mixed 2 Mbps
and 268 Kbps HDLC Module Fieldbus (Conceptual) ................................................. 11
1-3. Example Network with FCP270 with Dual Baud Functionality (Conceptual) ............ 12
1-4. Fieldbus Cable Length Restrictions ............................................................................. 13
1-5. Fieldbus Cable Length Restrictions w/FCM2Fs .......................................................... 13
1-6. Expanded Fieldbus Cable Length Restrictions ............................................................. 14
1-7. Expanded Fieldbus Cable Length Restrictions w/FCM2Fs .......................................... 14
2-1. FCP270 Module Installation (Typical) ....................................................................... 20
2-2. Initializing a Self-Hosting Controller .......................................................................... 24
2-3. Self-Hosting Status via Station Block Display ............................................................. 26
2-4. Cabling the FCP270 Fault-tolerant Controllers (Two-Position Baseplate Example) .... 31
2-5. Cabling the FCP270 Fault-tolerant Controllers (Four-Position Baseplate Example) ... 32
2-6. Cabling Y-Module FBMs to an FCP270 Baseplate (Without FBI200s/FBI100s) ........ 42
2-7. TCA Cable Connection to 268 Kbps Fieldbus Splitter/Terminator
(Without FBI200s/FBI100s) ....................................................................................... 43
2-8. TCA Termination Block Assembly Mounting ............................................................. 43
2-9. TCA Termination Block Removal .............................................................................. 44
2-10. Remote Redundant Fieldbus Cabling (FCP270 End) ................................................. 45
2-11. Example of Extending Fieldbus in Two Directions from FCP270 ............................... 46
3-1. Typical Control Scheme Using an FCP270 and 200 Series FBMs ............................... 51
5-1. FCP270 LED Indicators, Reset Button, and Infrared Port .......................................... 80
A-1. Equipment Replacement Order for CP60-to-FCP270 Conversions ............................ 92
A-2. Converting CP10/30/40 with Local I/O to FCP270s .................................................. 93
A-3. Converting CP60 with DCM10E to FCP270 ............................................................. 94
A-4. Converting CP60 with DCM10Ef to FCP270 ............................................................ 95
A-5. Converting CP60 with DCM10Ef with Fiber Optic Hub to FCP270 ........................ 96
A-6. Converting CP60 with FBI10E and 100 Series FBMs to FCP270s ............................. 97
A-7. Converting CP60 with 200 Series DIN Rail Mounted Equipment to FCP270 ........... 98
A-8. Converting Micro-I/A Station to FCP270 .................................................................. 99
A-9. Converting AW51/AW70 to FCP270s ..................................................................... 100
B-1. Overview for FCP270-to-FEM100 Cabling .............................................................. 102
B-2. Overview for Expanded Fieldbus Cabling (FCP270 to Four FEM100s) .................... 103
B-3. Overview for Dual Baud Cabling (FCP270 to FEM100 and FBI100) ...................... 104

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B0700AR – Rev N Figures

viii
Tables
2-1. Cables for Connecting the FCP270 or Splitter/Combiners to the Ethernet
Switches ...................................................................................................................... 29
2-2. Cables for Connecting the Splitter/Combiners to the FCP270 .................................... 34
4-1. Equipment Information Display Fields for FCP270 .................................................... 55
4-2. Configuration Information Display Fields for FCP270 ............................................... 59
4-3. Equipment Change Display Fields for FCP270 ........................................................... 61
4-4. SMON Log Messages Following Checkpoint Operation ............................................. 65
4-5. Equipment Information Display Fields for Primary ECB (FBM0) .............................. 71
4-6. Equipment Change Display Fields for Primary ECB (FBM0) ..................................... 74
4-7. Equipment Change Display Fields for Primary ECB (FBM0) ..................................... 77
5-1. FCP270 LED Indicators, Reset Button, and Infrared Communication Ports .............. 80
5-2. FCP270 Operational Status LEDs .............................................................................. 81

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B0700AR – Rev N Tables

x
Safety Information
Important Information
Read these instructions carefully and look at the equipment to
become familiar with the device before trying to install, operate, ser-
vice, or maintain it. The following special messages may appear
throughout this manual or on the equipment to warn of potential
hazards or to call attention to information that clarifies or simplifies
a procedure.

The addition of either symbol to a "Danger" or

"Warning" safety label indicates that an electrical
hazard exists which will result in personal injury if
the instructions are not followed.

This is the safety alert symbol. It is used to alert you to

potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.

DANGER
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.

CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.

NOTICE
NOTICE is used to address practices not related to physical injury.
Please Note
Electrical equipment should be installed, operated, serviced, and main-
tained only by qualified personnel. No responsibility is assumed by
Schneider Electric for any consequences arising out of the use of this
material.

A qualified person is one who has skills and knowledge related to the con-
struction, installation, and operation of electrical equipment and has
received safety training to recognize and avoid the hazards involved.
Preface
The Field Control Processor 270 (FCP270) is an optionally fault-tolerant station that performs
regulatory, logic, timing, and sequential control together with connected Fieldbus Modules
(FBMs) and other process interface devices. It also performs data acquisition (via the FBMs
and/or other devices) and alarm detection and notification.
This document describes how to configure and install the Field Control Processor 270 (FCP270)
in a Foxboro DCS™ Process Automation System with the Foxboro DCS Control Network. It
also describes how the FCP270 functions in the Foxboro DCS Control Network. Finally, it
describes how to troubleshoot system problems.
This book is designed for the use of process control engineers and operators, instrument and
maintenance engineers, and other qualified and authorized personnel involved in installing,
configuring and maintaining the FCP270 for operation in the Foxboro DCS Control Network.
Prior to using this book, you should be generally familiar with the Foxboro DCS Process
Automation System, and with Standard and Compact 200 Series Subsystem User’s Guide
(B0400FA). Detailed information relating to the various Foxboro DCS software and hardware
elements is found in the reference documents listed below.

Revision Information
For this revision of the document (B0700AR, Rev. N), the following changes were made:
Global
♦ Updated the document to implement new corporate and product branding.
♦ Rewrote all safety messages.
♦ Updated terminology to meet safety standards.
Chapter 2 “Installing the Field Control Processor 270”
♦ Added sentence to the end of “Auto-Checkpoint While Enabling/Disabling Self-
Hosting” on page 26.

Schneider Electric Products Mentioned in this

Document

EcoStruxure™ Foxboro™ DCS

EcoStruxure™ Foxboro™ DCS Control Core Services
EcoStruxure™ Foxboro™ DCS Control Network
EcoStruxure™ Foxboro™ DCS Control Network Interface (CNI)
EcoStruxure™ Foxboro™ DCS Control Software
EcoStruxure™ Foxboro™ DCS Control Editors
EcoStruxure™ Foxboro™ DCS Control HMI

xiii
B0700AR – Rev N Preface

EcoStruxure™ Foxboro™ DCS FCP270

EcoStruxure™ Foxboro™ DCS Fieldbus Modules
EcoStruxure™ Foxboro™ DCS FoxView/ FoxDraw
EcoStruxure™ Foxboro™ DCS System Manager
EcoStruxure™ Foxboro™ DCS System Definition

Related Documents
These documents provide additional and related information.
For information about defining control blocks and compounds, see:
♦ Integrated Control Block Descriptions (B0193AX)
♦ Integrated Control Software Concepts for CP270, FCP280, and FDC280 (B0700AG)
For information about configuring and managing the FCP270, see:
♦ Control Processor 270 (CP270) On-Line Image Update (B0700BY)
♦ System Definition: A Step-by-Step Procedure (B0193WQ)
♦ Letterbug Configurator User’s Guide (B0700AY)
♦ Integrated Control Configurator (B0193AV)
♦ I/A Series Configuration Component (IACC) User’s Guide (B0700FE)
♦ System Manager (B0750AP)
♦ Process Operations and Displays (B0700BN)
♦ System Management Displays (B0193JC)
♦ Field Control Processor 270 (FCP270) Sizing Guidelines and Excel Workbook
(B0700AV).
For information about associated 200 Series Fieldbus Modules, the Fieldbus Expansion Module
100, the FBI200 and the FBI100, see:
♦ Standard and Compact 200 Series Subsystem User’s Guide (B0400FA).
For information about the 200 Series Fieldbus Modules used to upgrade a 100 Series system and
the FBI200A, see:
♦ 100 Series Fieldbus Module Upgrade User's Guide (B0700BQ).
For information about Y-module Fieldbus Modules, see:
♦ I/A Series System Equipment Installation (B0193AC).
For information about system power and earthing (grounding), see:
♦ Power, Earthing (Grounding), EMC and CE Compliance (B0700AU)
For information about supported migration products, see:
♦ SPECTRUM™ Migration Integrator User's Guide (B0193RC)
♦ SPEC 200™ Control Integrator User's Guide (B0193RD)
♦ SPEC 200 MICRO™ Control Integrator User's Guide (B0193RR)
♦ SPEC 200 CCM Control Integrator User's Guide (B0193VU)
♦ DCS Fieldbus Modules for Westinghouse® WDPF Systems User's Guide (B0400BA).

xiv
Preface B0700AR – Rev N

♦ DCS Fieldbus Modules for APACS+™ Automation Systems User’s Guide (B0700BK)
♦ DCS Fieldbus Modules for Honeywell® TDC 2000 Systems User’s Guide (B0193VL)
♦ DCS Fieldbus Modules for Honeywell TDC 3000 Systems User’s Guide (B0193YW)
♦ DCS Fieldbus Modules for Bailey® NET90 and INFI90® Systems User’s Guide
(B0193XG)
♦ DCS Fieldbus Modules for Fisher PROVOX® Series 10 Systems User’s Guide
(B0193WV)
♦ DCS Fieldbus Modules for Fisher PROVOX Series 20 Systems User’s Guide (B0193YV)
♦ DCS Fieldbus Modules for Fisher PROVOX Controller Series Systems User’s Guide
(B0400AR)
For information about the Foxboro DCS Control Network, see:
♦ The Foxboro DCS Control Network Architecture Guide (B0700AZ)
The latest revisions of each document are also available through our Global Client Support at
https://pasupport.schneider-electric.com.

Global Customer Support

For support, visit https://pasupport.schneider-electric.com (registration required).

We Welcome Your Comments

We want to know about any corrections, clarifications, or further information you would find
useful. Send us an email at: [email protected].

xv
B0700AR – Rev N Preface

xvi
1. Introduction

Overview
The FCP270 supports process control via the standard 2 Mbps HDLC fieldbus for the following
products:
♦ All DIN rail mounted 200 Series FBMs (FBM201, FBM202, and so forth). The
FCP270 supports up to 32 modules itself, and supports up to 128 modules when
used with a Fieldbus Expansion Module 100 (FEM100); based on the loading of
FCP270. See Field Control Processor 270 (FCP270) Sizing Guidelines and Excel
Workbook (B0700AV).
♦ Field Device Systems Integrator (FDSI) modules (FBM230/231/232/233)
♦ DCS Fieldbus Modules for APACS+™ Automation Systems
♦ DCS Fieldbus Modules for Westinghouse® WPDF Systems
The FCP270 also supports process control via the optional 268 Kbps HDLC fieldbus for the
following products:
♦ All Y-module FBMs, also known as 100 Series FBMs (FBM01, FBM02, and so forth)
– up to 64 modules, via an extended fieldbus
♦ Fieldbus Cluster I/O via FBP10 fieldbus processor module
♦ Foxboro® Hydrostatic Interface Unit (HIU)
♦ Foxboro Mass Flowmeter
♦ Foxboro Panel Display Stations
♦ SPECTRUM™ Migration Integrators
♦ SPEC 200™ Control Integrators
♦ SPEC 200 MICRO™ Control Integrators
♦ SPEC 200 CCM Control Integrators
♦ DCS Fieldbus Modules for Honeywell® TDC 2000 and TDC 300 Systems
♦ DCS Fieldbus Modules for Bailey® Net90 and Infi90 Systems
♦ DCS Fieldbus Modules for Fisher’s PROVOX® Series 10, Series 20, and Controller
Series Systems.

NOTE
The FCP270 can support the 2 Mbps and/or the 268 Kbps HDLC fieldbus, while
the FBI100 is used on the 268 Kbps HDLC fieldbus between the FCP270 and the
100 Series FBMs or competitive migration modules. However, the FBI200 provides
similar functionality as the FBI100 and supports both the 2 Mbps and the 268
Kbps HDLC fieldbus at the same time. For the maximum number of devices sup-
ported by each fieldbus, see the device specific Product Specification Sheets.

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B0700AR – Rev N 1. Introduction

NOTE
Before loading a SaveAll control database from a CP60 or previous control proces-
sor onto an FCP270, make sure all the ECBs are supported by the FCP270. For
example, ECB110 (for FCM10s) is not supported by the FCP270.
If you do not do this, ALL the ECBs are blocked (invalid and valid) from being
loaded into the new FCP270.

Features
The FCP270 provides the following new features and improvements.
♦ A direct 100 Mbps Ethernet fiber connection to the Foxboro DCS Control Network
for high speed data communication that is immune to electromagnetic interference
over the distance of the fiber cable.
♦ A fault-tolerant option that delivers improved availability using unique, dual
controller comparison on all outgoing messages.
♦ Optional self-hosting mode allows the FCP270 to start up and run, executing its
configured control scheme using the checkpoint file stored in flash memory. This
allows the FCP270 to boot itself with a valid control database even if its host
workstation is not present.
♦ On-line image update replaces the executable image (operating system) of a running,
fault-tolerant FCP270 controller with a newer image without having to shut down
the equipment being controlled by the FCP270.
♦ Hardened, field-mounted control (100 Mbps Ethernet fiber controller, 2 Mbps
fieldbus, 200 Series DIN rail mounted FBMs, Termination Assemblies, and
FPS400-24 power supply). The new configuration eradicates the need for a rack room
(you only need a control room and a field enclosure).
♦ Supports up to 128 200 Series DIN rail mounted FBMs, or equivalent modules
(depending on the sizing guidelines), when connected to an optional Fieldbus
Expansion Module 100 (FEM100) or, depending on the configuration, an FBI200A
in a conversion mounting structure (described in 100 Series Fieldbus Module Upgrade
User's Guide (B0700BQ)).
♦ Dual baud functionality supports communication with both 200 Series FBMs and
100 Series FBMs and migration products. When installed as specified, the FBI200s or
FBI100s filter the 2 Mbps communications from the FCP270 to maintain the
100 Series FBMs and similar Migration modules only receive the 268 Kbps signals
designed for them, and extend the 268 kbps Module Fieldbus up to 1830 m
(6000 ft).
♦ Connection to Ethernet or serial devices via FDSIs which allows for new device
interfaces. The FDSIs include FBM230, FBM231, FBM232, and FBM233.
♦ Optional global positioning system allows external time synchronization.
♦ The 200 Series FBMs may optionally time stamp concurrent SOE data with up to a
three millisecond time difference1, depending upon your configuration. For more
information, see the section on “Timestamp Accuracy and Precision of SOE Data” in
Time Synchronization User's Guide (B0700AQ).

2
1. Introduction B0700AR – Rev N

♦ Optional Transient Data Recorder (TDR) allows 10 ms sampling of analog data for
later analysis of events using Transient Data Analyzer (TDA). The 200 Series FBMs
may optionally time stamp concurrent TDR data with up to a three millisecond time
difference1. For more information, see the section on “Timestamp Accuracy and
Precision of SOE Data” in Time Synchronization User's Guide (B0700AQ).

NOTICE
POTENTIAL DATA LOSS

ac signals coming into SOE points cannot be synchronized to

1 millisecond in the same manner as dc based points can. The ac
SOE points will have a delay of ~8-20 milliseconds due to the 50 or 60
Hz ac wave form. If 1 millisecond time synchronization is required,
avoid the use of ac inputs. Also, digital data coming from FBMs with ac
driven inputs could be delayed due to the dynamics of the ac
waveform and filtering in the FBM and therefore may not be recorded
until the following 10 millisecond sampling period.

Failure to follow these instructions can result in data loss.

♦ Infrared interface to the I/A Series system Letterbug Configurator allows setting and
reading the controller letterbug.
♦ Memory resident image for fast station reboot. Reboot time is less than 10 seconds.
♦ Improved controller performance. Block executions/second is 10,000 for the FCP270
compared to 3400 for the CP60.
♦ Up to 4000 blocks can be configured for the FCP270 (or fault-tolerant FCP270 pair)
♦ A scalable license lets you start small with a full-featured control system. You can grow
your system over time.
♦ Alarm enhancements to the function blocks: re-alarming on changes to alarm priority,
re-alarming based on time, alarm suppression based on time.
♦ Foundation Fieldbus, FoxCom™, HART, Profibus, and Modbus FBMs are
supported.
♦ 100 Series (Y-module) FBMs and DCS migration FBMs are supported.
♦ For enhanced reliability during maintenance operations, a recessed reset button,
located at the front of the module, allows you to manually reset the module without
removing it from the baseplate.

1.
Time stamping has 1 ms accuracy only when using the optional GPS external time synchronization.
For a complete discussion on accuracy and precision of timestamp data under various
configurations, see the section on “Timestamp Accuracy and Precision of SOE Data” in Time
Synchronization User's Guide (B0700AQ).

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B0700AR – Rev N 1. Introduction

Fault-Tolerance
Fault-tolerant operation is unique with Foxboro control processors and uses patented technology.
Fault-tolerance is superior to redundancy because outgoing messages from the fault-tolerant
controller must be identical in both modules for a message to transmit successfully.
The following sections describe the difference between redundancy and fault-tolerance from an
applications standpoint and how fault-tolerance is implemented using the FCP270.

Traditional Redundant Systems

Traditionally, the goal of improved availability through redundancy has been achieved using a
second, or “backup” controller. Redundant systems that use a secondary controller may have the
following shortcomings:
♦ Problems with the primary controller are not detected or are only detected after a
number of potentially bad messages have been transmitted to the field.
♦ Secondary controllers may not use the latest “good” data when they take over from the
primary controller. Configuring the secondary controller correctly can result in
substantial system downtime.
♦ Secondary controllers may have health problems that are hard to determine after they
have been idle for a long period of time.
To remove these shortcomings from Foxboro DCS and I/A Series systems, the FCP270 uses a
patented method of fault-tolerance.

FCP270 Fault-tolerant Operation

The fault-tolerant version of the FCP270 consists of two modules operating in parallel (primary
and shadow), with redundant connections to both the Foxboro DCS Control Network and the
HDLC module fieldbus. The two control processor modules, married together as a fault-tolerant
pair, provide continuous operation of the event of a one module of the pair becoming unavailable.
When the primary and shadow modules boot up, they join together in a process which is referred
to as “marriage.”
Both modules receive and process information simultaneously, and issues are detected by the
modules themselves. One of the significant methods of fault detection is comparison of
communication messages at the module’s external interface. Upon detection of an issue, the
communication message is aborted, and self-diagnostics are run by both modules to determine
which module is unable to continue operation. The operational module then assumes control
without affecting normal system operations. An aborted control network communication message
is then sent by the operational module via the retry mechanisms of the communications protocol.
An aborted fieldbus communication message is retried on the next BPC. For more information,
see “Diagnostics” on page 89.

Self-Hosting and Non-Self-Hosting Modes

An FCP270 requires the latest control database to download to its local memory when it boots
up. This database is provided in a checkpoint file, which the controller acquires based on one of
two modes: non-self-hosting mode (the default mode) and the new self-hosting mode introduced
with I/A Series software v8.4-v8.8 or Foxboro DCS Control Core Services (hereinafter referred to

4
1. Introduction B0700AR – Rev N

as the Control Core Services) v9.0 or later. FCP270 controllers running I/A Series software v8.4-
v8.8 or Control Core Services v9.0 or later software images support the new self-hosting mode.
When the controller boots up in the traditional non-self-hosting mode, it requests the checkpoint
file from its host workstation. When the controller is using the new self-hosting mode of
operation, the checkpoint file is stored locally in the FCP270’s flash memory. Thus, the controller
can boot up in environments where a host workstation is not present. A controller cannot be
configured to run in self-hosting mode until after the station boots up the first time in non-self
hosting mode. Non-self-hosting mode is the default for a newly commissioned controller. If a
controller boots up without a valid checkpoint file in flash, it will load the checkpoint file from
the host workstation. When the database download is complete, the controller issues a checkpoint
command automatically, during which the checkpoint file is written to flash.
The new self-hosting feature provides a mechanism for an FCP270 controller to start up and
execute its configured control scheme in the absence of a host workstation. A host workstation is
only required when you change the control configuration or the controller image.
Controllers running in self-hosting mode require a link to the Ethernet to fully support the self-
hosting functionality, and they must be connected to a fully functional switch. The link is
required for the fault-tolerant network logic to operate. Without this link, the mechanism that is
used to pass the checkpoint file from the primary to the shadow module will not work.
There are certain limitations on the self-hosting mode of an FCP270 controller.
♦ When you enable self-hosting in a controller, the smallest time interval allowed for the
auto-checkpoint option is two (2) hours.
♦ If you attempt to set an auto-checkpoint time of less than two hours, the FCP270 will
force the time to two hours and send a message to the SMON log identifying the
change.
♦ Flash memory is capable of at least 100,000 write operations. There are two areas of
flash in the controller that are used to save checkpoint files. Flash burns alternate
between the two flash memory areas, providing a total of at least 200,000 checkpoint
file writes. The SMDH display for the primary ECB (FBM0) includes a flash burn
counters for the primary and shadow modules.
For more information, see “Enabling the FCP270 Self-Hosting Option” on page 24.

Self-Hosting Feature, Available with 200 Series FBMs Only

The self-hosting feature is recommended only for use in FCP270s which are used with 200 Series
FBMs, or similar modules such as those included in the intrinsically safe I/O subsystem. It is not
recommended for use when the FCP270 is controlling any 100 Series FBMs (Y-module FBMs) or
100 Series FBM based migration cards including Cluster I/O.
All the information that 200 Series FBMs (or similar modules in the intrinsically safe I/O
subsystem) need to operate correctly is either burned in the flash of the FCP270 or is included in
the checkpoint file. This means that if a 200 Series FBM (or similar module) needs to reboot and
go on-line after a power cycle, it will be able to do so without the presence of a boot host
workstation. However, 100 Series FBMs have a different behavior. If a 100 Series FBM is power-
cycled, it downloads information it needs to operate correctly from a boot host workstation. If the
FCP270 is running in self-hosting mode and the boot host workstation is unavailable, the 100
Series FBM will not be able to boot or go on-line.

5
B0700AR – Rev N 1. Introduction

If desired, you can minimize the chance that 100 Series FBMs will need to boot up by making
sure that the 100 Series FBMs are mounted on a rack with a battery back-up or an
Uninterruptable Power Supply (UPS). With this type of configuration, as long as the I/O source
does not need to boot up, the 100 Series FBMs will reconnect when the FCP270 comes back on-
line.

On-Line Image Update

For a fault-tolerant FCP270 controller, on-line image update replaces the executable image
(operating system) of a running FCP270 with a newer image without having to shut down the
equipment being controlled by the FCP270. This feature allows you to take advantage of product
enhancements while interrupting process control for only 1.5 seconds, approximately.

FCP270 Network Configuration

The Foxboro DCS Control Network uses redundant communication paths to enhance control
reliability. Figure 1-1 shows a simplified FCP270 network configuration using redundant
Ethernet fiber switches, 100Mbps fiber cables, splitter/combiners, FCP270 controllers (fault-
tolerant), and redundant 2 Mbps fieldbus and redundant 268 Kbps fieldbus. Multiple FCP270s
can share the same redundant switch.
The FCP270 uses 100 Mbps Ethernet fiber connections to communicate with Foxboro DCS
workstations connected to Ethernet switches in the control network. For information about
general guidelines and specific requirements for designing the control network above the FCP270
level, including site planning and network installation guidelines, see The Foxboro DCS Control
Network Architecture Guide (B0700AZ).
For instructions on installing and cabling the FCP270 in the non-fault-tolerant and fault-tolerant
configurations, see Chapter 2 “Installing the Field Control Processor 270”.

Network Path Switching

The Foxboro DCS Control Network provides redundant communications paths. The control
network architecture and the software in the controller allow it to switch paths when a
communications path becomes unavailable or when replacing modules.
Each FCP270 has two station MAC addresses and two IP addresses, which are not embedded in
hardware. When you replace the controller, the new controller acquires its station MAC and IP
addresses from the system configuration file based on its assigned letterbug. Software on the
FCP270 then selects the network path that is used to transmit outbound communication.

Splitter/Combiner
Fault-tolerant FCP270s require a pair of splitter/combiners, one to connect to each of the
Foxboro DCS Control Network paths (see Figure 1-1). Non-fault-tolerant FCP270s can
optionally use splitter/combiners to provide for a future upgrade to fault-tolerant operation. The
splitter/
combiner has three 100 Mbps connections: one to the primary module of a fault-tolerant pair,
one to the shadow module, and one to the control network. One splitter/combiner in the pair is
connected to one Ethernet switch, the other is connected to another Ethernet switch.

6
1. Introduction B0700AR – Rev N

The splitter/combiner is connected via fiber optic cables. Inbound traffic from the control
network is split and sent to each FCP270 controller. Output traffic is sent from the primary
module, which can be either physical module, to the control network.

7
B0700AR – Rev N 1. Introduction

The Foxboro DCS Control Network

Ethernet Fiber Switch Ethernet Fiber Switch
FAST ETHERNET WORKGROUP SWITCH FAST ETHERNET WORKGROUP SWITCH
RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR PWR
RESET
CPU CPU
RESET
COM COM

1 Gbps Ethernet
Fiber Optic Cables

FAST ETHERNET WORKGROUP SWITCH FAST ETHERNET WORKGROUP SWITCH

RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PWR PWR
RESET
CPU RESET
CPU
COM COM

100 Mbps Ethernet

Fiber Optic Cables
(Redundant)
Splitter*

Splitter*

Splitter*
FCP270 Only
Baseplate Splitter*
Splitter*
F F F F
C C C C FCP270 Control Splitter*
P P FCP270 Control P P
Processor Processor
2 2 2 2
7 7 (Fault-Tolerant) 7 7 (Fault-Tolerant) F F
0 0 0 0 C C FCP270 Control
P P Processor
FCP270 Only 2 2
Baseplate 7 7 (Fault-Tolerant)
0 0
2 Mbps HDLC FCP270 Only
Module Fieldbus Baseplate
(Shielded Twisted
Pair Cables)
268 Kbps HDLC
Module Fieldbus
(Shielded Twisted
Pair Cables)

F F F
B B B
M M M Equipment Rack
IPM2

IPM2

FBI

100 SERIES

100 SERIES

100 SERIES

100 SERIES

100 SERIES

100 SERIES

100 SERIES
FBM

FBM

FBM

FBM

FBM

FBM

FBM
FBI
IPM2

IPM2

Up to 8 FBMs per Baseplate Competitive Migration Modules

(See B0400FA) (See “Overview” on page 1)
1x8 FBM Mounting
Structure
DIN Rail Mounted 200 Series FBMs
Up to 32 per FCP270 or FCP270 Pair
(See Note) Y-module FBMs or Migration Modules
Up to 64 Y-module FBMs per FCP270 or
FCP270 Pair
* Splitter/Combiner. (See Note below and “Overview” on page 1)
Note: For additional sizing information, see Field Control Processor 270 (FCP270) Sizing
Guidelines (B0700AV).
Figure 1-1. Typical FCP270 Network Configuration (Simplified)

8
1. Introduction B0700AR – Rev N

Fieldbus Expansion Module 100 (FEM100)

When an FCP270 is connected to a Fieldbus Expansion Module 100 (FEM100), the FEM100
increases the number of 200 Series (or equivalent) FBMs supported up to 128 FBMs. (See Field
Control Processor 270 (FCP270) Sizing Guidelines and Excel Workbook (B0700AV) to determine
actual sizing for your system.)
The FCP270 requires a software level 8.3 or higher to support the FEMs.
The FEM100 generates four single fieldbus ports, or Expanded Fieldbus 1 through 4. Each
Expanded Fieldbus is capable of communicating with up to thirty-two FBMs. The FEM100 and
Expanded Fieldbuses are transparent to the 2 Mbps HDLC Module Fieldbus between the
FCP270 and the 200 Series (or equivalent) FBMs.
A pair of FEM100s provides redundancy for both paths of the redundant 2 Mbps HDLC module
fieldbus network. Both FEM100s are always active. In the event of a module becoming
unavailable, the other provides backup coverage until the non-operational module is returned to
service. The condition is reported as an interruption to one path of the redundant fieldbus
network.
Additional information on the FEM100 is provided in the Standard and Compact 200 Series
Subsystem User’s Guide (B0400FA).

NOTE
The FBI200A, which is installed exclusively in conversion mounting structures, in
the 100 Series Fieldbus Module Upgrade subsystem, can perform a similar function
as the FEM100 when used with an FCP270. A redundant pair of FBI200As in a
mounting adapter support up to thirty-one 200 Series FBMs in a baseplate chain.
However, they can enable their associated FCP270 to support up to one hundred
twenty-four (124) 200 Series FBMs as described in the 100 Series Fieldbus Module
Upgrade User's Guide (B0700BQ).
The FEM100 cannot be used in conjunction with the FBI200A in any CP-to-FBM
configuration. A CP’s subsystem may only have FEM100s or FBI200As.

I/O Communications
The FCP270 contains several I/O communication features and functions:
♦ Without use in conjunction with the FBI200 or FBI100, support for redundant
HDLC fieldbus at only 2 Mbps or 268 Kbps (depending on whether to connect to
200 Series or 100 Series FBM types and protocols, respectively) for connection to the
FCP270 module
With use in conjunction with the FBI200 or FBI100, support for redundant HDLC
fieldbus to both 2 Mbps or 268 Kbps for connection to the FCP270 module (for
connections to both 100 Series and 200 Series FBM types and protocols)
♦ Simultaneous support of 200 Series FBM types and protocols (HART, Foundation
Fieldbus, Profibus, Modbus, FoxCom, FDSI and standard 200 Series FBMs).
When used with FBI200 or FBI100, simultaneous support of 100 Series FBMs and
100 Series and 200 Series competitive migration modules types and protocols as well.

9
B0700AR – Rev N 1. Introduction

♦ A maximum of 32 DIN railed mounted 200 Series FBMs2 is allowed per 2 Mbps
HDLC fieldbus. The FEM100 provides four Expanded Fieldbuses, which supports
up to 128 200 Series FBMs (or equivalent modules) per FCP270. (See the note above
for the FBI200As.)
♦ A maximum of 39 Siemens APACS+ DCS migration FBMs2 is allowed on the 2
Mbps HDLC fieldbus. The FEM100 provides two Expanded Fieldbuses, which
supports up to 78 Siemens APACS+ DCS migration FBMs per FCP270.
♦ A maximum of 36 Westinghouse DCS migration FBMs2 is allowed on the 2 Mbps
HDLC fieldbus. The FEM100 provides two Expanded Fieldbuses, which supports up
to 72 Westinghouse DCS migration FBMs per FCP270.
♦ A maximum of 64 Y-module (100 Series) FBMs and/or DCS migration FBMs2 is
allowed on the 268 Kbps fieldbus.
I/O communications support the following multiple data streams:
♦ Real-time I/O
♦ AI Stream data for the TDR
♦ Sequence of Events (SOE) data3
♦ I/O maintenance activity
♦ Pass-through activity for device configuration, and so forth.

Dual Baud Functionality

The FCP270 supports the dual baud functionality, allowing the FCP270 to communicate with
both 200 Series FBMs and 100 Series FBMs and migration modules when the FBI200 or FBI100
is properly installed between the FCP270 and the 100 Series FBMs. When installed as specified,
the FBI200s or FBI100s filter the 2 Mbps communications from the FCP270 to maintain the
100 Series FBMs and migration modules only receive the 268 Kbps signals designed for them.
The FBI200s/FBI100s also extend the 268 kbps Module Fieldbus between the FBI200s/FBI100s
and the 100 Series FBMs up to 1830 m (6000 ft). See Figure 1-2 and Figure 1-3.
For a typical redundant module Fieldbus configuration, two FBI200s/FBI100s are needed; one
for the A fieldbus and another for the B fieldbus. These FBI200s/FBI100s are installed in their
own special baseplate for high speed communication between the FBM modules and FCP270s.
The process for setting up dual baud functionality for the FCP270 is discussed in Standard and
Compact 200 Series Subsystem User’s Guide (B0400FA).

2. Maximums listed are for FCPs connected only to modules of the specified type. See Field Control
Processor 270 (FCP270) Sizing Guidelines and Excel Workbook (B0700AV) for the appropriate sizing
guidelines for the FCP270.
3. Using the new SOE feature or the original SOE via ECB6. Also see the footnote and Notice on
page 3.

10
1. Introduction B0700AR – Rev N

Mixed 268 Kbps and 2 Mbps HDLC Module Fieldbus

CP Fieldbus Cable - 60 m (198 ft) Max. To other 200 Series
Baseplates via
Fault-Tolerant 2 Mbps HDLC
FCP270s in FBI200 Pair in Two-Slot Module Fieldbus
Modular Baseplate Vertical Baseplate (P0924RT)*
A
FCP270

FCP270

FBI200

FBI200

FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM
B

200 Series FBMs

Twinaxial Termination
Assemblies (P0903VY)

268 Kbps HDLC Module

Fieldbus (Shielded Twinaxial) To other FBIs
Cables - Includes Fieldbus Fieldbus Isolators (FBIs)
A and B - Total length (FBI200
Baseplate to 1x8 Mounting I O I O

1x8 Mounting Structure

Structure) is up to
1830 m (6000 ft)

100 Series FBMs or

Twinaxial Termination Competitive Migration
Assemblies (P0903VY) Modules
(100 Series FBI TCA) To other FBIs

* Communications Mode in FBI200 Baseplate must be set to 268 Kbps mode.

Figure 1-2. FBI200 Connections to 200 Series and 100 Series FBMs on Mixed 2 Mbps
and 268 Kbps HDLC Module Fieldbus (Conceptual)

11
B0700AR – Rev N 1. Introduction

Fault-Tolerant HDLC Module Fieldbus

FCP270s in Mix of 268 Kbps and 2 Mbps messages
Modular Baseplate (Shielded Twisted Pair Cables) 2 Mbps Module Fieldbus
Includes Fieldbus A and B (Shielded Twisted Pair Cables)

Termination
A ...
F F
C C B ...
P P
2 2
7 7 F F F F F F
0 0 B B B B B B
M M M M M M

DIN Rail Mounted 200 Series FBMs

And 200 Series-based Migration Modules
Up to 32 per FCP270 or FCP270 Pair (See Note)
F F Other FBIs
B B
FBI100s in I I Mounting Structure or
Two-Slot 100 100 Equipment Rack
Vertical
Baseplate A B
IPM2

IPM2

FBI

100 SERIES

100 SERIES

100 SERIES

100 SERIES

100 SERIES

100 SERIES

100 SERIES
FBM

FBM

FBM

FBM

FBM

FBM

FBM
FBI
IPM2

IPM2

268 Kbps HDLC

Module Fieldbus Only Y-module FBMs or 100 Series based
(Shielded Twisted Migration Modules. Up to 64 Y-module
Pair Cables) FBMs per FCP270 or FCP270 Pair
(See Note below and “Overview” on page 1)
Other FBIs
Note: For additional sizing information, see Field Control Processor 270 (FCP270) Sizing
Guidelines (B0700AV).
Figure 1-3. Example Network with FCP270 with Dual Baud Functionality (Conceptual)

Communication to 200 Series Fieldbus Modules

The 200 Series DIN rail mounted FBMs connect to the optionally-fault-tolerant FCP270
through the baseplate. The 2 Mbps HDLC fieldbus is connected to both paths of the redundant
fieldbus network, providing continuous communication in the event one path becomes
unavailable (see Figure 1-1).
Fieldbus cabling lengths for the FCP270 and 200 Series FBMs are as follows:
♦ Overall module Fieldbus, shielded twisted-pair (all segments): 60 m (198 ft)
maximum
(For example, this length includes both the 2 Mbps Module Fieldbus for the
200 Series FBMs, and the cable length between the FCP270 and the FBI200s or
FBI100s, if present)
♦ Module Fieldbus, fiber optic segment (between two baseplates): 10 km (6.2 mi) per
segment maximum, up to 20 km (12.4 mi) total.
♦ FCP270 Fieldbus without FCM2Fs
The cable length of the Fieldbus cannot exceed 60 m (198 ft) (see Figure 1-4).

12
1. Introduction B0700AR – Rev N

FCP
FCP FCP Baseplate

First
FBM Baseplate
60 m
(198 ft)

Last
in
FBM Baseplate Chain

Figure 1-4. Fieldbus Cable Length Restrictions

♦ FCP270 Fieldbus with FCM2Fs

Each FCP/FCM drives a segment of interconnected baseplates of up to 60 m (198 ft).
Up to four pairs of FCM2Fxs can be used in a Fieldbus (see Figure 1-5).

FCP
FCP FCP Baseplate
60 m
(198 ft)

FCM2Fx FCM2Fx
2/4/10 km
(1.24/2.5/6.2 mi)
FCM2Fx FCM2Fx

First
60 m
FBM Baseplate (198 ft)

FCM2Fx FCM2Fx
2/4/10 km
(1.24/2.5/6.2 mi)
FCM2Fx FCM2Fx

Last 60 m
in (198 ft)
FBM Baseplate Chain

Figure 1-5. Fieldbus Cable Length Restrictions w/FCM2Fs

13
B0700AR – Rev N 1. Introduction

♦ FCP270 Fieldbus and Expanded Fieldbuses (1-4) without FCM2Fs

The cable length of the Module Fieldbus (shielded twisted-pair segment) cannot
exceed 60 m (198 ft). See Figure 1-6.

FCP/FEM FCP
FCP FCP Baseplate Baseplate FCP FCP
60 m
FEM (198 ft)
FEM FEM Baseplate FEM FEM

First First
FBM FBM FBM FBM
Base Base Base Base
Plate Plate Plate Plate
60 m 60 m
(198 ft) (198 ft)
Last Last
FBM FBM in FBM FBM in
Base Base Chain Base Base Chain
Plate Plate Plate Plate

Figure 1-6. Expanded Fieldbus Cable Length Restrictions

♦ FCP270 Fieldbus and Expanded Fieldbuses (1-4) with FCM2Fs

Each FCP/FCM drives a segment of interconnected baseplates of up to 60 m (198 ft).
Up to four pairs of FCM2Fxs can be used in each Expanded Fieldbus. See Figure 1-7.

FCP/FEM FCP
FCP FCP Baseplate Baseplate FCP FCP
60 m
FEM (198 ft)
FEM FEM Baseplate FEM FEM

FCM FCM FCM FCM

2Fx 2Fx * 20 km distance is 2Fx 2Fx
10 km* allowed through 10 km*
(6.2 mi) the use of four (6.2 mi)
FCM FCM pairs of FCM2F10s. FCM FCM
2Fx 2Fx 2Fx 2Fx

First First

FBM Baseplate FBM Baseplate

60 m 60 m
(198 ft) (198 ft)
Last Last
in in
FBM Baseplate Chain FBM Baseplate Chain

Figure 1-7. Expanded Fieldbus Cable Length Restrictions w/FCM2Fs

14
1. Introduction B0700AR – Rev N

For complete information on DIN Rail mounted devices, see Standard and Compact 200 Series
Subsystem User’s Guide (B0400FA).

Communication to Y-Module (100 Series) Fieldbus Modules

The Y-module FBMs connect to the optionally-fault-tolerant FCP270 through the baseplate. The
268 Kbps HDLC fieldbus is connected to both paths of the redundant fieldbus network,
providing continuous communication in the event one path becomes unavailable (see Figure 1-1).
The fieldbus connects to the baseplate via the P0926LC adapter and the P0903VY termination
cable assembly (TCA). A 268 Kbps Splitter/Terminator connects the extended fieldbus to 2-
position FCP270 only modular baseplate. This splitter/terminator does not support time strobe
signals. The extended fieldbus can be up to 1 Km (3200 ft) in length.
For complete information on DIN Rail mounted devices, see Standard and Compact 200 Series
Subsystem User’s Guide (B0400FA).

Communication to Migration Modules

For communication with migration modules, see the appropriate migration module document.
For example:
♦ For Siemens APACS+ DCS migration FBMs, see DCS Fieldbus Modules for Moore
APACS+ Systems User's Guide (B0700BK).
♦ For Westinghouse DCS migration FBMs, see DCS Fieldbus Modules for Westinghouse
WDPF Systems User's Guide (B0400BA).
Additional documents are listed in the Preface.

Time Synchronization
The Foxboro DCS Process Automation System supports time synchronization using either an
optional, externally maintained source of Universal Coordinated Time (UTC) from GPS satellites
or an internal source using proprietary software.
Time synchronization within a Foxboro DCS system synchronizes controllers to provide accurate
timestamps for event and data reporting throughout the system. Time stamping is used for SOE
evaluation, TDA, and alarm messages.

Overview
A Main Timekeeper (MTK), residing in an Application Workstation (AW, WSTA70, or
WSVR70), maintains the time source and distributes the system time to all other stations in the
Foxboro DCS Control Network. A SecondaryTimekeeper (STK) receives time information from
the MTK and keeps itself synchronized with the MTK, and thus with all other stations in the
control network. STKs reside in all controllers.
The MTK determines the time for synchronizing all secondary stations by using either the AW’s
real-time clock (internal time source) or the optional GPS receiver and time strobe generator
(external time source).
For complete information on time synchronization, see Time Synchronization User’s Guide
(B0700AQ).

15
B0700AR – Rev N 1. Introduction

Internal Source Time Synchronization

For internal source time synchronization (standard), the MTK station uses time from the internal
clock in the hosting PC. The MTK distributes time as UTC to all stations in the control network.
This time is displayed as local time.
Date and time is entered using the System Management Set Date and Time display. At run-time,
the time can be changed using the Set Date and Time display or time can continue to run on its
internal clock.
For procedures on how to set the date and time using System Management, see System
Management Displays (B0193JC).

External Source Time Synchronization

For external source time synchronization (optional), the MTK station uses an externally
maintained source of Universal Coordinated Time (UTC) from GPS satellites. Equipment to
support this option includes a GPS receiver and time strobe generator.
The MTK uses a hardware connection to the controllers to increase the synchronization accuracy
by providing a time strobe pulse, which is sent continuously by the MTK at a precise time
interval. The controllers have built-in hardware to receive the sync pulses generated by the MTK.
UTC is the international time standard (commonly referred to as Greenwich Meridian Time or
GMT).

FCP270 Sizing Constraints

FCP270 has several aspects that consume its capacity, including BPC settings, the number and
type(s) of I/O points, number of blocks, block memory usage, and so forth. Since the FCP270’s
capacity is consumed based on the configuration of these aspects, it is strongly recommended to
review the sizing guidelines described in Field Control Processor 270 (FCP270) Sizing Guidelines
and Excel Workbook (B0700AV) when determining the FCP270 sizing constraints.
In general, the following apply to FCP270:
♦ The number of 200 Series FBMs hosted by an FCP270 (or fault-tolerant FCP270
pair) is 32 maximum alone, 124 with FBI200As (used only in the 100 Series Fieldbus
Module Upgrade subsystem) or 128 with FEM100s, depending on the selected scan
periods.
♦ The number of 100 Series FBMs and/or DCS FBMs hosted by an FCP270 (or fault-
tolerant FCP270 pair) is 64 maximum, depending on the selected scan periods,
discussed in “FCP270 Supported Block Processing Cycles” below.
♦ The maximum number of blocks that can be configured for use with the FCP270 (or
fault-tolerant FCP270 pair) is 4000. The maximum number of blocks used in a given
configuration depends on scan periods and block type selection. These blocks include
all types: control blocks, ECBs, compounds, data blocks, and so forth.

FCP270 Supported Block Processing Cycles

When planning the number of 100 Series FBMs for your FCP270, take into consideration the
length of each Block Processing Cycle (BPC). The FCP270 supports BPC settings with 100 Series
FBMs from 50 ms up to 1 second:

16
1. Introduction B0700AR – Rev N

♦ An FCP270 with a BPC of 50 ms can support a maximum of five 100 Series FBMs
that can be a combination of basic input and output types.
♦ An FCP270 with a BPC of 100 ms can support a maximum of seventeen 100 Series
FBMs that can be a combination of basic input and output types.
FoxCom FBMs are not supported for a 50 or 100 ms BPC, but it is the responsibility of you to
determine capacity and load.
Due to these speeds, the FCP270 is a viable replacement for high-speed CP30/40 applications.
Note that the slower 2 second BPCs supported by earlier generations of control processors are not
supported by the FCP270.

17
B0700AR – Rev N 1. Introduction

18
2. Installing the Field Control
Processor 270
The FCP270 is available in two configurations, non-fault-tolerant and fault-tolerant.
Communication between the two modules in the fault-tolerant configuration takes place via a
module connector in the baseplate in which the modules are installed.
The FCP270 can only be plugged into a baseplate connector that specifically supports the
FCP270. This rule is enforced since the FCP270 connectors are located differently from the
connectors of FBMs or FCMs. This deters accidental installation of a module in the wrong
baseplate location.
♦ The FCP270 is designed for installation in Foxboro DCS equipment enclosures. For
general information on installing equipment into these enclosures, see Foxboro Evo
Process Automation System and Triconex, Enclosures and Mounting Structures - Site
Planning and Installation User's Guide (B0700AS).
♦ The FCP270 installs on DIN Rail mounted baseplates. For complete information on
these baseplates, see Standard and Compact 200 Series Subsystem User’s Guide
(B0400FA).

System Definition
System Definition identifies the Foxboro DCS system components, system software required by
each component, the system component letterbugs, and other system characteristics for correctly
loading system software and identifying the system software objects. The letterbug is an
alphanumeric string that you define to identify a station in a Foxboro DCS system.
System Definition is initially performed prior to installation of the system equipment, and it is
updated with any hardware/software system changes. Reports produced by System Definition
(SysDef ) software define the system network and provide information that can be used in
conjunction with equipment installation.
♦ To use the Foxboro DCS Control Editors to define the system, see the “System
Development” and “Security” manuals listed under “Foxboro DCS Control Software
and Foxboro DCS Control Core Services Specific Documentation” in Control
Software Deployment Guide (B0750BA). See the section “Controllers” in Hardware
Configuration User’s Guide (B0750BB) to define the FCP270.
♦ IACC allows you to import system configuration information from a Foxboro DCS
system using SysDEF Export media created with the System Definition configuration
application. For importing procedures, see I/A Series Configuration Component (IACC)
User’s Guide (B0700FE).
♦ For a step-by-step procedure for defining a Foxboro DCS system configuration using
the System Definition (SysDEF) software, see System Definition: A Step-By-Step
Procedure (B0193WQ).

19
B0700AR – Rev N 2. Installing the Field Control Processor 270

Installing a Single or Primary FCP270 Module

Figure 2-1 shows how to install a single (non-fault tolerant) or primary (fault-tolerant) FCP270
module on two example FCP270 modular baseplates (P0926HC and P0973CN).

2-Position FCP270 and 2-Position FEM100,

Vertical DIN Rail Mounted Baseplate (P0973CN)

Self-Retaining
Hex Screw
(1 of 2)

FCP270 Module
(P0917YZ)

Position 1 Position 2

FCP270 only, 2-Position Horizontal

DIN Rail Mounted Baseplate (P0926HC)

Figure 2-1. FCP270 Module Installation (Typical)

20
2. Installing the Field Control Processor 270 B0700AR – Rev N

NOTICE
POTENTIAL DATA LOSS

Be aware of the following when working with FCP270 modules in self-

hosting mode:

1) When replacing a module in a fault-tolerant pair and the other

module remains running as Single Primary, plug in the new module
and it will receive the image and checkpoint file from the Primary
module prior to marrying. However, when replacing a module and the
station is currently powered down, boot up the module that was not
replaced first before powering on the replacement module. This
maintains that the new module will be given the proper checkpoint file
during its marriage.

2) When FCP270 modules are installed for the first time (that is, two
fault-tolerant modules are installed together, or one non-fault-tolerant
module is installed, where none of these modules have generated or
received the checkpoint file for their control scheme) and these
modules are designed to run in self-hosting mode, they must be
booted initially in non-self-hosting mode (set by default). This
maintains that the modules download the most recent checkpoint file
from the host workstation. To maintain these modules boot-up in the
default mode, change the letterbug to a non-existent letterbug and
then back to desired letterbug. This helps ensure the FCP270 will load
the checkpoint file from the host workstation.

Failure to follow these instructions can result in data loss.

This procedure requires a hex driver tool (Foxboro part number X0179AZ) or other 5/32 hex
driver tool.
To install a single (non-fault tolerant) or primary (fault-tolerant) FCP270 on a modular
baseplate:
1. Install the modular baseplate to the DIN rail and connect the dc power cable and the
fieldbus/time strobe cable to the baseplate as described in Standard and Compact 200
Series Subsystem User's Guide (B0400FA). Connection to an external time strobe
generator is optional.

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B0700AR – Rev N 2. Installing the Field Control Processor 270

NOTICE
POTENTIAL EQUIPMENT DAMAGE

Observe the signal and power cable separation and segregation

guidelines in System Power and Earthing (Grounding) (B0700AU).

Failure to follow these instructions can result in equipment

damage.

2. Install the FCP270 module (P0917YZ) by pressing it into position 1 on the

designated modular baseplate.

NOTE
1. The FCP270 can only be plugged into a baseplate connector that specifically
supports the FCP270. These baseplate slots are labeled “FCP270” (see Figure 2-1).
For example, the 4-position P0973CN modular baseplate supports two FCP270
modules and two FEM100 modules, but their connectors are physically different to
keep a module from being installed in the wrong connector.

3. Tighten the two self-retaining hex screws on the module using a hex driver tool
(Foxboro part number X0179AZ).

NOTICE
POTENTIAL EQUIPMENT DAMAGE

1. When using the hex driver tool (Foxboro part number X0179AZ) or
other 5/32 hex driver tool, make sure that it does not generate more
than 12 inch pound of torque, or you might strip the threaded inserts
out of the baseplate.

2. The FCP270 module must be screwed in place for secure

operation. Do not rely on the signal connectors to hold the module in
place.

Failure to follow these instructions can result in equipment

damage.

4. Assign the FCP270 letterbug through the module’s infrared communication port
using the I/A Series system Letterbug Configurator. For procedures to assign
letterbugs to the FCP270, see Letterbug Configurator User’s Guide (B0700AY).

22
2. Installing the Field Control Processor 270 B0700AR – Rev N

NOTICE
POTENTIAL DATA LOSS

Make sure you assign the FCP270 letterbug before connecting the
Ethernet fiber optic cables to the FCP270. This avoids potential
process control safety issues if a letterbug has previously been
assigned to the module. Label space is provided on the front of the
module to record the letterbug.
Also, when replacing a non-fault-tolerant FCP270 set to self-hosting
mode, change the letterbug to a non-configured letterbug and then to
its hosted letterbug. This maintains the correct letterbug is configured
and there is no valid checkpoint file in flash. Without following this
order, you cannot be certain of what letterbug is configured for that
module.

Failure to follow these instructions can result in data loss.

5. Connect the FCP270 module to Ethernet switches in the control network:

♦ To connect a single (non-fault-tolerant) module to Ethernet switches in the con-
trol network, see “Cabling a Single (Non-Fault-Tolerant) FCP270 Module” on
page 29.
♦ To connect a fault-tolerant module to Ethernet switches in the control network,
see “Cabling a Fault-Tolerant FCP270 Module Pair” on page 30.
The module follows one of the following boot-up sequences:
♦ “Case 2 – Connecting an FCP270 with the Same Letterbug” on page 35
♦ “Case 3 – Connecting an FCP270 with a New Letterbug” on page 36
6. If replacing an existing non-fault tolerant module, update the FCP270 software image
in the new module with the same image as the module you are replacing. See “Image
Update Procedure for a Non-Fault-Tolerant FCP270” on page 63.
If the FCP270 will run in non-self-hosting mode, the installation procedure is finished.
Otherwise, continue to the next section.

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B0700AR – Rev N 2. Installing the Field Control Processor 270

Enabling the FCP270 Self-Hosting Option

Modify the CFGOPT parameter in the Station block to enable or disable self-hosting.
To enable self-hosting in an FCP270, use system configurator software to set the self-hosting bit
(Bit 8) of the CFGOPT parameter in the Station block (CFGOPT=0x01XX) and issue a
Checkpoint command. See Integrated Control Block Descriptions (B0193AX) for additional
information on the CFGOPT Station block parameter.
For additional details on the operation of an FCP270 with self-hosting enabled, see:
♦ “Initializing the FCP270 with Self-Hosting Enabled” and “Verifying Self-Hosting
Information Using SMDH” below
♦ “Fault Tolerance Behavior in Self-Hosting FCP270” on page 39
♦ “Messages Following Checkpoint Operation in Self-Hosting FCP270” on page 64.

Initializing the FCP270 with Self-Hosting Enabled

Be aware that the FCP270’s database cannot be initialized with self-hosting enabled. If you try to
initialize the database on an FCP270 that is configured for self-hosting, you will get the detected
error message shown below. If the FCP270 is operating in self-hosting mode, you must first
disable self-hosting and perform a checkpoint as indicated in Figure 2-2 before initializing the
FCP270.

Figure 2-2. Initializing a Self-Hosting Controller

Disabling Self-Hosting
To disable self-hosting in an FCP270, use system configurator software to reset the self-hosting bit
(Bit 8) of the CFGOPT parameter in the Station block (CFGOPT=0x00XX). See Integrated
Control Block Descriptions (B0193AX) for additional information on the CFGOPT Station block
parameter.
The SMON log indicates the outcome of the Checkpoint command. For example, the SMON
log will contain the following line:
2007-11-03 10:03:20 FP0101 Process = Self Hosting RDHSS 000131 - Self
Hosting Disabled

24
2. Installing the Field Control Processor 270 B0700AR – Rev N

NOTE
When an FCP270 has self-hosting enabled (CFGOPT=0x01XX) and auto-
checkpoint is set for 2 hours but configured for 1 hour (CKPOPT=1 and
AUTCKP=2), and self-hosting is then disabled by resetting CFGOPT to 0x00XX
without altering the CKPOPT or AUTCKP values and a checkpoint is performed,
the auto-checkpoint frequency continues to be 2 hours (instead of the originally
configured 1 hour). For ICC only, if the desired auto-checkpoint frequency is 1
hour, place the cursor at the AUTCKP parameter and press Enter (Return) and
DONE without any modifications and then perform a checkpoint operation for the
FCP270. Also see “Auto-Checkpoint While Enabling/Disabling Self-Hosting” on
page 26.

Verifying Self-Hosting Information Using SMDH

The status of the FCP270’s self-hosting mode is indicated in the “Equipment Information
Display for Primary ECB (FBM0)” on page 69.
The Primary ECB (FBM 0) display for the FCP270 controllers includes three fields related to
self-hosting.
♦ The PRIM CHK POINT and SHAD CHK POINT fields are used to display the number of
times the Primary (or Single Primary) and Shadow FCP270 module’s flash memory
has been burned.
♦ The SELF HOSTING field identifies the status of self-hosting. This field is set to
Enabled when the FCP270 controller is in self-hosting mode (Bit 8 of the CFGOPT
Station block parameter is set to 1), and Not Enabled when the controller is not in
self-hosting mode (Bit 8 of the CFGOPT Station block parameter is set to 0, the
default).

Verifying Self-Hosting Information Using Station Block Display

The status of the FCP270’s self-hosting mode is also indicated in the processor’s Station block
display. Proceed as follows:
1. Open FoxSelect.
2. Select the FCP270’s letterbug.
3. Open the Station block for the FCP270. Refresh if necessary.
The status of self-hosting is shown under Options, as illustrated in Figure 2-3.

25
B0700AR – Rev N 2. Installing the Field Control Processor 270

If self-hosting is disabled, the following is shown:

Figure 2-3. Self-Hosting Status via Station Block Display

Auto-Checkpoint While Enabling/Disabling Self-Hosting

When you enable self-hosting in a controller, the smallest time interval allowed for the auto-
checkpoint option is two (2) hours. This is to maintain that the minimum life of a FCP270’s flash
memory for a module running auto-checkpoint full time is at least 20 years.
If you attempt to set this interval to a smaller amount, the FCP270 will override this command.
The following message may appear in the SMON log:
2008-01-24 14:56:27 FP0101 Process = Checkpoint CIO_DB 000015 - Auto
Checkpoint Override to 2 Hours
If this occurs, you should do one of the following to maintain the configurator’s work file reflects
the actual AUTCKP value in the FCP270:
♦ Using system configurator software, modify AUTCKP to reflect 2 hours and issue a
Checkpoint command.
♦ Perform an “Upload Block/ECB Parameters” operation from system configurator
software. This will force the FCP270 to upload its current parameter values to the
work file on the workstation.
If either of these steps is not performed when you disable self hosting, the auto-checkpoint
intervals will remain at two hours but the value of AUTCKP in the work file will remain
unchanged. To verify the time interval set for auto-checkpoint, view the Station Block Display for
the current FCP270 value.

26
2. Installing the Field Control Processor 270 B0700AR – Rev N

Be advised if you use the ICC script (ICCPRT) to periodically acquire database parameters, it
performs an ICC function. As with any ICC function, the ICCPRT script causes the auto-
checkpoint counter to reset, clearing this timer. This also affects self-hosting if relying on the
auto-checkpoint feature to perform checkpoints to flash memory.
If you want periodic auto-checkpoints to occur, the auto-checkpoint time must be set to less than
the periodic interval of the use of ICC scripts. If you want to use ICCPRT once every 24 hours,
we recommend you set auto-checkpoint interval to less than 24 hours.

Installing a Shadow FCP270 Module

All FCP270 modules are shipped from the factory with the latest software image (operating
system) stored in flash memory. If the software image of the shadow and primary modules
differ, the shadow module copies the software image from the primary module and burns it to
flash memory before marrying the primary.
If self-hosting is enabled and the checkpoint file of the shadow and primary modules differ, the
shadow module copies checkpoint file from the primary module and burns it to flash memory
before marrying the primary.
If the letterbug of the shadow module differs from the primary module, the shadow copies the
primary’s letterbug to flash memory before marrying the primary.
Also, if the shadow module is to be run in self-hosting mode, see the first item in the first Notice
on “Installing a Single or Primary FCP270 Module” on page 20.
To perform this procedure, you require a hex driver tool (Foxboro part number X0179AZ) or
other 5/32 hex driver tool.
To install a shadow (fault-tolerant) FCP270 module on a modular baseplate:
1. While holding the module (P0917YZ) in hand, install the Ethernet fiber optic cables
by connecting them to the shadow module as instructed in “Cabling a Fault-Tolerant
FCP270 Module Pair” on page 30.
2. Install the shadow FCP270 module by pressing it into the position next to the
primary module on the designated modular baseplate.
3. Tighten the two self-retaining hex screws on the module using a hex driver tool
(Foxboro part number X0179AZ).

27
B0700AR – Rev N 2. Installing the Field Control Processor 270

NOTICE
POTENTIAL EQUIPMENT DAMAGE

1.When using the hex driver tool (Foxboro part number X0179AZ) or
other 5/32 hex driver tool, make sure that it does not generate more
than 12 inch pound of torque, or you might strip the threaded inserts
out of the baseplate.

2. The FCP270 module must be screwed in place for secure

operation. Do not rely on the signal connectors to hold the module in
place.

Failure to follow these instructions can result in equipment

damage.

4. Verify that the shadow module boots up and marries the primary module as described
in one of the following boot-up sequences:
♦ “Case 4 – Connecting a Shadow Module with Same Software Image” on page 36
♦ “Case 5 – Connecting a Shadow Module with Different Software Image” on
page 38
5. Verify that the shadow module is married to the primary module using the
Equipment Information display in System Management to confirm the following:
PRIMARY MODE: Married Prim
SHADOW MODE: Married Shad
For more information, see “Equipment Information Display for FCP270” on
page 54.
6. Verify the following using the Equipment Information display for the FCP270 in
System Management to confirm the following (see Chapter 4 “System
Management”):
♦ The shadow module is married to the primary module:
PRIMARY MODE: Married Prim
SHADOW MODE: Married Shad
♦ The self-hosting mode:
SELF HOSTING: Disabled (or Enabled)
The installation procedure is finished.

28
2. Installing the Field Control Processor 270 B0700AR – Rev N

Cabling a Single (Non-Fault-Tolerant) FCP270 Module

NOTICE
POTENTIAL EQUIPMENT DAMAGE

When installing fiber optic cable, do not exceed the minimum bend
radius of 5 cm (2 in), or the cable has a chance of breaking.

Failure to follow these instructions can result in equipment

damage.

NOTICE
POTENTIAL DATA LOSS

An issue may occur with the custom fiber optic transceiver used in the
FCP270 when connecting to the control network, if the fiber optic
cable run is short and there is not enough loss in the path to reduce
the optical power 6.0 dB at 850nm. For the upgrade kit that can
resolve this issue, see “Fiber Budgeting Between Foxboro DCS
Devices and Switch Fiber Optic Connections” in The Foxboro DCS
Control Network Architecture Guide (B0700AZ).

Failure to follow these instructions can result in data loss.

To connect a single (non-fault-tolerant) FCP270 module to Ethernet switches in the control

network:
1. Remove any rubber fiber optic port dust covers from the module’s Control Network A
and B ports, Ethernet switches ports, and fiber cable connectors. Retain the dust
covers for use on any unused ports.
2. Connect the Control Network A connector on the FCP270 to one Ethernet Fiber
switch (switch 1) in the control network using 100 Mbps fiber optic cable with LC to
MT-RJ connectors (see Table 2-1).
3. Connect the Control Network B connector on the FCP270 to another Ethernet Fiber
switch (switch 2) in the control network using 100 Mbps fiber optic cable with LC to
MT-RJ connectors (see Table 2-1).

Table 2-1. Cables for Connecting the FCP270 or Splitter/Combiners to the Ethernet Switches

Part Number Length Material

P0972TR 3 m (9.8 ft) MMF 62.5/125 μm, orange riser. Two ceramic type LC connec-
tors on one end with an MT-RJ connector on the other end.

29
B0700AR – Rev N 2. Installing the Field Control Processor 270

Table 2-1. Cables for Connecting the FCP270 or Splitter/Combiners to the Ethernet Switches

Part Number Length Material

P0972TS 15 m (49.2 ft) MMF 62.5/125 μm, orange riser. Two ceramic type LC connec-
tors on one end with an MT-RJ connector on the other end.
P0972TT 50 m (164 ft)1 MMF 62.5/125 μm, orange riser. Two ceramic type LC connec-
tors on one end with an MT-RJ connector on the other end.
1. For fiber optic cable lengths greater than 50 m (164 ft), use a customer-supplied cable up to a max-
imum length of 2 km (6562 ft).

Cabling a Fault-Tolerant FCP270 Module Pair

To cable the fault-tolerant FCP270 module pair, you must first install the splitter/combiners to
split inbound traffic to the modules and combine outbound traffic from the modules. The
splitter/combiners connect the fault-tolerant modules to Ethernet fiber switches in the control
network using fiber optic cables. The cabling scheme for an FCP270 on a two-position baseplate
is shown in Figure 2-4, while the cabling scheme for an FCP270 on a four-position baseplate is
shown in Figure 2-5.
The cable color scheme helps you to properly connect the fiber cables to the splitter/combiners
and modules so that the FCP270 can operate in the fault-tolerant mode. However, you can use
fiber cables of any color to make these connections.

30
2. Installing the Field Control Processor 270 B0700AR – Rev N

To/From To/From
The Control Network The Control Network
DC Power
Ethernet Fiber Switch 1 Ethernet Fiber Switch 2
Connector

100 Mbps Orange Baseplate Baseplate

MMF Fiber Cables Position 1 Position 2
See Table 2-1
FCP270 Fault-Tolerant
Module Pair
Splitter/Combiner Pair

Port 1 + 2
Port 1
Port 2

100 Mbps Orange Duplex

Fiber Cable (P0972VG) 100 Mbps Gray Duplex
Fiber Cable (P0972UN)
Notes:
1. Port labeled “1 + 2” on the splitter/combiner connects to one Ethernet Fiber switch.
2. Port labeled “1” on the splitter/combiner connects to the FCP270 mounted in baseplate position 1.
3. Port labeled “2” on the splitter/combiner connects to the FCP270 mounted in baseplate position 2.

Figure 2-4. Cabling the FCP270 Fault-tolerant Controllers (Two-Position Baseplate Example)

31
B0700AR – Rev N 2. Installing the Field Control Processor 270

To/From
The Control Network
To/From FCP270 Fault-Tolerant
Ethernet Fiber Switch 2
The Control Network Module Pair
Ethernet Fiber Switch 1 Baseplate Baseplate DC Power
Position 1 Position 2 Connector
100 Mbps Orange
MMF Fiber Cables

See Table 2-1

Optional
Splitter/
Terminator
Splitter/ P0916RB/
Combiner P0926KZ
Pair

To/From
To/From Expanded
Expanded Fieldbuses
Fieldbuses 1-2
3-4

FEM100 FEM100
Module Module
(Bus A) (Bus B)
Notes:
1. Port labeled “1 + 2” on the splitter/combiner connects to one Ethernet Fiber switch.
2. Port labeled “1” on the splitter/combiner connects to the FCP270 mounted in baseplate position 1.
3. Port labeled “2” on the splitter/combiner connects to the FCP270 mounted in baseplate position 2.

Figure 2-5. Cabling the FCP270 Fault-tolerant Controllers (Four-Position Baseplate Example)

32
2. Installing the Field Control Processor 270 B0700AR – Rev N

NOTICE
POTENTIAL DATA LOSS

Failure to properly connect the cables will result in the modules not
being able to operate in a fault-tolerant mode.

Failure to follow these instructions can result in data loss.

NOTICE
POTENTIAL EQUIPMENT DAMAGE

When installing fiber optic cable, do not exceed the minimum bend
radius of 5 cm (2 in), or the cable has a chance of breaking.

Failure to follow these instructions can result in equipment

damage.

NOTICE
POTENTIAL DATA LOSS

An issue may occur with the custom fiber optic transceiver used in the
FCP270 when connecting to the control network, if the fiber optic
cable run is short and there is not enough loss in the path to reduce
the optical power 6.0 dB at 850nm. For the upgrade kit that can
resolve this issue, see “Fiber Budgeting Between Foxboro DCS
Devices and Switch Fiber Optic Connections” in The Foxboro DCS
Control Network Architecture Guide (B0700AZ).

Failure to follow these instructions can result in data loss.

The splitter/combiners (P0926AH) install in a Foxboro DCS enclosure on the following:

♦ DIN rail mounted modular baseplate
♦ DIN rail
♦ Chassis assembly.
For detailed mounting procedures for the splitter/combiners, see Standard and Compact 200 Series
Subsystem User’s Guide (B0400FA).
To connect the splitter/combiners to the control network Ethernet switches and fault-tolerant
FCP270 modules, see Figure 2-4 and proceed as follows:

33
B0700AR – Rev N 2. Installing the Field Control Processor 270

1. Remove any rubber fiber optic port dust covers that are installed in the module’s
Control Network A and B ports, splitter/combiner ports, Ethernet switch ports, and
cable connectors. Retain the dust covers for use on any unused ports.
2. Connect the port labeled “1 + 2” on one splitter/combiner to one Ethernet fiber
switch (switch 1) in the control network using 100 Mbps fiber optic cable with LC to
MT-RJ connectors (P0972TR, P0972TS or P0972TT in Table 2-1, or custom cable
up to 2 km (6400 ft) in length).
3. Connect port “1 + 2” on the other splitter/combiner to another Ethernet fiber switch
(switch 2) in the control network using 100 Mbps fiber optic cable with LC to MT-RJ
connectors (P0972TR, P0972TS or P0972TT in Table 2-1, or custom cable up to
2 Km (6400 ft) in length).
4. Connect port 1 on the splitter/combiner for switch 1 to the Control Network A
connector on the FCP270 in baseplate position 1 using orange duplex fiber optic
cable with LC to LC connectors (P0972VG in Table 2-2).
5. Connect port 2 on the splitter/combiner for switch 1 to the Control Network A
connector on the FCP270 in baseplate position 2 using orange duplex fiber optic
cable with LC to LC connectors (P0972VG in Table 2-2).
6. Connect port 1 on the splitter/combiner for switch 2 to the Control Network B
connector on the FCP270 in baseplate position 1 using gray duplex fiber optic cable
with LC to LC connectors (P0972UN in Table 2-2).
7. Connect port 2 on the splitter/combiner for switch 2 to the Control Network B
connector on the FCP270 in baseplate position 2 using gray duplex fiber optic cable
with LC to LC connectors (P0972UN in Table 2-2).

Table 2-2. Cables for Connecting the Splitter/Combiners to the FCP270

Part Number Length Material

P0972UN 0.5 m (1.6 ft) MMF 62.5/125 μm, gray riser. Ceramic type LC
connectors with clip on each end.
P0972VG 0.5 m (1.6 ft) MMF 62.5/125 μm, orange riser. Ceramic type LC
connectors with clip on each end.

Boot-Up Sequence
The boot up sequence for the FCP270 has the following typical cases:
♦ Case 1: Rebooting a commissioned FCP270 module.
♦ Case 2: Connecting a module with the same letterbug to the baseplate with the
Ethernet network cables connected.
♦ Case 3: Connecting a module with a new letterbug to the baseplate with the Ethernet
network cables connected.
♦ Case 4: Connecting a shadow module with the same software image to the baseplate,
after the primary module has booted up, loaded the checkpoint file, and initialized
on-control.

34
2. Installing the Field Control Processor 270 B0700AR – Rev N

♦Case 5: Connecting a shadow module with different software image to the baseplate,
after the primary module has booted up, loaded the checkpoint file, and initialized
on-control.
The boot up sequence for above cases are described in the following five sections.

NOTE
For procedures to assign letterbugs to the FCP270, see Letterbug Configurator User’s
Guide (B0700AY).

NOTE
For FCP270s in self-hosting mode, a 14 second delay occurs before the module
attempts to download its checkpoint file from flash memory.

Case 1 – Rebooting a Commissioned FCP270

When a Reboot command is issued to a commissioned FCP270 controller running non-fault-
tolerant, the operational sequence is as follows:
1. The controller lights the red Operational Status LED while running the on-line
diagnostics.
2. If the on-line diagnostics test results are OK, the controller lights the red and green
Operational Status LEDs and performs other internal tests.
3. If the internal test results are OK, the controller lights the green Operational Status
LED and turns off the red LED.
4. In non-self-hosting mode, the controller loads the checkpoint file (control database)
from the host server.
In self-hosting mode, the controller either loads the checkpoint file (control database)
from the host server and performs a checkpoint operation if it does not have the
checkpoint file in flash memory, or it loads the checkpoint file from its internal flash
memory if the file is present.
5. The controller initializes on-control as defined by the control database.

Case 2 – Connecting an FCP270 with the Same Letterbug

When connecting to the baseplate an FCP270 module with the same letterbug as the removed
module, with the control network cables connected, the operational sequence is the same as for
Case 1.
The controller reboots, loads the checkpoint file from the host, and initializes on-control as
described in Steps 1 through 5 in Case 1.

35
B0700AR – Rev N 2. Installing the Field Control Processor 270

WARNING
POTENTIAL DEATH OR SERIOUS INJURY

Make sure you assign the FCP270 letterbug before connecting the
Ethernet fiber optic cables to the FCP270. This avoids potential
process control safety issues if a letterbug has previously been
assigned to the module. Label space is provided on the front of the
module to record the letterbug.
Also, when replacing a non-fault-tolerant FCP270 set to self-hosting
mode, change the letterbug to a non-configured letterbug and then to
its hosted letterbug. This maintains the correct letterbug is configured
and there is no valid checkpoint file in flash.
Without following this order, you will not be able to determine what
letterbug is configured for that module. The FCP270 may attempt to
boot up with an obsolete checkpoint file that is stored in its flash, which
could have an adverse effect on the process running.

Interrupting plant operations while the plant is running has the

potential to cause injury within the plant.

Failure to follow these instructions can result in death or serious

injury.

Case 3 – Connecting an FCP270 with a New Letterbug

A “new letterbug” is a letterbug for a station which has not been commissioned to date.

NOTE
If the letterbug of a FCP270 is changed, the checkpoint file in flash memory is
invalidated. The next time the FCP270 reboots, it will load the checkpoint file from
the host workstation.

When connecting an FCP270 module with a new letterbug to the baseplate, with the control
network network cables connected, the operational sequence is as follows:
1. The controller boots up as described in Steps 1 through 3 in Case 1.
2. The controller loads the network addresses from the host server.
3. The controller reboots, loads the checkpoint file from the host, and initializes on-
control as described in Steps 1 through 5 in Case 1.

Case 4 – Connecting a Shadow Module with Same Software

Image
When connecting a shadow module with the same software image as the primary module to the
baseplate – after the primary module has booted up, loaded the checkpoint file, and initialized
on-control – the operational sequence is as follows:

36
2. Installing the Field Control Processor 270 B0700AR – Rev N

1. The shadow module boots up as described in Steps 1 through 3 in Case 1.

2. If the station is in self-hosting mode and the checkpoint file in flash of the shadow
module differs from the checkpoint file in flash of the primary module or the shadow
module lacks a checkpoint file, the shadow controller lights the red Operational Status
LED while the green LED remains on.
3. The shadow module copies the checkpoint file from the primary module and burns it
to flash memory.
If the checkpoint operation succeeds, messages similar to the following examples are
sent to the SMON log:
2008-01-21 13:53:11 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint update Needed
2008-01-21 13:53:28 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint File Sent
These messages are sent by the primary module and only indicate that the primary has
sent the checkpoint file to the shadow module. The shadow module still has to write
the checkpoint file to its flash. This process could take more than a minute before the
shadow module has completed the write to flash.
If the checkpoint operation does not succeed, messages similar to the following exam-
ples are sent to the SMON log by the primary module:
2008-01-21 13:52:43 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint update Needed
2008-01-21 13:53:00 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint Incomplete - Reboot Shadow
2008-01-21 13:53:00 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint File Sent
Then, one of two scenarios will occur:
♦ The shadow module will reboot automatically to reinitiate the marriage process.
♦ The shadow module will remain in the red/green LED state and not reboot. In
this scenario, you must reboot the Shadow module manually to restart the mar-
riage process.
4. The shadow module boots up again as described in Steps 1 through 4 in Case 1.
5. If the letterbug of the shadow module differs from the primary module, the shadow
copies the primary’s letterbug to flash memory.
6. The shadow module marries the primary module, as indicated by the single,
simultaneous quick flashing of the red Operational Status LED on both modules,
then the modules run fault tolerant.
The marriage should occur within 10 seconds, except for the following conditions
when the station is in self-hosting mode:
♦ If the primary module (in Single Primary mode) is downloading the checkpoint
file from flash memory, the marriage will be held off until the download is com-
plete. The shadow module's LEDs will remain green while it waits for the mar-
riage to occur.
♦ If the primary module (in Single Primary mode) is performing a checkpoint,
which includes a write to its flash, the marriage will be held off until the check-

37
B0700AR – Rev N 2. Installing the Field Control Processor 270

point operation is complete. The shadow module's LEDs will remain green while
it waits for the marriage to occur.

Case 5 – Connecting a Shadow Module with Different Software

Image
When connecting a shadow module with a different software image than the primary module to
the baseplate – after the primary module has booted up, loaded the checkpoint file, and initialized
on-control – the operational sequence is as follows:
1. The shadow module boots up as described in Steps 1 through 3 in Case 1.
2. Since the shadow module’s software image differs from the primary module, the
controller lights the red Operational Status LED while the green LED remains on.
3. The shadow module copies the software image from the primary module and burns it
to flash memory.
4. The shadow module boots up again as described in Steps 1 through 3 in Case 1.
5. If the station is in self-hosting mode and the checkpoint file in flash of the shadow
module differs from the checkpoint file in flash of the primary module or the shadow
module lacks a checkpoint file, the shadow controller lights the red Operational Status
LED while the green LED remains on.
6. The shadow module copies the checkpoint file from the primary module and burns it
to flash memory.
If the checkpoint operation succeeds, messages similar to the following examples are
sent to the SMON log:
2008-01-21 13:53:11 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint update Needed
2008-01-21 13:53:28 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint File Sent
These messages are sent by the primary module and only indicate that the primary has
sent the checkpoint file to the shadow module. The shadow module still has to write
the checkpoint file to its flash. This process could take more than a minute before the
shadow module has completed the write to flash.
If the checkpoint operation does not succeed, messages similar to the following exam-
ples are sent to the SMON log by the primary module:
2008-01-21 13:52:43 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint update Needed
2008-01-21 13:53:00 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint Incomplete - Reboot Shadow
2008-01-21 13:53:00 FP0101 Process = Flash Loader RDHSS 000131 -
Shadow Checkpoint File Sent
Then, one of two scenarios will occur:
♦ The shadow module will reboot automatically to reinitiate the marriage process.
♦ The shadow module will remain in the red/green LED state and not reboot. In
this scenario, you must reboot the Shadow module manually to restart the mar-
riage process.
7. The shadow module boots up again as described in Steps 1 through 3 in Case 1.

38
2. Installing the Field Control Processor 270 B0700AR – Rev N

8. If the letterbug of the shadow module differs from the primary module, the shadow
copies the primary’s letterbug to flash memory.
9. The shadow module marries the primary module, as indicated by the single,
simultaneous quick flashing of the red Operational Status LED on both modules.
Then the modules run fault tolerant.
The marriage should occur within 10 seconds, except for the following conditions
when the station is in self-hosting mode:
♦ If the primary module (in Single Primary mode) is downloading the checkpoint
file from flash memory, the marriage will be held off until the download is com-
plete. The shadow module's LEDs will remain green while it waits for the mar-
riage to occur.
♦ If the primary module (in Single Primary mode) is performing a checkpoint,
which includes a write to its flash, the marriage will be held off until the check-
point operation is complete. The shadow module's LEDs will remain green while
it waits for the marriage to occur.

NOTE
Since the shadow module assumes the software image and letterbug of the primary
controller, the boot up sequence can be used to identify the shadow controller if its
letterbug and ID are both unknown. When the shadow controller is married, its
letterbug is now known and its Manufacturing ID can be viewed from the
Equipment Information display in System Management, where the ID is the last six
characters of the SHAD ROM ADDRESS.

Fault Tolerance Behavior in Self-Hosting FCP270

When a fault-tolerant FCP270 station is running in self-hosting mode, the primary module
maintains that its shadow module has a matching version of the checkpoint file in flash before
allowing the shadow module to marry with the primary module. To be sure that the files match,
the FCP270s maintain the following behaviors:
♦ When a fault-tolerant pair of FCP270s are running in self hosting mode, and a
checkpoint command is issued, the fault-tolerant station sends the checkpoint file to
the host workstation. When the process sending the checkpoint file to the host is
complete, the FCP270 station requests that checkpoint file from the host and copies
the file to flash in both the primary and shadow module.
♦ If two fault-tolerant FCP270 modules, with a newly assigned letterbug, are booted up,
the modules will marry and load the checkpoint file from the host workstation. If self-
hosting is enabled (i.e. the CFGOPT parameter in the checkpoint file has self-hosting
enabled), the FCP270 station will automatically issue a checkpoint command at the
completion of the checkpoint download. As part of the checkpoint process for self-
hosting, the checkpoint file is burned into both the primary and shadow modules’
flash memory.
♦ When a new FCP270 module is booted up, with the intention of marrying with a
FCP270 that is running as Single Primary mode, and the station is configured for self-
hosting mode, the Single Primary module first downloads its checkpoint file to the

39
B0700AR – Rev N 2. Installing the Field Control Processor 270

shadow module before the shadow module is allowed to marry the Single Primary
module.
If the Single Primary module is downloading the checkpoint file from flash memory
or writing the checkpoint file from the host to flash, the marriage will be held off until
all operations to the Single Primary flash have completed. Normally, a marriage takes
a maximum of 10 seconds to occur when self-hosting is not enabled. However, in this
case the marriage may be held off longer than 10 seconds. Operations should not be
adversely affected.
♦ If one module of a fault-tolerant pair does not burn a checkpoint file to flash
successfully and the other module does succeed, the module that does not burn to
flash will invalidate the checkpoint file in flash and go off-line. The module that
successfully burns to flash transitions to Single Primary and sends a detected error
message to the SMON log indicating why the other module went off-line.
♦ If both modules of a fault-tolerant pair do not burn the checkpoint file to flash
successfully, both modules will invalidate the checkpoint file in flash and send a
detected error message to the SMON log. The station continues to run fault-tolerant
and will attempt to load a new checkpoint file on the next checkpoint command or
from their host when they are rebooted.
♦ If a non-fault-tolerant module does not burn a checkpoint file to flash successfully, the
module invalidates the checkpoint file in flash and sends a detected error message to
the SMON log. The station continues to run as Single Primary and will load a new
checkpoint file on the next checkpoint command or from its host when it is rebooted.

Cabling Y-Module FBMs to an FCP270 Baseplate

Cabling Y-module FBMs to an FCP270 baseplate consists of extending the remote 268 Kbps
fieldbus from the FBM mounting structure (see Figure 2-6). This extension, used between
enclosures, involves the use of termination cable assemblies (TCAs) and Fieldbus Isolators (FBIs)
to provide cable connections between primary and extended fieldbus segments, for a maximum
fieldbus length of 1 km (3200 ft).
The FBI200 or FBI100 must be installed between the remote 268 Kbps fieldbus and the FCP270
in order to support the dual baud functionality and/or extend the length of the 268 Kbps
fieldbus.
If the fieldbus is non-redundant, only one TCA is connected to the fieldbus splitter/terminator
(P0926LC - shown in Figure 2-7) or to the FBI200 baseplate (P0924RT) or the FBI100 baseplate
(P0923LR). (The connections to these baseplates are also shown in Figure 2-7.) TCA part
number P0903VY includes a strain relief bracket, labels for bus A and B, and a 110 ohm
terminating resistor. You must install one of the labels on the TCA (see Figure 2-6 for label
orientation).
You can mount the FCP270 module(s) on either the two-position, vertical DIN rail mounted
baseplate (P0926HW) or the two-position, horizontal DIN rail mounted baseplate (P0926HC).
The optional FBI200 or FBI100 modules(s) are only available on a two-position, vertical DIN
rail mounted baseplate (P0924RT for the FBI200, P0923LR for the FBI100).

40
2. Installing the Field Control Processor 270 B0700AR – Rev N

Remote Fieldbus Extension, Cable Connections

Remote fieldbus extension cable connections are implemented as shown in Figure 2-6 and
Figure 2-10. For cable connections to the Fieldbus Isolator TCA, see “Remote Fieldbus
Extension, Cable Connections” in System Equipment Installation (B0193AC).
To make the remote fieldbus extension cable connections:
1. Assemble the termination blocks associated with the termination cable assemblies
(P0903VY), snap them onto the mounting rails (DIN rails) in the enclosure (as
shown in Figure 2-8), and connect the ground wires. (For future reference, Figure 2-9
illustrates how to remove the TCA termination blocks.)
If you are not installing the FBI200/FBI100 modules in your configuration, see
Figure 2-7 to see how to connect the TCAs directly to the fieldbus splitter/terminator
(P0926LC).
If you are installing the FBI200 or FBI100 modules in your configuration, see
“Cabling the FCP270 to the 268 Kbps or 2 Mbps Fieldbus Via the FBI200 or
FBI100” in Standard and Compact 200 Series Subsystem User’s Guide (B0400FA) for
instructions on how to connect the TCAs directly to the FBI200 or FBI100 baseplate.
2. For configurations without FBI200/FBI100 modules, connect the fieldbus
splitter/terminator (P0926LC) to the “Fieldbus and Time Strobe” connector on the
FCP270 baseplate (see Figure 2-6). See “Cabling the FCP270 to the 268 Kbps or 2
Mbps Fieldbus (Without FBI100)” in Standard and Compact 200 Series Subsystem
User’s Guide (B0400FA).
3. For configurations without FBI200/FBI100 modules, make cable connection(s) to
the fieldbus splitter/terminator as shown in Figure 2-7.
For configurations with FBI200/FBI100 modules, make cable connection(s) to the
FBI200 or FBI100 baseplate as shown in Cabling the FCP270 to the 268 Kbps
Fieldbus Via the FBI200 or FBI100” in Standard and Compact 200 Series Subsystem
User’s Guide (B0400FA).
4. Make the fieldbus cable connections between termination cable assemblies (see
Figure 2-10).
5. Add the terminating resistors (supplied with the termination cable assemblies)
according to the following rules:
♦ Terminating resistors are used only at the ends of the bus.
♦ The Fieldbus can be extended in two directions from the FCP270. (See
Figure 2-11.)
6. Connect an insulated 14 AWG green wire between connection point 3 (shield) on the
last Fieldbus Isolator termination cable assembly (or assemblies) and the earth bus in
the enclosure. For Foxboro DCS system earthing requirements, see Power, Earthing
(Grounding), EMC and CE Compliance (B0700AU).

41
B0700AR – Rev N 2. Installing the Field Control Processor 270

Customer Installed Label Termination Cable

Assemblies (P0903VY)
and 110 ohm resistor
Fieldbus A (E0157CZ) across the
F+ and F- terminals
at the end of the
Vertical DIN Rail Mounted Fieldbus
Baseplate (P0926HW)
with Fault-Tolerant
FCP270 Modules
Fieldbus B

268 Kbps Fieldbus

Splitter/Terminator
(P0926LC)

No Terminator on
this connector

14 Gauge Twinaxial Cables

1 Km (3200 ft) Maximum
(P0170GF or P0170GG)
~~

Wire Connection to
Enclosure Earth Bus
Fieldbus Isolator
Termination Cable
Assemblies (P0800DC)

1X8 FBM Mounting Structure

with Fieldbus Isolators

Mounting Slots for

Y-Module FBMs

Figure 2-6. Cabling Y-Module FBMs to an FCP270 Baseplate (Without FBI200s/FBI100s)

42
2. Installing the Field Control Processor 270 B0700AR – Rev N

Fieldbus A TCA
Cable Connector

Baseplate (P0926HW)

268 Kbps Fieldbus

Splitter/Terminator
(P0926LC)

Fieldbus B TCA
Cable Connector

Figure 2-7. TCA Cable Connection to 268 Kbps Fieldbus Splitter/Terminator

(Without FBI200s/FBI100s)

Slide strain relief bracket onto TCA Connect ground wire to DIN rail using
1 3
termination block. screw, lock washer and nut (customer
supplied).
Snap assembled termination block
2
onto DIN rail.

TCA Termination Block

Earth (Ground) Wire

Screw

Lock Washer
Strain Relief Bracket
DIN Rail
Ring Lug

Figure 2-8. TCA Termination Block Assembly Mounting

43
B0700AR – Rev N 2. Installing the Field Control Processor 270

1 Disconnect the earth wire from 3 Move the screw drive handle in the
from the DIN rail. direction shown, while lifting the TCA
termination block from the DIN rail.

2 Insert a medium-size flat-head

screw driver as shown.

Lift

Earth (Ground) Wire

Screw
Washer
Move
TCA Termination Block

Figure 2-9. TCA Termination Block Removal

44
2. Installing the Field Control Processor 270 B0700AR – Rev N

Termination Cable Assemblies (2)

(P0903VY)
100 Ohm Twinaxial
Cable P0170GF,
P0170GG, or
Note 1
Equivalent

Note 2
Note 3 Note 3
BK BK
Fieldbus A
W W To Fieldbus
Fieldbus B Isolator TCA
SH SH (See B0193AC)
F F- S F F- S
F F- S Note 5 F F- S

Fieldbus Fieldbus
Note 4 Note 4
B A

B B
BR G/Y BR G/Y
F+ F- SH F+ F- SH

To Splitter/Terminator
(P0926LC)

Notes:
1. For cable strain relief, it is recommended that the Fieldbus cable(s) be routed over the strain
relief bracket and secured using nylon cables ties.
2. TCAs can be daisy chained as indicated by the dashed cable lines, but terminating resistors
(110 ohms) must be installed at the ends of the fieldbus.
3. Wire colors shown (BK and W) are for reference purposes only.
4. Earth (ground) the surge protection network contained within the TCAs by attaching the green
earth wire to a screw on the DIN rail connected to system earth. For more information on
earthing, see Power, Earthing (Grounding), EMC and CE Compliance (B0700AU).
5. The shield of the twinaxial cable (terminal 3) should be earthed at the farthest end from the
FCP270 baseplate. The fieldbus shield must be earthed at one end only. (See text for
earthing instructions.)

Figure 2-10. Remote Redundant Fieldbus Cabling (FCP270 End)

45
B0700AR – Rev N 2. Installing the Field Control Processor 270

Termination Cable Assembly

(P0903VY)

SH
To Next Fieldbus
Isolator Termination W BK To Next Fieldbus
Cable Assembly Isolator Termination
(See Notes 1, 2 and 4) BK W Cable Assembly
SH (See Notes 1, 2, 3 and 4)

F F- S
F F- S

Fieldbus
A

B
BR G/Y
F+ F- SH
To Splitter/Terminator
(P0926LC)

Notes:
1. Earth the shield (terminal 3) at the termination cable assembly farthest from the FCP270
baseplate.
2. Install terminating resistors at both ends of the extended fieldbus cable. For the last TCA
in the fieldbus, install the termination resistor between terminals 1(F) and 2(F-) and the
earth (ground) wire (14 Gauge) must connect to terminal 3(S) as shown in Figure 2-6.
3. If this TCA is the last TCA in the fieldbus, the cable on this side of the TCA will not be
added.
4. Earth (ground) the surge protection network contained within the TCAs by attaching the
green earth wire to a screw on the DIN rail connected to system earth. For more
information on earthing, see Power, Earthing (Grounding), EMC and CE Compliance
(B0700AU).

Figure 2-11. Example of Extending Fieldbus in Two Directions from FCP270

46
2. Installing the Field Control Processor 270 B0700AR – Rev N

Decommissioning an FCP270 Module

You can decommission an FCP270 module that you no longer plan to use. For example, you want
to remove the FCP270 from the system and place it into storage.

WARNING
POTENTIAL DEATH OR SERIOUS INJURY

For safety reasons, always consider the possible impact on plant

operations before removing an FCP270 module from a baseplate in an
active control system. Interrupting plant operations while the plant is
running has the potential to cause injury within the plant.

Failure to follow these instructions can result in death or serious

injury.

Perform the following procedure to maintain that when you remove the module for use in
another application, the module will not load a stale checkpoint file out of its flash memory.
Proceed as follows:
1. Plug the module into the system without connecting to the Foxboro DCS Control
Network.
2. Set the station letterbug to a non-existent value, such as NOSUCH, using the
I/A Series Letterbug Configurator.
3. Allow the module to reboot to accept the new letterbug.
4. Read the module status with the I/A Series Letterbug Configurator. The letterbug
should be the non-configured value, and the IP address should be 255.255.255.255.
The FCP270 module can be removed now.

47
B0700AR – Rev N 2. Installing the Field Control Processor 270

48
3. Configuration Information
In general, “configuration” refers to the act of specifying to the Control Core Services the types of
hardware and software modules that comprise the system, and the control blocks that will be used
in the control scheme. Prior to performing configuration procedures, you are encouraged to
develop I/O signal lists. You should develop loop control schemes and loop drawings to document
the control scheme. From the signal lists and loop drawings, you can determine the type and
quantity of equipment required for your control scheme.

System Definition
Your system configurator application is used to identify the Foxboro DCS system components,
system software required by each component, the system component letterbugs, and other system
characteristics for correctly loading system software and identifying the system software objects.
System definition with your system configurator produces the Commit media, which is required
for software installation and, therefore, must be completed before software installation. It is
initially performed prior to installation of the system equipment, and it is updated with any
hardware/software system changes. Reports produced by the system configurator define the
network of the system and provide information that can be used in conjunction with equipment
installation. In the future, if changes are made to the initial hardware layout, the system definition
database must be updated to reflect these changes.
Using the system configurator, you define the type and quantity of FCP270s and associated
FBMs, their letterbugs, and the software (for example, digital input, ladder logic, and so forth) for
the FBMs. Letterbugs are unique, 6-character strings that identify stations, such as FCP270s and
FBMs, to the Foxboro DCS system software.

NOTICE
POTENTIAL DATA LOSS

Before loading a SaveAll control database from a CP60 or previous

control processor onto an FCP270, make sure all the ECBs are
supported by the FCP270. For example, ECB110 (for FCM10s) is not
supported by the FCP270.
If you do not do this, this will block ALL the ECBs (invalid and valid)
from being loaded into the new FCP270.

Failure to follow these instructions can result in data loss.

49
B0700AR – Rev N 3. Configuration Information

System Definition Procedure

To perform system definition, configure the Foxboro DCS system as described in the
corresponding document provided with your system configurator.
After you have completed system definition, install the system software. See the appropriate
Hardware and Software Specific Instructions for your workstation.
To use Y-module FBMs (100 Series FBMs) with your FCP270s, use your applicable system
configurator to create and configure the required ECBs. See the documentation included with
your system configurator to complete the process.

System Configuration
When you have defined and installed the FCP270, you are ready to configure your control system
and download the control database to the FCP270. System configuration comprises designing
your control strategy loop diagrams and configuring the compounds and control blocks for these
loops. The FCP270 control database consists of configuration data for the compounds and
associated control blocks, including Equipment Control Blocks (ECBs) required for the FBMs
and the FCP270.
As a compound/block editor, the Schneider Electric system configurators provide compound or
block building templates along with a full range of editing functions.
In general, you create a compound in which to locate control blocks for a specific control strategy,
for example, the blocks required to control the outlet temperature of a heat exchanger. Then, you
create the blocks required for implementing the control strategy.
For each FBM, you create a specific ECB which serves as a “holding place” for the FBM data. The
primary ECB for the FCP270 control station is automatically created by the system configurator.
The ECBs provide the software interface between the I/O control blocks and the FBMs. Actual
control of the process is performed by compounds, consisting of control blocks, which you
configure. Figure 3-1 shows a typical application of control blocks.

50
3. Configuration Information B0700AR – Rev N

4-20 MA Remote Setpoint

AIN

4-20 MA Meas.
AIN PID
FBM204 ECB2

4-20 MA Output
AOUT
To/From
Process

Contact
Out Alarm
Status High
COUT
Contact FBM241 ECB5 Alarm
Out Status Low
COUT

Control Compound

Primary
ECB

<Letterbug>_ECB Compound

FCP270 Controller

Foxboro DCS System Enclosure

Notes:
1. For ECB parameters definitions and ECB to FBM assignments, see
Integrated Control Block Descriptions (B0193AX).
2. The Primary ECB is automatically assigned to a compound named <Letterbug>_ECB,
for example, if an FCP letterbug is H51FCP, the compound name is H51FCP_ECB.
Figure 3-1. Typical Control Scheme Using an FCP270 and 200 Series FBMs

Available Foxboro DCS Control Blocks

The Control Core Services offer a wide range of control blocks, providing solutions for a broad
spectrum of process control applications. For details on the selection and usage of control blocks,
see Integrated Control Block Descriptions (B0193AX) and Integrated Control Block Descriptions for
Foundation fieldbus Specific Control Blocks (B0700EC).

System Configuration with Dual Baud Functionality

The FCP270 can communicate with both 200 Series FBMs (over 2 Mbps signals) and 100 Series
FBMs (over 268 Kbps signals) simultaneously when the FBI200 or FBI100 is properly installed
between the FCP270 and 100 Series FBMs. The FBI200 or FBI100 filter out the 2 Mbps signals,
allowing only the 268 Kbps signals through.

51
B0700AR – Rev N 3. Configuration Information

The process for setting up this hardware configuration with the FBI200 or FBI100 is discussed in
Standard and Compact 200 Series Subsystem User’s Guide (B0400FA).
The process for setting up this hardware configuration with the FBI200A is discussed in
100 Series Fieldbus Module Upgrade User's Guide (B0700BQ).
However, additional I/O overhead is incurred each BPC cycle for both inputs and outputs when
the FCP270 has to perform baud switching to accommodate the different I/O baud rates
(2 Mbps versus 268 Kbps).
The FCP270 scan order is based on the configuration order of compounds and ECBs for the I/O
input scan cycle and the I/O output scan cycle. For example, during the I/O input scan cycle, first
the ECB compound and all its ECBs are processed, followed by the first compound and all its
ECBs, following by the second compound and all its ECBs, and so forth. This is also the case for
the I/O output scan cycle.
To stop unnecessary baud switching and achieve maximum I/O scan efficiency, you must
configure your compounds and ECBs for all 100 Series FBMs, followed by all compounds and
ECBs for all 200 Series FBMs.
When upgrading 100 Series FBMs to 200 Series FBMs in a dual baud configuration, you only
need to change the configuration order if you wish to increase I/O performance. The increase in
200 Series FBMs performance versus 100 Series FBMs will compensate for any efficiency loss due
to baud switching.

52
4. System Management
The general Foxboro DCS system management philosophy applies to the Field Control Processor
270 in the Foxboro DCS system. Through the System Management Displays, you can receive
status information on the FCP270 and send change requests to the FCP270.
System management for the FBMs is supported on the following system management tools:
♦ System Manager v2.1 or later (supported on I/A Series system software v8.6-v8.8 and
Control Core Services v9.0 or later) - discussed in System Manager (B0750AP)
♦ SMDH - discussed in System Management Displays (B0193JC)
♦ FoxView™ - discussed in Process Operations and Displays (B0700BN)
The security of this system is maintained via the standard Foxboro control processor software and
the customer-engineered user interface to the control block database. All access to the I/O data is
through the control blocks. The end user has no direct access to any of the I/O functions or the
data in the FBMs.

Operating Status
The operating status of the FCP270 is reported by the Foxboro DCS system using on-screen and
printed messages. See the following documents for information on the reporting of equipment
operating status and detected errors:
♦ System Manager (B0750AP)
♦ System Management Displays (B0193JC)
♦ Control Core Services V9.x System Error Messages (B0700AF)
♦ Process Operations and Displays (B0700BN).

System Management Displays for the FCP270

The System Manager and System Management Display Handler (SMDH) allow you to access:
♦ Equipment information
♦ Configuration information
♦ Equipment change actions.
These displays reflect the system’s current operating status and provide a valuable maintenance aid
by allowing you to observe the current operating status of the various system elements and
intervene in system operations.
For information on navigating through the System Manager, see System Manager (B0750AP).
For information on navigating through the SMDH screens, see System Management Displays
(B0193JC).

53
B0700AR – Rev N 4. System Management

Equipment Information Display for FCP270

The SMDH Equipment Information display pages for the FCP270 contain operational status,
equipment change action status, hardware and software information. Table 4-1 describes the
available text fields in the order that they appear on the display pages, from left column to right
column.

54
4. System Management B0700AR – Rev N

Table 4-1. Equipment Information Display Fields for FCP270

Field Description
STATION NAME Controller letterbug assigned during definition of system hardware.
RUN MODE On-line or Off-line. This field is initially Off-line. It changes to On-
line when the FCP270 reports to the System Monitor after booting up.
If reporting is disabled, the last known state appears in this field.
RUN MODE and FAIL STATE should be viewed as separate, but
related fields. Although certain Equipment Change options change the
RUN MODE to Off-line, they do not cause the station to become
unavailable. However, an unavailable station will result in the RUN
MODE changing to Off-line.
The field changes to Off-line if any of the following occur:
♦ Reboot of the station
♦ EEPROM update
♦ Power interruption or unavailability
Any station hardware becoming unavailable or communication path
becoming unavailable that results in the station no longer being able
to send its internal reports for one minute or more.
For fault-tolerant stations, see the PRIMARY MODE and SHADOW
MODE fields for current RUN MODE of each module of the pair.

55
B0700AR – Rev N 4. System Management

Table 4-1. Equipment Information Display Fields for FCP270 (Continued)

Field Description
FAIL ACK STATE Acknowledged or Not Acknowledged. This field is initially set to
Acknowledged. If the FAIL STATE changes from Not Failed to Failed,
the FAIL ACK STATE field changes to Not Acknowledged to indicate
this transition. Use the ACK key in the top menu bar of the
Equipment Information Display to acknowledge the selected
unavailable device or use the ACK ALL key in the top menu bar of the
initial System Management Display to acknowledge all the
unacknowledged devices for which the workstation has responsibility.
FT STATE Fault-Tolerant State is Operational or Non-Operational for fault-
tolerant controllers only. FT STATE indicates Non-Operational if the
shadow module is not installed/configured.
FAIL DEV ACK Acknowledged or Not Acknowledged. This field is initialized to
Acknowledged. If any of the attached devices become
unacknowledged, the field changes to Not Acknowledged.
EE UPDATE STATE EE Updating or Not Updating. This field is initially set to Not
Updating. When IMAGE UPDATE is selected under Equipment
Change options, the status changes to EE Updating until the FCP270
image (operating system software) has been burned to flash memory.
For fault-tolerant stations, see the PRIMARY MODE and SHADOW
MODE fields for the current EEPROM Updating State. For more
information, see “Image Update Procedure for a Non-Fault-Tolerant
FCP270” on page 63.
SM REPORT STATE Report All or No Reporting. This refers to the type of internal
reporting taking place from the Station Manager to the System
Monitor. The various states are selectable from the Equipment Change
Display ENABLE ALL REPORTS and DISABLE ALL REPORTS.
The default setting is Report All.
TYPE Type of controller defined when the letterbug is assigned during the
site planning and system definition phases. Field Control
Processor 270 has the type Fld Ctl Proc270.

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4. System Management B0700AR – Rev N

Table 4-1. Equipment Information Display Fields for FCP270 (Continued)

Field Description
FAIL STATE Failed or Not Failed. This field is initially Not Failed. This field
changes to Failed if any of the following occur:
♦ A hardware problem causes the station to becoming unavailable
for more than two minutes
♦ A physical pull/push of the station (requiring more than two
minutes to come back on-line) is performed
♦ Any station hardware becoming unavailable or communication
path becoming unavailable that results in the station no longer
being able to send its internal reports for one or more minutes.
Operator-initiated Equipment Change actions (REBOOT, IMAGE
UPDATE) change the RUN MODE to off-line, but do not change the
FAIL STATE to Failed.
For fault-tolerant stations, see the PRIMARY MODE and SHADOW
MODE fields for the current FAIL STATE of each
module in the fault-tolerant pair.
ALARMING STATE Enabled or Inhibited. This field indicates whether alarming for system
alarms, not process alarms, is Enabled or Inhibited for the station.
When alarming is Inhibited, the System Monitor continues to indicate
overall system and network health (a green “Sys” bar) while equipment
is unavailable or off-line. Additionally, when alarming is inhibited,
System Alarm messages are not logged to the system printer, nor the
Historian.
FAIL DEV ATT Yes or No. Yes if one or more peripherals attached to the controller are
unavailable.
DIAG STATE Not Active is always displayed because there are no off-line diagnostics
for the FCP270 station.
DOWNLOAD STATE Downloading or Not Downloading. This field is initially set to Not
Downloading. When the station is rebooted via an operator-initiated
request, the status changes to Downloading until the action is
completed. For fault-tolerant stations, see the PRIMARY MODE and
SHADOW MODE fields for the current Downloading State.
CABLE STATE Both Cables Okay or Fault. This field indicates if there is a cable Fault
on either the Foxboro DCS Control Network cables A or B, or both.
PRIMARY MODE Single Primary, Married Primary, EE Updating, Downloading or
Failed appears for fault-tolerant controllers.
PRIM ROM ADDRESS A six-octet Media Access Control (MAC) address of the Primary
controller assigned during manufacturing. The Manufacturing ID,
labeled on the left side of the module, is the last six characters of this
address, for example, 220626 in the screenshot above.
PRIM HARD PART Primary controller hardware part number.
PRIM HARD REV Primary controller hardware revision number. Typically, for an
FCP270 this part number is P0917YZ.
PRIM HARD DATE Primary controller hardware manufacturing date.

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Table 4-1. Equipment Information Display Fields for FCP270 (Continued)

Field Description
PRIM EEPROM REV Primary controller EEPROM revision level.
STATION ADDRESS Six-octet MAC address. This field specifies a unique MAC address that
other stations in the system use to communicate with the FCP270.
SHADOW MODE Married Shadow, EE Updating, Downloading, Failed, or Off-line
appears for fault-tolerant controllers. A non-existent shadow module is
marked as Off-line.
SHD ROM ADDRESS Last known six-octet MAC address of the shadow controller. This is
assigned during manufacturing. The last six characters of this address
are the module hardware ID, which is stamped on a label on the
module’s left side. For a non-existent shadow module, this field is all
zeroes.
SHAD HARD PART Last known shadow controller hardware part number. This field is
blank if the shadow controller does not exist.
SHAD HARD REV Last known shadow controller hardware revision number. This field is
blank if the shadow controller does not exist.
SHAD HARD DATE Last known shadow controller hardware manufacturing date. This
field is blank if the shadow controller does not exist.
SHAD EEPROM REV Last known shadow controller EEPROM revision level. This field is
blank if the shadow controller does not exist.
MT REPORT STATE Indicates the status of UTC time and time strobe from the Main
Timekeeper (MTK), as received by the FCP270.

STATE Description
Pulsed STK FCP270 is receiving UTC time from MTK
and time strobe from both ports A and B.
Sync_A_In_Fail FCP270 is receiving UTC time from MTK
and time strobe only from port B.
Sync_B_In_Fail FCP270 is receiving UTC time from MTK
and time strobe only from port A.
Sync_AB_In_Fail FCP270 is receiving UTC time from MTK,
but lost time strobe from ports A and B.
Sync_not_Cfg FCP270 is not configured as a Sync Pulse
station.

Configuration Information Display for FCP270

The SMDH Configuration Information display for the FCP270 contains system domain and
network configuration information. You can use the information shown in this display when
diagnosing system problems. Table 4-2 describes the available text fields in the order that they
appear on the display, from left column to right column.

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Table 4-2. Configuration Information Display Fields for FCP270

Field Description
STATION NAME Controller letterbug assigned during definition of system hardware.
SMON NAME System monitor name for the selected FCP270.
LI NAME Not applicable (N/A)
IP ADDR Internet Protocol network address. Assigned by system during system
definition phases.
SW CONNECTION Ethernet switches to which the FCP270 is connected, per system
configuration.
TYPE Type of station defined when the letterbug is assigned during site
planning and system definition phases. This should read
Fld Ctl Proc270.
SMON AP NAME Name of the application workstation that hosts the controller’s system
monitor.
BOOT HOST Boot image host name for the selected FCP270.

Equipment Change Display for FCP270

You can use the SMDH Equipment Change display for the FCP270 to perform equipment
change actions on the selected controller. Only workstations designated (during System Monitor
configuration) to perform actions on this FCP270 can access the equipment change actions.
Table 4-3 describes the actions that are available for this display.

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WARNING
POTENTIAL DEATH OR SERIOUS INJURY

Only designated personnel who are aware of the effects of making

equipment changes should initiate equipment changes. Interrupting
plant operations while the plant is running has the potential to cause
injury within the plant.

Failure to follow these instructions can result in death or serious

injury.

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Table 4-3. Equipment Change Display Fields for FCP270

Action Description
CHECKPOINT Saves operator set values and process tuning changes for a controller
COMMAND to the checkpoint file in the host file server. To retain these changes,
you must save them to the host file server checkpoint file before you
reboot (restart) the controller. This checkpoint file contains an
image of the current database. When you reboot (restart) the
controller, the system downloads the current checkpoint file to the
controller to update its database. Checkpointing takes
approximately 5 seconds to 30 seconds depending on the database
size.
ENABLE STATION Enables the controller system alarms to be propagated up the
ALARMING equipment hierarchy and enables controller system alarm messages.
This action does not affect process alarms.
INHIBIT STATION Keeps the controller system alarms from being propagated up the
ALARMING equipment hierarchy and disables controller system alarm messages.
Does action not affect process alarms.
REBOOT STATION Restarts the FCP270 and reloads the checkpoint file, which contains
an image of the controller database, from the host file server if
ENABLE DOWNLOAD is active on the Equipment Change
display.
IMAGE UPDATE Updates the existing FCP270 software image in flash memory with
new software image if ENABLE DOWNLOAD is active on the
Equipment Change display. The update downloads a file and burns
it to flash memory. The system printer logs the update results.

Selecting IMAGE UPDATE for a fault-tolerant FCP270 and

selecting “Yes” in the dialog box initiates the EEPROM update to
both modules of the fault-tolerant pair. Once initiated, the IMAGE
UPDATE process is entirely automatic. The fault-tolerant FCP270
places the Shadow module off-line and then downloads and burns
the new code in the Primary module. After verification, the Primary
reboots automatically. When the Primary finishes rebooting it sends
the new image to the Shadow. The Shadow reboots and the module
pair marries using the new code. IMAGE UPDATE takes
approximately 1 minute to 5 minutes depending on database size.
ENABLE UPLOAD Enables uploading of the station image to a file on the host file
server if the controller becomes unavailable.
DISABLE UPLOAD Disables uploading of the station image to a file on the host file
server if the controller becomes unavailable.
ENABLE DOWNLOAD Enables download of files needed for REBOOT STATION,
IMAGE UPDATE and ON-LINE IMAGE UPDATE actions.
DISABLE DOWNLOAD Disables download of files needed for REBOOT STATION,
IMAGE UPDATE and ON-LINE IMAGE UPDATE actions.

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Table 4-3. Equipment Change Display Fields for FCP270 (Continued)

Action Description
ENABLE ALL REPORTS Enables reporting of all status for the controller and any attached
devices, and reporting of system and peripheral counters to the
System Monitor.
DISABLE ALL REPORTS Disables reporting of all status for the controller and any attached
devices and reporting of system and peripheral counters to the
System Monitor.
ON-LINE IMAGE Allows you to update the software image on a fault-tolerant
UPDATE FCP270, with minimum hold-control time. For more information,
see “Image Update Procedure for a Fault-Tolerant FCP270” on
page 63.

The REBOOT STATION, IMAGE UPDATE (EEPROM Update) and ON-LINE IMAGE
UPDATE actions and their procedures are described below.

NOTE
For more information and procedures for performing equipment change actions,
see System Management Displays (B0193JC).

Reboot Station Procedure

The REBOOT STATION action restarts the selected FCP270 and reloads its control database
from a file server. While the station is rebooting, it is off-line until the reboot is complete; this
suspends any access to the station database. Rebooting typically is used during system
maintenance and upgrades.
To reboot an FCP270 station:
1. Access the Equipment Change Display for the desired FCP270 (see System
Management Displays (B0193JC).
2. In the Equipment Change Display, check that the Enable Download state is active. If
it is not, click ENABLE DOWNLOAD.
To check that download is currently enabled, verify that the ENABLE DOWNLOAD
button is back-lighted dark cyan.
3. Click REBOOT STATION.
If this is a fault-tolerant FCP270 station, a dialog box offers choices for primary
module, shadow module, or both. The dialog box displays the MAC address and
status of the primary and shadow modules.

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The following module operational statuses can be displayed:

M PRIM = married primary, M SHAD = married shadow, S PRIM = single primary
4. Click the module to reboot. The system reboots that module.
If there is a detected error, the system displays a message on the screen and/or at the
system printer. See Control Core Services V9.x System Error Messages (B0700AF).

Image Update Procedure for a Non-Fault-Tolerant FCP270

The IMAGE UPDATE action updates the existing image (operating system software) in the
selected FCP270’s EEPROM flash memory with a new image. The update downloads a file and
burns a new image to flash memory.

WARNING
POTENTIAL DEATH OR SERIOUS INJURY

The IMAGE UPDATE command allows you to upgrade the existing

image (operating system software) in a non-fault-tolerant FCP270,
while interrupting process control for the duration of the image update.
IMAGE UPDATE takes approximately 1 minute to 5 minutes
depending on database size.

Interrupting plant operations while the plant is running has the

potential to cause injury within the plant.

Failure to follow these instructions can result in death or serious

injury.

To update the existing image in flash memory for a non-fault-tolerant FCP270 station, see the
Control Processor 270 (CP270) On-Line Image Update (B0700BY) document.

NOTE
If self-hosting is enabled during an Image Update procedure, the checkpoint files in
flash will be invalidated forcing the checkpoint file to be loaded from the host work-
station. When the procedure is complete and the Database Download is complete, a
checkpoint command will automatically be issued that will result in the checkpoint
file being burned to flash.

Image Update Procedure for a Fault-Tolerant FCP270

The IMAGE UPDATE action updates the existing image (operating system software) in the
selected FCP270’s EEPROM flash memory with a new image. The update downloads a file and
burns a new image to flash memory in both modules of the fault-tolerant FCP270.
The ON-LINE IMAGE UPDATE command allows you to upgrade the existing image (operating
system software) in an on-line, fault-tolerant FCP270, while interrupting process control for only
1.5 seconds, approximately.

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To update the existing image in flash memory for a fault-tolerant FCP270 station, see the Control
Processor 270 (CP270) On-Line Image Update (B0700BY) document. While IMAGE UPDATE
runs, the system sends standard EEPROM update progress messages to the system printer.
IMAGE UPDATE takes approximately 1 minute to 5 minutes depending on database size.

NOTE
Selecting IMAGE UPDATE for a fault-tolerant FCP270 automatically updates
both modules of the fault-tolerant pair. Once initiated, the IMAGE UPDATE pro-
cess is entirely automatic.

NOTE
If self-hosting is enabled during an Image Update procedure, the checkpoint files in
flash will be invalidated forcing the checkpoint file to be loaded from the host work-
station. When the procedure is complete and the Database Download is complete, a
checkpoint command will automatically be issued that will result in the checkpoint
file being burned to flash.

Messages Following Checkpoint Operation in Self-Hosting FCP270

The Checkpoint action saves the checkpoint file database on the host workstation, and if the self-
hosting capability of the FCP270 controller is enabled, the checkpoint file is also burned to the
controller’s flash memory. When a checkpoint command is issued, the FCP270 sends it's control
database to the host workstation and if self-hosting is enabled, the FCP270 will send a request to
the host workstation requesting that checkpoint file to be sent back to the FCP270 to be burned
into flash memory.
When self-hosting is disabled, you will see a message similar to the following after successfully
completing a checkpoint action:
10-31-07 09:58:38 0 SYSMON = SYSMN1 CP0008 Software Manager
SYSMON -00021 Checkpoint Successful
The following is an example of the series of messages (dates are provided as examples in the format
YYYY-MM-DD HH:MM:SS) that are sent to the System Monitor log when performing a
checkpoint with self-hosting enabled. It is important to note that the checkpoint operation is not
complete until the message “Checkpoint installed into flash” appears in the SMON log. When
“Checkpoint installed into flash” appears in the SMON log, the checkpoint file has been sent to
the host workstation and burned into the FCP270 flash memory.
2007-10-17 14:25:51 FP0101 Process = Checkpoint CIO_DB 000015 -
Checkpoint to Flash Requested
2007-10-17 14:25:51 FP0101 Process = Checkpoint CIO_DB 000015 -
Wait For Message 'Checkpoint installed into flash'
2007-10-17 14:26:33 FP0101 Software Manager SYSMON -00021
Checkpoint Successful
2007-10-17 14:26:35 FP0101 Process = Self Hosting RDHSS 000131 -
Checkpoint loading to Flash
2007-10-17 14:27:15 FP0101 Process = Self Hosting RDHSS 000131 -
Backup Checkpoint erased
2007-10-17 14:29:27 FP0101 Process = Self Hosting RDHSS 000131 -
Checkpoint File verified

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2007-10-17 14:29:28 FP0101 Process = Self Hosting RDHSS 000131 -

Checkpoint installed into flash
These messages are explained in Table 4-4.

Table 4-4. SMON Log Messages Following Checkpoint Operation

Message Definition Meaning

Checkpoint to This message indicates a The checkpoint process has started. The
Flash Requested checkpoint command has been checkpoint file has not been written to the
issued and self-hosting is Host or FCP270 flash. If the FCP270 is
enabled. If self-hosting is rebooted after this message, the FCP270
disabled, this message will not will load the checkpoint file out of flash.
be sent to the SMON log. The loaded checkpoint file from flash will
not contain any changes that were made
prior to issuing the checkpoint command.
Wait For This message is a reminder to The checkpoint process has started. The
Message you that the checkpoint checkpoint file has not been written to the
'Checkpoint
operation will not be complete Host or FCP270 flash. If the FCP270 is
installed into
flash' until the message “Checkpoint rebooted after this message, the FCP270
installed into flash” has been will load the checkpoint file out of flash.
sent. If self-hosting is disabled, The loaded checkpoint file from flash will
this message will not be sent to not contain any changes that were made
the SMON log. prior to issuing the checkpoint command.
Checkpoint This message indicates the The checkpoint file has been written to the
Successful checkpoint file was successfully host but not the FCP270 flash. If the
sent to the host workstation FCP270 is rebooted after this message, the
only. It is not an indication FCP270 will load the checkpoint file out
that the complete checkpoint of flash. The checkpoint file will not
operation is complete if self- contain any changes that were made prior
hosting is enabled. This to issuing the checkpoint command.
message is sent to the SMON A checkpoint command should be issued
log if self-hosting is enabled or to synchronize both checkpoint files. Once
disabled. the checkpoint command completes, the
changes will be lost. If you want to
load/use the checkpoint file and contains
the latest changes to the host, the flash in
the FCP270 must be invalidated (that is,
disable self-hosting or reconfigure the
letterbug) and the FCP270 must be
rebooted. This will force the FCP270 to
load the checkpoint file from the host.

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Table 4-4. SMON Log Messages Following Checkpoint Operation (Continued)

Message Definition Meaning

Checkpoint This message indicates that the The checkpoint file has been written to the
loading to process of downloading the host but not the FCP270 flash. If the
Flash
checkpoint file from the host FCP270 is rebooted after this message, the
to be burned into the FCP270 FCP270 will load the checkpoint file out
flash area has begun. If self- of flash. The loaded checkpoint file from
hosting is disabled, this flash will not contain any changes that
message will not be sent to the were made prior to issuing the checkpoint
SMON log. command. The checkpoint file on the host
and the checkpoint file in flash of the
FCP270 will not match. A checkpoint
command should be issued to sync up both
checkpoint files.
Once the checkpoint command completes,
the changes will be lost. If you want to
load/use the checkpoint file that contains
the latest changes from the host, the flash
in the FCP270 must be invalidated (that is,
disable self-hosting or reconfigure the
letterbug) and the FCP270 must be
rebooted. This will force the FCP270 to
load the checkpoint file from the host.
Backup The flash area that is to receive The checkpoint file has not been written to
Checkpoint the new checkpoint file has the FCP270 flash. The area that is to
erased
been erased and is ready for the receive the checkpoint file has been erased
checkpoint file to be burned. If but the previous area still contains a valid
self-hosting is disabled, this checkpoint file. If the FCP270 is rebooted
message will not be sent to the after this message, the FCP270 will load
SMON log. the checkpoint file out of flash. The loaded
checkpoint file from flash will not contain
any changes that were made prior to
issuing the checkpoint command. The
checkpoint file on the host and the
checkpoint file in flash of the FCP270 will
not match. A checkpoint command should
be issued to sync up both checkpoint files.
Once the checkpoint command completes,
the changes will be lost. If you want to
load/use the checkpoint file that contains
the latest changes from the host, the flash
in the FCP270 must be invalidated (that is,
disable self-hosting or reconfigure the
letterbug) and the FCP270 must be
rebooted. This will force the FCP270 to
load the checkpoint file from the host.

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Table 4-4. SMON Log Messages Following Checkpoint Operation (Continued)

Message Definition Meaning

Checkpoint File The checkpoint file has been The checkpoint file has been written to the
verified burned to flash and has been FCP270 flash and marked valid. If the
verified that it is an exact copy FCP270 is rebooted after this message, the
of the checkpoint file on the FCP270 will load the checkpoint file out
host workstation. The of flash. The checkpoint file will contain
checkpoint file in flash will be all changes that were made prior to issuing
marked as valid. If self-hosting the checkpoint command. The checkpoint
is disabled, this message will file on the Host and the checkpoint file in
not be sent to the SMON log. flash of the FCP270 are identical.
Checkpoint The checkpoint operation is The checkpoint file has been written to the
installed into complete. The checkpoint file FCP270 flash and marked valid. If the
flash
has been sent to the host FCP270 is rebooted after this message, the
workstation and burned into FCP270 will load the checkpoint file out
the FCP270 flash. of flash. The checkpoint file will contain
all changes that were made prior to issuing
the checkpoint command. The checkpoint
file on the Host and the checkpoint file in
flash of the FCP270 are identical.

NOTICE
POTENTIAL DATA LOSS

If self-hosting is enabled, the message “Checkpoint Successful” only

indicates that the checkpoint file has been sent to the host
workstation. If a station reboot were to occur prior to the message
“Checkpoint installed into flash”, the newest checkpoint file would not
be burned in the FCP270 flash. Always wait for the message
“Checkpoint installed into flash” to maintain the latest checkpoint file is
burned correctly into the FCP270 flash area.

Failure to follow these instructions can result in data loss.

Checkpoint Invalidation in Self-Hosting FCP270

There are some conditions that exist that will result in the checkpoint in flash to be invalidated.
An invalid checkpoint file in flash results in the FCP270 loading the checkpoint file from the host
workstation on reboots.
The following is a list of conditions that result in the checkpoint file in flash to be invalidated:
♦ If the letterbug of an FCP270 is changed, the checkpoint file in flash is invalidated.
This helps ensure the checkpoint file from the host workstation is loaded and not a
leftover checkpoint file in flash.

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♦ If an FCP270 in self-hosting mode does not load the checkpoint file from flash suc-
cessfully, the checkpoint file in flash is invalidated. The checkpoint file not loading
from flash properly indicates there is some form of corruption on the database. The
station will be rebooted forcing the FCP270 to load the checkpoint file from the host
workstation.
♦ If an FCP270 with a valid checkpoint file in flash marries into a Single Primary
FCP270 operating with self-hosting disabled, the newly booted module will invalidate
the checkpoint file in flash and reboot to complete the marriage. This keeps that mod-
ule from loading the checkpoint file from flash in the event the station is rebooted
causing that module to come up as the primary module.
♦ If an On-line Image Update or Image Update operation is performed, the checkpoint
file in flash is invalidated forcing the checkpoint file to be loaded from the host work-
station. Only after the On-line Image Update or Image Update operation is complete
will the checkpoint file be burned to flash.
♦ If one module of a fault-tolerant pair does not burn to flash successfully and the other
module successfully burns to flash memory, the module that does not burn to flash
will invalidate the checkpoint in flash and go off-line. The module that successfully
burns to flash will switch to Single Primary mode and send a message to the SMON
log indicating why the other module went off-line.
♦ If both modules of a fault-tolerant pair do not burn to flash successfully, both modules
will invalidate the checkpoint in flash and send a message to the SMON log. The sta-
tion will continue to run fault-tolerant.
♦ If a Single Primary module does not burn to flash successfully, the module will invali-
date the checkpoint in flash and send a message to the SMON log. The station will
continue to run single.
♦ If one side of a fault-tolerant pair goes off-line while running in self-hosting mode, the
off-line modules flash will be invalidated the next time the Single Primary module
performs a checkpoint.
If any of the above conditions occurred and:
♦ a checkpoint command is issued before the station has been rebooted, there will be an
attempt to burn the checkpoint file to the flash of the FCP270 if self hosting is
enabled.
♦ the station is rebooted before a checkpoint command is issued, the checkpoint file will
be loaded from the host workstation. In addition, if self hosting is enabled, a check-
point command will be automatically issued after the Database Download is
complete. This will result in the checkpoint file getting burned to flash.
These actions can keep an incorrect checkpoint file from being loaded.

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System Management Displays – Primary ECB (FBM0)

The System Management Display Handler allows you to access the following displays for FBM0,
which is actually the primary ECB (ECBP), which resides in the FCP270 station.
♦ Equipment information
♦ Equipment change actions
♦ On-line diagnostics (PIO).
These displays reflect the current operating status of the Fieldbus and its attached devices, and
provide a valuable maintenance aid by allowing you to intervene in Fieldbus operations. For
information on navigating through the SMDH screens, see System Management Displays
(B0193JC).

Equipment Information Display for Primary ECB (FBM0)

The SMDH Equipment Information display pages for the Primary ECB (FBM0) contain
operational status, equipment change action status, device status, and power status fields. These
fields are updated when a status change occurs:

♦ RUN MODE ♦ DEVICE STATE

♦ FAIL ACK STATE ♦ ALARMING STATE
♦ CP POWER 1 ♦ ACTIVE PIO BUS
♦ SWITCHING MODE ♦ CP POWER 2
♦ DIAG STATUS 1
♦ PRIM CHK POINT ♦ SHAD CHK POINT
♦ SELF HOSTING

All other fields are either static, updated when the display is recalled, or unused. Table 4-5
describes the available text fields in the order that they appear on the display pages, from left
column to right column.

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Table 4-5. Equipment Information Display Fields for Primary ECB (FBM0)

Field Description
NAME The letterbug of the FCP270 in which the primary ECB (FBM 0) is
located.
RUN MODE On-line or Off-line. The primary ECBP is installed as On-line after
it is configured. For the primary ECB (FBM0) located in an
FCP270, changing the FBM0 status to Off-line stops all
communication to the Fieldbus. Subsequently, all attached FBMs
become unavailable. As a result, a number of messages appear at the
printer indicating communication interruptions and peripheral
equipment becoming unavailable.
Changing an FBM status to Off-line causes communications to that
specific device to stop.
You can change the RUN MODE using the GO ON-LINE and GO
OFF-LINE options in the Equipment Change Display. If station
reporting is disabled, the last known run state appears in this field.
The system updates this field when a status change occurs.
FAIL ACK STATE Displays Acknowledged (default) or Not Acknowledged. If the
DEVICE STATE value changes from Not Failed to Failed, the value
in this field changes to Not Acknowledged.
Click ACK in this display to acknowledge the selected non-
operational device; or click ACK ALL in the initial system
management display to acknowledge all unacknowledged devices for
which the workstation is responsible.
The system updates this field when a status change occurs.
Not Acknowledged Status: Check printed/historical log for type of
condition in which equipment or communications became
unavailable. To clear, click ACK or ACK ALL on the configured
application workstation (AW/WSTA70/WSVR70).
DOWNLOAD STATE This field does not apply to FBM0. It displays “Not Downloading”.
FAIL DEV ATT This field does not apply to FBM0. It displays “No”.
CP POWER 1 OK or Failed indicates the state of primary power to FCP270.
SWITCHING MODE Displays Enabled (default) or Not Enabled. If Enabled, automatic
switching can occur in the event of a bus fault for the BUS AUTO
SELECT mode.
You can change this field to Not Enabled by selecting SELECT
BUS A ONLY or SELECT BUS B ONLY in the Equipment Change
Display.
DIAG STATUS 2 This field does not apply to FBM0. It displays “0”.
DIAG STATUS 4 This field does not apply to FBM0. It displays “0”.
SOFTWARE TYPE This field does not apply to FBM0. It displays “0”.
PRIM CMD STAT This field does not apply to FBM0. It displays “0”.
FBM STATUS This field does not apply to FBM0. It displays “0”.
HARDWARE REV This field does not apply to FBM0. It displays “00”.

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Table 4-5. Equipment Information Display Fields for Primary ECB (FBM0) (Continued)

Field Description
SERIAL NUMBER This field does not apply to FBM0.
EEPROM REV This field does not apply to FBM0.
TYPE FBM0 represents the primary ECB.
DEVICE STATE The system updates this field when a status change occurs. The
possible mutually exclusive states are:
♦ Not Failed: The device is healthy.
♦ On Scan: The device is connected to the control strategy,
though measurements may not be accurate.
♦ Comm Failures: No real device information is available.
♦ Failed: Hardware has become unavailable or another similar
fault is reported by the device. Presupposes that communication
continues unabated.
♦ Not Ready: A transition state. The device is healthy and normal
automatic start-up procedures are bringing the device On Scan.
♦ Out of Service: The device is healthy, but is operating in a mode
incompatible with its normal control functions.
ALARMING STATE Indicates whether alarming is enabled or inhibited for this device.
When alarming is inhibited, the System Monitor continues to
indicate overall system and network health while equipment is non-
operational or off-line, and any system alarm messages are not logged
to the system printer or to the Historian.
The system updates this field when a status change occurs.
Not Responding or Not Acknowledged status: Check the hardware.
DEVICES ATT This field does not apply to FBM0. It displays “No”.
ACTIVE PIO BUS Indicates the current Fieldbus, either BUS A ONLY, BUS B ONLY,
or BUS A & B AUTO. This value is set initially to BUS A ONLY or
to the value saved in the checkpoint file. If SWITCHING MODE is
enabled, this field updates automatically if you switch
communications on the current Fieldbus to the other Fieldbus. BUS
A & B AUTO indicates that both Bus A and Bus B are active, and
the FCP270 determines which bus to use for each transaction.
CP POWER 2 OK or Failed indicates the state of secondary power to FCP270.
DIAG STATUS 1 Indicates CP Power status:
0 = CP Power 1 okay & CP Power 2 okay
1 = CP Power 1 Failed
2 = CP Power 2 Failed
DIAG STATUS 3 This field does not apply to FBM0. It displays “0”.
HARDWARE TYPE This field does not apply to FBM0. It displays “0”.
LOGICAL ADDR This field does not apply to FBM0. It displays “ff”.
FBM CMD STATUS This field does not apply to FBM0. It displays “0”.
HARDWARE PART NO. This field does not apply to FBM0.
DATE This field does not apply to FBM0.

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Table 4-5. Equipment Information Display Fields for Primary ECB (FBM0) (Continued)

Field Description
SOFTWARE REV This field does not apply to FBM0.
PRIM CHK POINT Indicates the number of flash write operations which have occurred
to the primary module’s flash memory.
SHAD CHK POINT Indicates the number of flash write operations which have occurred
to the shadow module’s flash memory.
SELF-HOSTING Indicates the station mode - “Disabled” (default) or “Enabled”.

Equipment Change Display for Primary ECB (FBM0)

You can use the SMDH Equipment Change display for the Primary ECB (FBM0) to perform
equipment change actions on Fieldbus communications and FBMs attached to the Fieldbus.
Only workstations designated (during System Monitor configuration) to perform actions on this
FCP270 can access the equipment change actions for FBM0. Table 4-6 describes the actions that
are available for this display.
In this figure, the following fields are not used:

♦ DOWNLOAD ♦ RESET ATTENTION BIT

♦ EEPROM UPDATE ♦ SWITCH ROLES

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WARNING
POTENTIAL DEATH OR SERIOUS INJURY

Only designated personnel who are aware of the effects of making

equipment changes should initiate equipment changes. Interrupting
plant operations while the plant is running has the potential to cause
injury within the plant.

Failure to follow these instructions can result in death or serious

injury.

Table 4-6. Equipment Change Display Fields for Primary ECB (FBM0)

Action Description
GO OFF-LINE Stops all communication to the Fieldbus, which causes all attached
FBMs to fail. As a result, a number of messages appear at the
printer indicating communication failures and peripheral
equipment failures. It is recommended that you place an FBM0
off-line for diagnostic purposes only.
GO ON-LINE Starts Fieldbus communication to all attached FBMs. The system
sends a message to the designated printer.
GENERAL DOWNLOAD Downloads FBM images for all off-line/failed FBMs attached to
the selected FCP270. Use GENERAL DOWNLOAD when you
add a new FBM to the FCP270 and the FBM data is not already in
the checkpoint file. Typically, you use GENERAL DOWNLOAD
action to download FBM images after you perform integrated
control configuration on each of the new FBMs.
SELECT BUS A ONLY Designates Fieldbus A as the current bus and deactivates automatic
switching. If the selected bus is not available or is not functioning,
the previous bus selection is maintained. If there is a detected error,
the system displays a message.
SELECT BUS B ONLY Designates Fieldbus B as the current bus and deactivates automatic
switching. If the selected bus is not available or is not functioning,
the previous bus selection is maintained. If there is a detected error,
the system displays a message.
BUS AUTO SELECT Automatically switches between Fieldbus A and B. The FCP270
determines which bus to use for each transaction. If the selected
bus is not available or is not functioning, the previous bus selection
is maintained. If there is a detected error, the system displays a
message.
ENABLE DEVICE Enables device alarming from FBMs attached to the Fieldbus.
ALARMING System alarm messages are logged to the system printer or
Historian.

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4. System Management B0700AR – Rev N

Table 4-6. Equipment Change Display Fields for Primary ECB (FBM0) (Continued)

Action Description
INHIBIT DEVICE Prohibits device alarming for FBMs attached to the Fieldbus.
ALARMING When you select to prohibit alarming, the system filters alarm
conditions so that the System Monitor continues to indicate
overall system and network health while equipment is “failed” or
off-line. While alarming is prohibited, system alarm messages are
not logged to the system printer or the Historian.

NOTE
For more information and procedures for performing equipment change actions,
see System Management Displays (B0193JC).

Overview of Fieldbus Switching Mode

The FCP270 records the number of FBM access operations which have not succeeded per
fieldbus A and/or B and determines whether switching occurs. The system checks the other bus
(cable) to stop switching to a bad or worse bus.
These scenarios can occur:
♦ If the current fieldbus has some suboptimal conditions and the other bus has fewer or
no suboptimal conditions, the station automatically switches to the better bus if the
BUS AUTO SELECT mode is selected.
♦ If both buses have an equal number of FBM access operations which did not succeed,
the station continues transmission over the existing bus if the BUS AUTO SELECT
mode is selected.
♦ If SELECT BUS A ONLY or SELECT BUS B ONLY are selected the station
attempts to continue transmission over the selected bus regardless of the condition.

Using the Fieldbus Switching Options

There are three Fieldbus switching options available from the Equipment Change Display.
To automatically switch between Module Fieldbus A and B:
♦ In the Equipment Change Display, click BUS AUTO SELECT. Both Bus A and Bus B
are active, and the FCP270 determines which bus to use for each transaction. If the
selected bus is not available or is not functioning, the previous bus selection is main-
tained. If there is a detected error, the system displays a message.
To designate Fieldbus A as the current bus and deactivate automatic switching:
♦ In the Equipment Change Display, click SELECT BUS A ONLY. The system does not
check the current health of the bus. The system displays a message if a detected error
occurs.
To designate Fieldbus B as the current bus and deactivate automatic switching:
♦ In the Equipment Change Display, select SELECT BUS B ONLY. The system does not
check the current health of the bus. The system displays a message if a detected error
occurs.

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B0700AR – Rev N 4. System Management

Use the SELECT BUS A ONLY or SELECT BUS B ONLY switching actions for diagnostic purposes,
or when only one bus is available (such as when you are replacing a non-operational cable or
Modular Baseplate).

Overview of the General Download

The GENERAL DOWNLOAD action downloads FBM images for all off-line/non-operational
FBMs attached to a selected FCP270. This action is available from the primary FBM (FBM0) for
the FCP270.
Use the GENERAL DOWNLOAD action when you add a new FBM to the FCP270 and the
FBM data is not already in the checkpoint file. Typically, you use the GENERAL DOWNLOAD
action to download FBM images after you perform integrated control configuration on each of
the new FBMs.
If the file information in the station already includes the selected FBM data (that is,
checkpointing was performed while the FBMs were on-line), downloading occurs automatically,
when necessary.

Downloading all FBM Images

You can download FBM images for all off-line, non-operational FBMs attached to a selected
FCP270 from the Equipment Change display. This option applies to the primary FBM (FBM0)
for the FCP270.
To download FBM images for all off-line/failed FBMs:
1. In the SMDH Equipment Change display, select GENERAL DOWNLOAD. This loads the
FBM images to all off-line/non-operational FBMs.
Messages indicating the success or non-success of the action for each downloaded
FBM appear. If the GENERAL DOWNLOAD action is successful, each FBM goes
on-line. If an operation does not succeed, the system displays a “Not Responding”
message.
2. If you use the GENERAL DOWNLOAD action during initial start-up, perform a
checkpoint from the FCP270 after downloading to all the FBMs. This preserves the
on-line state of the FBMs in the checkpoint file. See CHECKPOINT COMMAND
in Table 4-3 on page 61.

On-Line Diagnostics (PIO) Display for Primary ECB (FBM0)

You can use the SMDH On-line Diagnostics (PIO) display for the Primary ECB (FBM0) to
inhibit or enable PIO bus (Fieldbus) cable alarms. Only workstations designated (during System
Monitor configuration) to perform actions on this FCP270 can access the on-line diagnostics
actions for FBM0. Table 4-7 describes the actions that are available for this display.

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4. System Management B0700AR – Rev N

WARNING
POTENTIAL DEATH OR SERIOUS INJURY

Only designated personnel who are aware of the effects of making

equipment changes should initiate equipment changes. Interrupting
plant operations while the plant is running has the potential to cause
injury within the plant.

Failure to follow these instructions can result in death or serious

injury.

Table 4-7. Equipment Change Display Fields for Primary ECB (FBM0)

Action Description
ENABLE PIO BUS Enables PIO Bus A (Fieldbus A) cable alarms to monitor cable faults.
CABLE A ALARMS System alarm messages are logged to the system printer or Historian.
ENABLE PIO BUS Enables PIO Bus B (Fieldbus B) cable alarms to monitor cable faults.
CABLE B ALARMS System alarm messages are logged to the system printer or Historian.
INHIBIT PIO BUS Prohibits PIO Bus A (Fieldbus A) cable alarms. System alarm
CABLE A ALARMS messages are not logged to the system printer or Historian.

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Table 4-7. Equipment Change Display Fields for Primary ECB (FBM0) (Continued)

Action Description
INHIBIT PIO BUS Prohibits PIO Bus B (Fieldbus B) cable alarms. System alarm
CABLE B ALARMS messages are not logged to the system printer or Historian.

NOTE
For more information and procedures for performing on-line diagnostic actions, see
System Management Displays (B0193JC).

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5. Troubleshooting
In most cases, detected problems occur because the controller is misconfigured or there are
intermittent network connections. In the event of hardware becoming non-operational, the
Foxboro DCS maintenance approach is oriented toward module replacement. Any module can be
replaced without affecting the operation of any other module, including the other module of a
fault-tolerant pair.
The Station Block displays provide information to help you evaluate FCP270 performance. For
more information, see Integrated Control Block Descriptions (B0193AX) and Process Operations and
Displays (B0700BN).

LED Indicators, Reset Button, and Infrared Ports

Light-emitting diodes (LEDs) on the front of the FCP270 module (Figure 5-1) provide visual
indication of the module’s operational status and transmit/receive communications activity of the
Foxboro DCS Control Network A and B links. The red Reset button enables you to restart the
FCP270. The infrared communication ports enable you to assign or read the controller letterbug
and read controller status information using the I/A Series system Letterbug Configurator.
Table 5-1 describes these LEDs and controls.
The control network path Tx LEDs indicate which controller is primary as well as the network
path it is using; these LEDs are only active on the primary module.

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B0700AR – Rev N 5. Troubleshooting

Ethernet Switch A Communication

Activity Indicators

Operational Status LEDs

Reset Button (Recessed)

Infrared Communication Active LED

Fieldbus LED Indicators

Infrared Communication Port

Ethernet Switch B Communication

Activity Indicators

Figure 5-1. FCP270 LED Indicators, Reset Button, and Infrared Port

Table 5-1. FCP270 LED Indicators, Reset Button, and Infrared Communication Ports

Item Description
The Foxboro DCS Control Network A LED is on when the primary controller is transmitting
or B Tx data over control network A or B. LED is active only
on the primary controller.
The Foxboro DCS Control Network A LED is blinking when the controller is receiving data
or B Rx/Link over control network A or B. The LED is on when the
link is established. If the LED is off for more than 1 s,
the link is broken.
Green and Red Operational Status LEDs indicate the health of the controller. See “Using
LEDs the Operational Status LEDs” on page 82.

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Table 5-1. FCP270 LED Indicators, Reset Button, and Infrared Communication Ports (Continued)

Item Description
Reset Button Resets the controller. The controller’s database is
reloaded from the boot host workstation or from the
primary module.
IR Active LED LED is on when the I/A Series system Letterbug
Configurator is communicating with the controller to
assign, modify or read its letterbug.
Fieldbus A or B Tx LED is on when the primary controller is transmitting
data over fieldbus A or B. LED is active only on the
primary controller.
Fieldbus A or B Rx LED is on when the controller is receiving data over
fieldbus A or B.
Infrared communication port Enables assigning, modifying or reading the controller
letterbug and reading controller status information
using the handheld Letterbug Configurator.

Operational Status LED Indicators

The Operational Status LEDs (red and green) on the front of the FCP270 indicate the module’s
operational status. Table 5-2 describes the operational conditions indicated by these LEDs.

Table 5-2. FCP270 Operational Status LEDs

Red LED Green LED Status

OFF ON Module is on-line and functional. (This is the normal run state.)
OFF OFF No power, or a condition exists in which the green or red LED is
not turned on.
ON ON Start-up, or a condition exists in which the green LED is not turned
off. On power-up, the default condition of both LEDs is on. Once
the system is running, software turns off the red LED.
ON OFF Module is in “Failed” state, or it is running on-line diagnostics
during boot up.

FCP270 Troubleshooting
This troubleshooting information is written as a service guide for some of the most commonly
encountered system problems. Detected problems that surface in many cases are faults associated
with communication paths (cables, connectors, internal data and power buses, and so forth). At
the module (FCP270) level, the quickest way to determine and correct the problem is by
replacement. When spare parts are not available, the following checks may provide a practical
approach.

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WARNING
POTENTIAL DEATH OR SERIOUS INJURY

Do not attempt to repair modules in the field.

Interrupting plant operations while the plant is running has the

potential to cause injury within the plant.

Failure to follow these instructions can result in death or serious

injury.

WARNING
POTENTIAL DEATH OR SERIOUS INJURY

To reboot the FCP270, use System Management displays if possible.

This could lead to a loss of plant control.
Only designated personnel who are aware of the effects of making
equipment changes should initiate equipment changes.
For safety reasons, always consider the possible impact on plant
operations before placing the primary FCP270 module off-line or
rebooting it after the shadow module has become uanavailable.

Failure to follow these instructions can result in death or serious

injury.

Using the Operational Status LEDs

The Operational Status LEDs (red and green) on the front of the FCP270 (see Figure 5-1)
indicate the module’s operational status.

Red off, Green off

When the red and green LEDs are off, this typically indicates loss of dc power. Perform the
following checks. (These checks need not be followed in order.)
1. If other module(s) in the modular baseplate are operating correctly, then:
♦ Cycle power to the non-operational FCP270 module off then on by pulling the
module from the baseplate and pushing the module back on the baseplate. Make
sure you unscrew the two self-retaining hex screws on the module before pulling
the module from the baseplate (see “Replacing a Non-Operational Module” on
page 86).
♦ Replace the non-operational FCP270 module with a known good module to test
that slot in the baseplate (see “Replacing a Non-Operational Module” on
page 86).

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5. Troubleshooting B0700AR – Rev N

♦ Remove the FCP270 module and check the connector for bent pins. For module
removal procedures, see “Replacing a Non-Operational Module” on page 86).
2. Verify that the operational status LEDs on the front of the Schneider Electric power
supply (FPS400-24) are in the normal state (green LED is on, and red LED is off ).
3. Use a multimeter to verify that the dc voltage at the output connector is within the
range 21.6 to 25.2 V dc. For connector pin assignments, see the Standard and Com-
pact 200 Series Subsystem User's Guide (B0400FA).
4. Verify that the power cable is firmly connected to the baseplate and power supply.
5. If all modules on the baseplate have become non-operational and the Foxboro power
supply is operating normally, disconnect the power cable from the power supply and
baseplate, and use a multimeter to verify continuity of the cable conductors, or replace
the cable. For more information, see the Standard and Compact 200 Series Subsystem
User's Guide (B0400FA).
If none of the above checks resolve the condition keeping the module from functioning correctly,
you must replace the module.

Red on, Green off

When the red LED is on and the green LED is off, this indicates that the module was unable to
pass the startup diagnostics. This usually indicates a suboptimal condition with the hardware.
Hardware suboptimal conditions are typically internal to the FCP270 module, but you can try
these tests to correct the problem:
1. Reboot the FCP270 module using either the module Reset button (see Figure 5-1) or
the System Management displays (see “Reboot Station Procedure” on page 62).
2. Cycle power to the FCP270 module off then on by pulling the module from the
modular baseplate and pushing the module back on the baseplate. Make sure you
unscrew the two self-retaining hex screws on the module before pulling the module
from the baseplate (see “Replacing a Non-Operational Module” on page 86).
3. If the module is part of a fault-tolerant pair, replace it and verify that the new module
marries successfully.

NOTICE
POTENTIAL DATA LOSS

Do not disconnect the time strobe cable from the baseplate or it will
cause the primary FCP270 module on control to lose time
synchronization via the GPS (but it will continue to receive time
synchronization by system time).

Failure to follow these instructions can result in data loss.

4. Check for insufficient voltage, as shown in Steps 1 through 4 in the previous section.

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Red on, Green on

On power-up, the default condition of both LEDs is on. Once the FCP270 module is running,
software turns off the red LED. If this state persists, a suboptimal condition with your processor
may exist. Please be patient with this state – if the module is updating its software, it may stay in
the red-green state for as long as five minutes.
Suboptimal conditions with your processor can occur for several reasons when fault-tolerant
modules are married, but such conditions are unlikely to occur when the module is operating
single.
1. Verify that the module is properly configured using System Management or System
Manager.
2. Check the cabling to the splitter/combiner. If married, the module can persist in the
red-green state when the cables are improperly connected, for example, by swapping
The Foxboro DCS control network A and B cables on one module.
If these steps do not bring the green LED on and the red LED off, you must replace the module.

Cycling Red, Red/Green

When the LEDs cycle between red and red/green being on, this indicates that the probable cause
is a fault on the IOC (fieldbus) side of the FCP270 module. The module passes its main processor
diagnostics, then it tries to load software into the IOC. For whatever reason, this load is either not
succeeding or the cooperative diagnostics between the two processors reach a bad conclusion.
Also, the fieldbus Tx and Rx/Link LEDs probably flash once.
1. If the module is married to its fault-tolerant partner, make sure that the fieldbus
cabling is properly connected to the baseplate.
2. Cycle power to the FCP270 module off then on by pulling the module from the
baseplate and pushing the module back on the baseplate. Make sure you unscrew the
two self-retaining hex screws on the module before pulling the module from the
baseplate (see “Replacing a Non-Operational Module” on page 86).
If these steps do not bring the green LED on and the red LED off, you must replace the module.

Red off, Green on

When the red LED is off and the green LED is on, this indicates that the module is on-line and
functional. This is the normal operating state.

Using the Ethernet Tx and Rx/Link Status LEDs

The normal idle state of the yellow TX and Rx/Link LEDs on the front of the FCP270 module
(see Figure 5-1) is to have all of the Tx LEDs dark and all of the Rx/Link LEDs lit, which
indicates that the fiber links are established. Every time the module transmits on any Ethernet
cable, the Tx LED for that cable lights up; whenever the module receives a packet of data, the
Rx/Link LED for that cable blinks.
In normal operation, you should see the LEDs start as dark. Then each of the control network
and fieldbus LEDs flash in unison (diagnostics), followed by the LEDs settling into their light
(Rx/Link) and dark (Tx) states. Normal operation quickly causes all of the LEDs on a primary or
single module to start flashing busily. On the shadow module, the Rx/Link LEDs flashes.
If the LEDs on your module are not behaving this way:

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5. Troubleshooting B0700AR – Rev N

1. There is no data being processed. Make sure that some FBMs and workstations
connected to the FCP270 are on-line using System Management.
2. The cabling for that port is disconnected, broken, or otherwise compromised. Check
the cable to the splitter/combiner or Ethernet switch for that port.
3. If the same LEDs are dark on both the primary and shadow modules of a married
fault-tolerant module pair, check the cabling between the Ethernet switch and the
splitter/combiner.
If none of the above issues caused the module to become non-operational, you must replace the
module.

Using the Fieldbus Tx and RX Status LEDs

The yellow Tx and Rx LEDs for Fieldbus A and B only indicate communication activity on their
respective links.
In normal operation, the Tx LED is on when it is transmitting data over fieldbus A or B. The Rx
LED is on when the controller is receiving data over fieldbus A or B. For a fault-tolerant FCP270,
the Tx LEDs are active only on the primary module, but the Rx LEDs are active on both the
primary and shadow modules.
If the LEDs on your module are not behaving this way:
1. There is no data being processed. Make sure that some FBMs and workstations
connected to the FCP270 are on-line using System Management.
2. The fieldbus cabling is disconnected, broken, or otherwise compromised. Check the
fieldbus cabling between baseplates and the termination cable connections between
the baseplate and Termination Assemblies. For more information, see Standard and
Compact 200 Series Subsystem User’s Guide (B0400FA).
If none of the above issues caused the module to become non-operational, you must replace the
module.

Fault-Tolerant FCP270 Troubleshooting Addenda

Fault-tolerance in the FCP270 uses software synchronization to keep the two modules executing
exactly the same software, using exactly the same data. If the software is not synchronized,
synchronization is restored when the primary module transmits its database to the shadow
module in a sequence commonly referred to as a “hot remarry.” The hot remarry is essentially the
same as the initial station marriage.

NOTE
The fault-tolerant control processor marriage is broken if five hot remarries occur
within one minute. When the marriage is broken, the shadow is placed in off-line
state and the message “Error Escalation Threshold has been exceeded” is printed on
the system printer. You may then use the System Management Displays to reboot
(restart) the shadow module.

If either module in a fault-tolerant pair becomes non-operational, this module’s red LED turns
on. If this occurs, proceed with the following checks. (These checks need not be followed in
order.)
1. Make sure that the FCP270’s Ethernet fiber cables are correctly connected.

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B0700AR – Rev N 5. Troubleshooting

2. Make sure that the fault-tolerant module connector is in place.

3. Check for detected error messages at the system printer.
4. Replace the module if nothing else succeeds.

Replacing a Non-Operational Module

This procedure requires a 5/32 hex driver tool (Foxboro P/N X0179AZ).
To replace a module which System Management has reported to be in the “Failed” state and is
part of an FCP270 fault-tolerant pair:
1. Disconnect the fiber optic cables from the Control Network A and B connectors on
the front of the failed module. To release the LC connector latch, push on the latch
with your finger until the connector springs apart slightly to an unlatched position.
Then, grasp the LC connector by hand and pull it to disconnect it from the
module.

NOTE
If you grasp the connector and squeeze to unlatch it, the spring-apart action may be
overcome.

2. Loosen the module base mounting screws completely using a 5/32 hex driver tool
(Foxboro P/N X0179AZ).
3. Using both hands, pull on the module to remove it from the baseplate.
4. Install the new module using the appropriate procedure.
See “Installing a Shadow FCP270 Module” on page 27.
After the new module (shadow) is installed, it automatically boots up, acquires its letterbug, image
and control database from the primary module, and marries the primary module.

Available Memory Detected Error Messages

These detected error messages indicate any issues that arise with regards to the available memory
in the FCP270. The available memory in a FCP270 is required not to go below 500Kb and these
messages are sent to SMON when various memory thresholds (below 500Kb) are passed. They
may precede various suboptimal conditions induced by CPs operating with reduced available
memory, such as communications slow-downs, loss of connections and potential serious issues
when the memory drops below 100Kb. The detected error messages and their thresholds are as
follows:
♦ Available Memory is below recommended limits - indicates that there are less
than 400Kb available
♦ Available Memory far below recommended limits - indicates that there are
less than 200Kb available
♦ Available Memory is critically low - indicates that there are less than 100Kb
available

Memory Dumps and Last Gasp Messages

These sections describe memory dumps and last gasp messages.

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Last Gasp Messages

Last gasp messages are a way of sending information about a module about to become unavailable
before the FCP270 restarts. Last gasp messages contain the controller ID and detected error code.
In the case of a module in the “Failed” state within a fault-tolerant pair, this controller passes the
last gasp message to the primary controller. The primary controller then transmits the message to
a workstation. Last gasp messages from a non-fault-tolerant controller are transmitted directly.

Memory Dumps
There are two kinds of memory dumps. If the module experiences a SW detected error while
running (such as WDT time-out or a memory violation), it saves a memory image of the FCP270
so that a thorough analysis of the detected issues that caused its unavailability can be performed.
To preserve the information about this event, the controller quickly compares its code image to
the code image in flash memory. Any differences are burned into the flash memory for later
analysis. The non-operational controller also compresses and burns the entire data space into flash
memory for later analysis. The controller will reboot immediately after writing the memory dump
into the flash memory (elapsed time approximately 30 seconds). Upon reboot, the module sends a
message to the detected error log indicating that it experienced a memory violation or WDT
time-out.
The other kind of memory dump is when a “Forced” dump is initiated, whereby the current
contents of memory are compressed and saved into flash. Forced dump analysis IS NOT useful to
analyze non-operational hardware of RED only or RED/GREEN modules. Forced dumps erase
any previous memory violation information stored in flash, so should only be initiated at the
express request of Schneider Electric development.
The memory dump information can be extracted from the controller in one of two ways.
1. The controller is replaced by another controller and its dump information extracted
off-line.
2. The controller can be uploaded on-line while still running all normal control
functions.

WARNING
POTENTIAL DEATH OR SERIOUS INJURY

For safety reasons, always consider the possible impact on plant

operations before placing the primary FCP270 module off-line or
rebooting it after the shadow module has failed. Interrupting plant
operations while the plant is running has the potential to cause injury
within the plant.

Failure to follow these instructions can result in death or serious

injury.

a. If the module was married at the time of the violation, only the information from
the primary can be uploaded (the shadow module will be placed off-line during
the dump upload). If the violation was in the shadow module, it must become the

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primary to upload the memory dump. To make the shadow module become pri-
mary, push the Reset button on the front of the current primary module or use the
SMDH Equipment Change display to reboot the primary module.
b. To initiate the dump upload from the command line prompt, execute the
iaboot_upld <letterbug> command from directory opt/fox/bin/tools.
The module sends its entire flash memory contents to a 16 MB file in directory
usr/fox/sp/files with the title <letterbug>_dumpX where X is a sequential number
with the current dump having the greatest number.
The entire upload process takes approximately 3 minutes and its status is
indicated by messages at the system printer.
Syntax
iaboot_upld <letterbug> action
where:
♦ <letterbug> = 6-character letterbug of the controller
♦ action = U to upload existing dump image from single/primary module. This
is the command that should always be used to extract memory violation
information.
♦ action = F to create a new dump image and restart single/shadow module

NOTE
The “F” option forces a dump of the current module state and WILL ERASE any
information from a previous memory violation. ONLY USE the “F” option when
directed by Schneider Electric Development personnel.

After successful launch of the program it issues a double-check message as follows.

If action = F:
“Create a new dump image and restart single/shadow module - enter Y/N:”
If action = U:
“Set controller to run single and upload existing dump image - enter Y/N:”
If Y (or y) is entered, a final message is issued
“Create new dump image initiated.”
or
“Upload dump initiated”
c. If the original detected issue occurred while the modules were married, you can
now restart the off-line module, which remarries its partner. To restart the mod-
ule, use the “Reboot Station Procedure” on page 62.

NOTE
Non-fault-tolerant controllers can transmit their memory dump at any time.

88
5. Troubleshooting B0700AR – Rev N

Diagnostics
The FCP270 diagnostic routines are broken down into four areas as follows:
♦ Start-up
♦ Error Recovery Local
♦ Error Recovery Cooperative

NOTE
There are no user scheduled diagnostics required for the FCP270.

Start-Up Diagnostics
Start-up diagnostics run every time the module is powered up or restarted. Start-up diagnostics
test the basic core functionality of the module prior to running control or attempting marriage.
They consist of boot flash checksum, code flash checksum, main and I/O shared memory tests,
Interrupt controller tests, and other low level functionality. The start-up diagnostics complete in
approximately five seconds. A condition that meets the criteria of a System Management “Failed”
state is indicated by the Operational Status LEDs (red LED remains on and green LED remains
off ).

Detected Error Recovery Local Diagnostics

Run at initial installation and whenever a fault is detected by the run-time mechanisms (output
miscompare, sync time-out, and so forth). Detected error recovery local diagnostics attempt to
identify any conditions that can be isolated to a particular controller. Examples are Ethernet port
loopback tests, state sequencer tests, interrupt controller tests, shared memory tests, and I/O
interface tests. A condition that meets the criteria of a System Management “Failed” state is
indicated by the Operational Status LEDs (red LED is on and green LED is off ) and by messages
at the system printer.

Detected Error Recovery Cooperative Diagnostics

Run when run-time mechanisms detect an output miscompare, sync time-out, and so forth.
Detected error recovery cooperative diagnostics tests work cooperatively to identify any of these
conditions that inhibit normal fault-tolerant operations.
If a detected issue is localized to a particular controller, that controller is sent to the “Failed” state.
An example of this type of detected issue is a detected compare logic failure. In this case, logic is
that controllers A and B perform cooperative loopback tests with comparison logic enabled;
controller B passes all tests and controller A is marked as “Failed” due to a miscompare.
If a suboptimal condition is detected in the mechanisms but it cannot be isolated to a particular
controller, the shadow controller is sent to the off-line state. An example of this is the non-success
of an inter-link exchange.
If operations are functioning normally then a PASSED indication is returned which results in a
Hot-Remarry where all variable data from the primary controller are copied into the shadow
controller.

89
B0700AR – Rev N 5. Troubleshooting

A condition that meets the criteria of a System Management “Failed” state is indicated by the
Operational Status LEDs (red LED is on and green LED is off ) and by messages at the system
printer.

90
Appendix A. Upgrade Diagrams
This Appendix contains cabling diagrams for upgrading various Control Processors to the
FCP270.
Multiple options are available for upgrading (converting) systems containing various control
processors to the FCP270 in a Foxboro DCS network. The figures in this Appendix illustrate how
to perform these upgrades (conversions) to the FCP270, including their parts and cables necessary
to interconnect the various modules. The illustrations are as follows:
♦ Figure A-2 “Converting CP10/30/40 with Local I/O to FCP270s” on page 93
♦ Figure A-3 “Converting CP60 with DCM10E to FCP270” on page 94
♦ Figure A-4 “Converting CP60 with DCM10Ef to FCP270” on page 95
♦ Figure A-5 “Converting CP60 with DCM10Ef with Fiber Optic Hub to FCP270” on
page 96
♦ Figure A-6 “Converting CP60 with FBI10E and 100 Series FBMs to FCP270s” on
page 97
♦ Figure A-7 “Converting CP60 with 200 Series DIN Rail Mounted Equipment to
FCP270” on page 98
♦ Figure A-8 “Converting Micro-I/A Station to FCP270” on page 99
♦ Figure A-9 “Converting AW51/AW70 to FCP270s” on page 100

NOTE
Systems with combinations of FCM10- and DCM10-type modules are not
supported.

The order in which to replace equipment when upgrading (converting) systems with the Control
Processor 60 to the FCP270 is illustrated in Figure A-1 “Equipment Replacement Order for
CP60-to-FCP270 Conversions” on page 92.

91
B0700AR – Rev N Appendix A. Upgrade Diagrams

CP60
CONFIGURATION

200 SERIES 200 SERIES 100 SERIES

or
100 SERIES

FCM10E FCM10E FCM10Ef DCM10E DCM10E DCM10Ef

or DCM10Ef or
FCM10Ef FBI10E

FBI10E
• Remove CP60 • Remove CP60 • Remove CP60 • Remove CP60
• Remove Coax Cable • Remove Coax Cable • Remove Coax Cable • Remove Coax Cable
• Remove CP60
• Remove Cox ‘Tees’ • Remove Cox ‘Tees’ • Remove Cox ‘Tees’ • Remove Cox ‘Tees’
• Remove Coax Cable
• Remove Terminators • Remove Terminators • Remove Terminators • Remove Terminators
• Remove Cox ‘Tees’
• Remove any fiber extension • Remove Fiber Equip. • Remove any fiber extension • Remove Fiber Equip.
• Remove Terminators
equipment • Re-use Fiber Cable equipment • Leave Fiber Cable
• Remove FCM10E modules • Remove any fiber extension
• Remove FBM01Ef modules • Remove DCM10E modules
equipment
• Replace FBI10e modules with
Fieldbus Isolator modules
• Connect Fieldbus Terminal
Assemblies
<60 m <60 m >60 m
or
>60 m
<975 m >975 to 1830 m <975 m
<975 m <975 m
or or
>975 m >975 m

>975 to
One FBM baseplate connection: One FBM baseplate connection:
2000 m
• FBM modules can be installed • Install FCM2f modules in FCM
in FCM locations locations
• Install FCP270, baseplate • Install FCP270, baseplate &
& supplies supplies
• Connect FCP270 baseplate to • Install FCM2f*, baseplate &
200 Series baseplates with an supplies near FCP270s
HDLC cable • Connect FCP270 baseplate
• Install FCP270 modules, • Install FCP270 modules, • Install FCP270 modules,
• Terminate the HDLC cables to FCM2f* baseplate with an
baseplate & supplies baseplate & supplies baseplate & supplies
HDLC cable
OR • Connect terminal assemblies • Install FBI200/100 modules, • Connect terminal assembly
• Connect FCM2f* modules with
to FCP270 baseplate baseplate & supplies near to FCP270 baseplate
More than one FBM baseplate fiber cables
• Connect FCP270 terminal the FCP270 modules • Install fiber optic modems,
connection: • Terminate the HDLC cables
assemblies to 100 Series • Connect FBI200/100 baseplate & supplies near
• FBM modules can be installed
OR terminal assemblies with baseplate to FCP270 the FCP270 modules
in FCM locations
More than one FBM baseplate Twinaxial cables baseplate with an HDLC • Connect fiber modems to
• Install FCP270, baseplate &
connection: • Terminate the HDLC cables cable FCP270 terminal
supplies
• Connect FBI200/100 assemblies using
• Install FEM100 modules, • FBM modules can be installed
baseplate to Fieldbus Twinaxial cables
baseplates & supplies near in FCM locations
Isolator terminal assemblies • Install fiber optic modems,
FBMs • Install FCP270, baseplate &
with Twinaxial cables baseplate & supplies
• Connect FEM100 baseplate to supplies
• Terminate the HDLC cables near the 100 Series
200 Series baseplate with • Install FCM2f*, baseplate &
supplies near FCP270s nest
HDLC cables
• Connect FCP270 baseplate • Connect the remote fiber
• Connect FEM100 baseplate to
to the FCM2f* baseplate with modems to FBI terminal
FCP270 baseplate with an
an HDLC cable assembly using
HDLC cable
• Install FEM100 modules, Twinaxial cables
• Terminate the HDLC cables
baseplates & supplies near • Connect the fiber modems
FBMs near the FCP270 modules
• Connect FEM100 baseplate to to the fiber modems near
the 200 Series baseplate with the 100 Series nest using
an HDLC cable the existing fiber cables
• Install FCM2f*, baseplate & • Terminate the HDLC cables
supplies near FEM100s
• Connect FEM100 baseplate to
the FCM2f* baseplate with an
HDLC cable
• Connect FCM2f* modules with
fiber cables
• Terminate the HDLC cables

Transfer the control scheme to the FCP270

Figure A-1. Equipment Replacement Order for CP60-to-FCP270 Conversions

92
Appendix A. Upgrade Diagrams B0700AR – Rev N

P0926CM = 33"
P0927AQ = 72”
P0927AR = 96”

FBI200/100

FBI200/100

Figure A-2. Converting CP10/30/40 with Local I/O to FCP270s

93
B0700AR – Rev N Appendix A. Upgrade Diagrams

FBI200/100
P0926CM = 33"
P0927AQ = 72”
P0927AR = 96”

FBI200/100

Figure A-3. Converting CP60 with DCM10E to FCP270

94
 Overview Cabling Diagram For Converting CP60 w/DCM10Ef To FCP270s
FIBER CABLE GROUP A FPS400 POWER CABLES FIBER CABLE GROUP C FPS400 LINE CORDS
MMF with MT-RJ/LC GROUP B MMF w/MTRJ CABLES GROUP D EXISTING CP60/DCM10Ef EQUIPMENT
CABLES P0926KK = 16" P0972KV = 3 m P0926CN = 11"
P0972TR = 3 m P0926KL = 36" P0972KW = 10 m P0923DA = 15" REMOVE EQUIPMENT HIGHLIGHTED IN YELLOW
P0972TS = 15 m P0926KM = 48" P0972KX = 50 m P0926CM = 33"
P0972TT = 50 m P0926KN = 60" CUSTOMER 10Base-2 COAX
P0927AQ = 72”
CUSTOMER SUPPLIED = P0926KP = 72" SUPPLIED = >50m, < 2 km 185 m /607 ft (max) END-OF-LINE
P0927AR = 96”
>50m, < 2 km P0926KQ = 84" NOTE: OTHER WELL TERMINATOR
FILTERED 24 TO 39 Vdc
TO OTHER MESH TO OPTIONAL ADDITIONAL
POWER SOURCES MAY BE
COMPONENTS BNC to FIBER 1 x 8 STRUCTURES
SUBSTITUTED FOR THE
MESH CONVERTER
P0904AU PDU.
CABLE GROUP C
NETWORK OPTIONAL 1 GBit UPLINK. ST/ST MMF FIBER
REQUIRES UPLINK CARDS 2 km (max) CABLE

TWINAXIAL CABLE
Appendix A. Upgrade Diagrams

P0972YC (EXAMPLE) P0972WP (EXAMPLE) 1 x 8 STRUCTURE

24-PORT, 100Base-FX SWITCH 24-PORT, 100Base-TX SWITCH
DCM 6000 ft (max)
W/MTRJ CONNECTORS W/RJ-45 CONNECTORS
10Ef

10Base-2 COAX
SWITCH GROUP A SWITCH GROUP A
FBI

IPM2
IPM2

TO OTHER MESH PDU

P0904AU
FBM
FBM

FBM
FBM
FBM

FBM
FBM

COMPONENTS
100 SERIES
100 SERIES

100 SERIES
100 SERIES
100 SERIES

100 SERIES
100 SERIES

FBI

IPM2
IPM2

P0972WP (EXAMPLE) TWINAXIAL CABLE

24-PORT, 100Base-TX SWITCH
6000 ft (max)
P0972YC (EXAMPLE) W/RJ-45 CONNECTORS
NODEBUS DCM
24-PORT, 100Base-FX SWITCH SWITCH GROUP B
W/MTRJ CONNECTORS CP60 10Ef
ST/ST MMF FIBER 2 km (max)
SWITCH GROUP B CABLE
CONNECTION TO EXISTING TO OPTIONAL ADDITIONAL
NODEBUS BNC to FIBER 1 x 8 STRUCTURES
CONVERTER
END-OF-LINE
TERMINATOR

10Base-2 COAX
POWER
MODULE 185 m/607 ft (max)
FIBER OPTIC
FPS400-24
CABLE GROUP A
P0917LY/
FBI TERMINAL ASSEMBLY
P0922YU UPGRADED EQUIPMENT P0800DC
ADD EQUIPMENT HIGHLIGHTED IN GREEN
1 x 8 STRUCTURE
P0973EE
CABLE P0904AT TWINAX
P0973ED
FAULT TOLERANT PAIR
GROUP D
EXISTING
ST/ST MMF FIBER
FBI

IPM2
IPM2

OR FIBER CABLE FIBER PDU

PRI PWR CABLE GROUP B
OPTIC OPTIC P0904AU
FBM
FBM
FBM
FBM
FBM
FBM
FBM

BASEPLATE TERMINAL MODEM 2 km (max) MODEM

100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES

FBI

ASSEMBLY KIT
A A
IPM2
IPM2

P0903QF P0903QF
OR OR

OPTICAL
SPLITTER
EXISTING TWINAXIAL CABLE
P0903VY FBI TERMINAL ASSEMBLY
3200 ft/975 m (Max - all segments)
P0800DC

FCP270
FCP270

P0917YZ
P0917YZ
ADAPTER
P0926LC TERMINATOR
B B (USE AT END OF LINE)
SEC PWR TO OTHER
TWINAX

REMOTE
I/O

Figure A-4. Converting CP60 with DCM10Ef to FCP270

P0904AT
P0972UN (GRAY, 50 cm) OPTIONAL 2nd

OPTICAL
SPLITTER
P0972VG (ORANGE, 50 cm) BASEPLATE TERMINAL 1 x 8 STRUCTURE
ASSEMBLY KIT EXISTING TWINAXIAL CABLE
P0973BU (GRAY, 25 cm)

SOCKET

FIELDBUS &
P0926AH P0972ZQ (ORANGE, 25 cm) 3200 ft/975 m (Max - all segments)

TIME STROBE
FBI

IPM2
IPM2

OR OR
EXISTING
BASEPLATE
FBM
FBM
FBM
FBM
FBM
FBM
FBM

P0903VY FIBER ST/ST MMF FIBER

FIBER
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES

HORIZONTAL = P0926HC
FBI

CABLE
OPTIC OPTIC
EXISTING
IPM2
IPM2

VERTICAL = P0926HW POWER CABLE GROUP B

MODEM 2 km (max) MODEM
MODULE OR
TWINAXIAL CABLE

FPS400-24 P0973ED TERMINATOR

P0903QF P0903QF (USE AT END OF LINE)
P0917LY/ TO OTHER
CYAN P0922YU REMOTE
COPPER (ie, Cu) ETHERNET CABLE P0973EE
I/O
MAGENTA FIBER (ie, FO) ETHERNET CABLE

CABLE GROUP D
B0700AR – Rev N

95
96
Overview Cabling Diagram For Converting CP60 w/DCM10Ef To FCP270s
FIBER CABLE GROUP A FPS400 POWER CABLES FIBER CABLE GROUP C FPS400 LINE CORDS
MMF with MT-RJ/LC GROUP B MMF w/MTRJ CABLES GROUP D EXISTING CP60/DCM10Ef EQUIPMENT
CABLES P0926KK = 16" P0972KV = 3 m P0926CN = 11"
P0972TR = 3 m P0926KL = 36" P0972KW = 10 m P0923DA = 15" REMOVE EQUIPMENT HIGHLIGHTED IN YELLOW
B0700AR – Rev N

P0972TS = 15 m P0926KM = 48" P0972KX = 50 m P0926CM = 33" 10Base-2 COAX FIBER OPTIC HUB
P0972TT = 50 m P0926KN = 60" CUSTOMER P0927AQ = 72” P0922KS END-OF-LINE
TERMINATOR
CUSTOMER SUPPLIED = P0926KP = 72" SUPPLIED = >50m, < 2 km P0927AR = 96” NOTE: OTHER WELL
>50m, < 2 km P0926KQ = 84" FILTERED 24 TO 39 Vdc TO OPTIONAL ADDITIONAL
ST CONNECTORS ST/ST MMF FIBER CABLE 1 x 8 STRUCTURES
POWER SOURCES MAY BE 2 km/6562 ft (max)
TO OTHER MESH
COMPONENTS SUBSTITUTED FOR THE
MESH P0904AU PDU.
TWINAXIAL CABLE
CABLE GROUP C
NETWORK 6000 ft (max)
OPTIONAL 1 GBit UPLINK. DCM
REQUIRES UPLINK CARDS 10Ef
1 x 8 STRUCTURE
P0972YC (EXAMPLE) P0972WP (EXAMPLE) PDU
24-PORT, 100Base-FX SWITCH 24-PORT, 100Base-TX SWITCH P0904AU
W/MTRJ CONNECTORS W/RJ-45 CONNECTORS
FBI

IPM2
IPM2

POWER

10Base-2 COAX
SWITCH GROUP A SWITCH GROUP A
CABLES
FBM
FBM
FBM

FBM
FBM
FBM
FBM

TO OTHER MESH
100 SERIES
100 SERIES
100 SERIES

100 SERIES
100 SERIES
100 SERIES
100 SERIES

FBI

COMPONENTS
IPM2
IPM2

P0972WP (EXAMPLE)
24-PORT, 100Base-TX SWITCH DCM
10Ef TWINAXIAL CABLE
P0972YC (EXAMPLE) W/RJ-45 CONNECTORS
NODEBUS 6000 ft (max)
24-PORT, 100Base-FX SWITCH SWITCH GROUP B
W/MTRJ CONNECTORS CP60 ST/ST MMF FIBER
CABLE
TO OPTIONAL ADDITIONAL
SWITCH GROUP B 2 km/6562 ft (max)
CONNECTION TO EXISTING ST CONNECTORS 1 x 8 STRUCTURES
NODEBUS FIBER OPTIC HUB END-OF-LINE
P0922KS TERMINATOR

POWER TWINAX FBI

MODULE TERMINAL ASSEMBLY
FIBER OPTIC
FPS400-24 UPGRADED EQUIPMENT P0800DC
CABLE GROUP A
P0917LY/
P0922YU
ADD EQUIPMENT HIGHLIGHTED IN GREEN
1 x 8 STRUCTURE
P0973EE
PDU
P0973ED P0904AU
EXISTING
CABLE ST/ST MMF FIBER
FBI

P0904AT
IPM2
IPM2

GROUP D OR FIBER CABLE FIBER

FAULT TOLERANT PAIR
CABLE GROUP B OPTIC OPTIC
FBM
FBM
FBM
FBM
FBM
FBM
FBM

MODEM 2 km/6562 ft (max) MODEM

100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES

FBI

PRI PWR
IPM2
IPM2

OR P0903QF P0903QF OR
A A EXISTING TWINAXIAL CABLE FBI
TWINAX

P0903VY 3200 ft/975 m (Max - all segments) TERMINAL ASSEMBLY

ADAPTER P0800DC

OPTICAL
SPLITTER
P0926LC EXISTING TWINAXIAL CABLE
P0903VY
3200 ft/975 m (Max - all segments) TERMINATOR
TWINAX (USE AT END OF LINE)
OR

FCP270
FCP270
OR

P0917YZ
P0917YZ
EXISTING
FIBER ST/ST MMF FIBER FIBER OPTIONAL 2nd
BASEPLATE CABLE
B B SEC PWR
TERMINAL ASSEMBLY OPTIC OPTIC P0904AT 1 x 8 STRUCTURE
KIT x 2 MODEM 2 km/6562 ft (max) MODEM

P0972UN (GRAY, 50 cm) P0903QF P0903QF

OPTICAL
SPLITTER
FBI

P0972VG (ORANGE, 50 cm)

IPM2
IPM2

P0973BU (GRAY, 25 cm)

SOCKET
TWINAX
TWINAX

OR

FIELDBUS &
P0972ZQ (ORANGE, 25 cm)
FBM
FBM
FBM
FBM
FBM
FBM
FBM

P0926AH

TIME STROBE
D
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES

FBI

BASEPLATE CABLE GROUP B

73E
IPM2
IPM2

HORIZONTAL = P0926HC
P09
E

VERTICAL = P0926HW POWER

73E

MODULE
P09

FPS400-24 TERMINATOR

Figure A-5. Converting CP60 with DCM10Ef with Fiber Optic Hub to FCP270
P0917LY/ (USE AT END OF LINE)
CYAN P0922YU
COPPER (ie, TP) ETHERNET CABLE TO OTHER REMOTE I/O

MAGENTA FIBER (ie, FO) ETHERNET CABLE

CABLE GROUP D
Appendix A. Upgrade Diagrams
Appendix A. Upgrade Diagrams B0700AR – Rev N

P0926CM = 33"
P0927AQ = 72”
P0927AR = 96”

Figure A-6. Converting CP60 with FBI10E and 100 Series FBMs to FCP270s

97
98
Overview Cabling Diagram For Converting CP60-200 Series To FCP270s
FIBER CABLE GROUP A FPS400 POWER CABLES FIBER CABLE GROUP C FPS400 LINE CORDS
MMF with MT-RJ/LC GROUP B MMF w/MTRJ CABLES GROUP D EXISTING CP60-200 SERIES EQUIPMENT
B0700AR – Rev N

CABLES P0926KK = 16" P0972KV = 3 m P0926CN = 11"

P0972TR = 3 m P0926KL = 36" P0972KW = 10 m P0923DA = 15" REMOVE EQUIPMENT HIGHLIGHTED IN YELLOW
P0972TS = 15 m P0926KM = 48" P0972KX = 50 m P0926CM = 33"
REDUNDANT FCMs Cable Group B
P0972TT = 50 m P0926KN = 60" CUSTOMER P0927AQ = 72” Fiber Extension
CUSTOMER SUPPLIED = P0926KP = 72" SUPPLIED = >50m, < 2 km P0927AR = 96” Equipment
>50m, < 2 km P0926KQ = 84" (Optional)

TO OTHER MESH
COMPONENTS FBM FBM
MESH
CABLE GROUP C FCM FCM POWER
NETWORK OPTIONAL 1 GBit UPLINK. I/A Series I/A Series I/A Series I/A Series MODULE
REQUIRES UPLINK CARDS
FPS400-24

P0972YC (EXAMPLE) P0972WP (EXAMPLE) P0922YU/

24-PORT, 100Base-FX SWITCH 24-PORT, 100Base-TX SWITCH P0917LY
Up to 4 Baseplace each with 30 FBMs
W/MTRJ CONNECTORS W/RJ-45 CONNECTORS
SWITCH GROUP A SWITCH GROUP A

TO OTHER MESH
COMPONENTS
FBM FBM
POWER
P0972WP (EXAMPLE) FCM FCM MODULE
I/A Series I/A Series I/A Series I/A Series
24-PORT, 100Base-TX SWITCH FPS400-24
P0972YC (EXAMPLE) W/RJ-45 CONNECTORS
P0922YU/
24-PORT, 100Base-FX SWITCH SWITCH GROUP B NODEBUS
DNBT CP60 CP60 P0917LY
W/MTRJ CONNECTORS OR REDUNDANT FCMs
SWITCH GROUP B CONNECTION TO EXISTING
NODEBUS P0916RB
Terminator Cable Group D

POWER MODULE NOTES:

POWER
FIBER OPTIC P0922YC available with
MODULE UPGRADED EQUIPMENT
CABLE GROUP A 24 Vdc INPUT
FPS400-24 ADD EQUIPMENT HIGHLIGHTED IN GREEN P0922YU and P0917LY =
P0917LY/ 85-240 Vac INPUT
P0922YU P0916RB or 125 Vdc INPUT
Terminator
CABLE GROUP D Cable Group B
CABLE GROUP B
Up to 60 meters, total lenght
FAULT TOLERANT PAIR

PRI PWR RX RX
FBM FBM
TX TX
FCM FCM
A A 2f2/4/10 2f2/4/10 POWER
I/A Series I/A Series I/A Series I/A Series MODULE
FPS400-24

OPTICAL
SPLITTER
OR
P0922YU/
RX RX
P0917LY
Up to 4 Baseplace each; with 30 FBMs Total
Up to 10Km

FCP270
FCP270
TX TX Cable Group C

P0917YZ
P0917YZ
P0916RB

SOCKETS
FCM FCM

FIELDBUS &
Terminator 2f2/4/10 2f2/4/10

TIME STROBE
I/A Series I/A Series
B B

RX RX
P0972UN (GRAY, 50 cm) FBM FBM

OPTICAL
SPLITTER
TX TX
P0972VG (ORANGE, 50 cm) POWER
P0973BU (GRAY, 25 cm) To another FCM FCM
SEC PWR FCP270 Controller 2f2/4/10 2f2/4/10 MODULE
P0926AH P0972ZQ (ORANGE, 25 cm) I/A Series I/A Series I/A Series I/A Series
FPS400-24
BASEPLATE CABLE GROUP B P0922YU/
HORIZONTAL = P0926HC P0917LY
VERTICAL = P0926HW POWER
MODULE
FPS400-24
CABLE GROUP D
P0917LY/
CYAN P0922YU
COPPER (ie, TP) ETHERNET CABLE

Figure A-7. Converting CP60 with 200 Series DIN Rail Mounted Equipment to FCP270
MAGENTA FIBER (ie, FO) ETHERNET CABLE
Appendix A. Upgrade Diagrams
Appendix A. Upgrade Diagrams B0700AR – Rev N

FBI200/100

FBI200/100
P0927AQ = 72”
P0927AR = 96”

Figure A-8. Converting Micro-I/A Station to FCP270

99
B0700AR – Rev N Appendix A. Upgrade Diagrams

FBI200/100

FBI200/100
P0927AQ = 72”
P0927AR = 96”

Figure A-9. Converting AW51/AW70 to FCP270s

100
Appendix B. FEM100 and FBI100
Connection Diagrams
The figures in this Appendix illustrate typical configurations for connecting the FEM100 and
FBI100 modules to the FCP270, including their parts and cables necessary to interconnect the
various modules. The illustrations are as follows:
♦ Figure B-1 “Overview for FCP270-to-FEM100 Cabling” on page 102
♦ Figure B-2 “Overview for Expanded Fieldbus Cabling (FCP270 to Four FEM100s)”
on page 103
♦ Figure B-3 “Overview for Dual Baud Cabling (FCP270 to FEM100 and FBI100)” on
page 104

101
102
FIBER CABLE GROUP A FIBER CABLE GROUP C HDLC CABLES
MMF with MT-RJ/LC MMF w/MTRJ CABLES GROUP E Overview Cabling Diagram For FEM100s
CABLES P0972KV = 3 m P0916ND = 0.25 m
P0972TR = 3 m P0972KW = 10 m P0917JJ = 0.5 m
P0972TS = 15 m P0972KX = 50 m P0916MZ = 1.0 m
FCP270 INSTALLATION WITH 32 FBM LIMIT
HDLC CABLES: LAST OF BASEPLATES HOLDING UP TO 32 FBMs
P0972TT = 50 m CUSTOMER P0916NC = 3.0 m PRI PWR CABLE GROUP E
CUSTOMER SUPPLIED = SUPPLIED = >50m, < 2 km P0916NB = 5.0 m FIBER OPTIC
>50m, < 2 km P0916NA = 10 m CABLE GROUP A
A A
B0700AR – Rev N

FPS400 LINE CORDS P0916UH = 20 m

FPS400 POWER CABLES GROUP D P0916UJ = 30 m FBM FBM
GROUP B

OPTICAL
SPLITTER
P0926CN = 11" BASE- BASE-

FBM
FBM
FBM
FBM

P0916UK = 60 m
P0926KK = 16"

SOCKET
P0923DA = 15" PLATE PLATE

200 Series
200 Series
200 Series
200 Series

FIELDBUS &
P0926KL = 36" TO OTHER MESH

TIME STROBE
P0926CM = 33" I/A Series I/A Series I/A Series I/A Series
COMPONENTS TERMINATOR

FCP270
FCP270
P0926KM = 48"

P0917YZ
P0917YZ
P0916RB
P0926KN = 60" CABLE GROUP C See Note 2
P0926KP = 72" OPTIONAL 1 GBit UPLINK. TERMINATOR
B B
P0926KQ = 84" REQUIRES UPLINK CARDS P0916RB

SOCKET
Notes:

FIELDBUS &
TIME STROBE
P0972YC (EXAMPLE) P0972YC (EXAMPLE) P0972UN (GRAY, 50 cm) 1. The number of FBMs supported is subject to

OPTICAL
SPLITTER
24-PORT, 100Base-FX SWITCH 24-PORT, 100Base-FX SWITCH P0972VG (ORANGE, 50 cm)
P0973BU (GRAY, 25 cm)
FCP270 sizing restraints.
W/MTRJ CONNECTORS W/MTRJ CONNECTORS P0972ZQ (ORANGE, 25 cm)
P0926AH SEC PWR
SWITCH GROUP A SWITCH GROUP A 2. The total cable length of the Module Fieldbus (shielded
BASEPLATE twisted-pair segment) cannot exceed 60 m (198 ft)
HORIZONTAL = P0926HC
VERTICAL = P0926HW
between the FCP, FEM100 or FCM2F2/4/10 and the
end of the baseplate chain.
P0972YC (EXAMPLE) P0972YC (EXAMPLE) FCP270 INSTALLATION WITH 4-SLOT FEM100 BASEPLATE (See Note 1)
24-PORT, 100Base-FX SWITCH 24-PORT, 100Base-FX SWITCH
3. The cable length between the FCP and FEMs
W/MTRJ CONNECTORS W/MTRJ CONNECTORS TO PRI POWER SUPPLY
cannot exceed 60 m (198 ft). See “FCP270 Product
SWITCH GROUP B SWITCH GROUP B Sizing” in B0400FA for the list of cabling restrictions.
A A TERMINATOR
P0916RB

P0926KZ
MESH OPTIONAL

FCP270
FCP270

P0917YZ
P0917YZ
TIME STROBE

OPTICAL
OPTICAL
NETWORK

SPLITTER
SPLITTER
B B ADAPTER/TERMINATOR
FBM
FBM
FBM
FBM

See Note 2
200 Series
200 Series
200 Series
200 Series

TERMINATOR
I/A Series I/A Series I/A Series I/A Series
P0916RB
FIBER OPTIC POWER FIELDBUS 3 FIELDBUS 1 FBM FBM
CABLE GROUP A MODULE 3 1 BASE- BASE- LAST OF BASEPLATES HOLDING UP TO 32 FBMs
FPS400-24 PLATE PLATE
P0926KW
P0926KW

FEM100
FEM100

P0973CA
P0973CA
P0917LY/ FIELDBUS 2
P0922YU 2
I/A Series I/A Series HDLC CABLES:
FIELDBUS 4 CABLE GROUP E
4-SLOT FEM100 BASEPLATE
FBM
FBM
FBM
FBM

TERMINATOR
200 Series
200 Series
200 Series
200 Series

FAULT TOLERANT PAIR BASEPLATE: P0973CN

FIELDBUS "A" CABLE FBM FBM P0916RB
I/A Series I/A Series I/A Series I/A Series

PRI PWR
BASE- BASE-

CABLE GROUP B
FIELDBUS "B" CABLE PLATE PLATE

A A

OPTICAL
SPLITTER
FCP270 INSTALLATION WITH 2-SLOT FEM100 BASEPLATE UPGRADE (See Note 1)

CA

SOCKET
BL
CABLE GROUP E

FIELDBUS &
TIME STROBE
EG

FCP270
FCP270
PRI PWR

RO

P0917YZ
P0917YZ
FIELDBUS 4 FBM FBM

UP
E
4
FBM
FBM
FBM
FBM

BASE- BASE-
TERMINATOR PLATE PLATE TERMINATOR
200 Series
200 Series
200 Series
200 Series

B B HDLC
P0916RB P0916RB

SOCKET
I/A Series I/A Series I/A Series I/A Series
FIELDBUS 3

FIELDBUS &

Figure B-1. Overview for FCP270-to-FEM100 Cabling

TIME STROBE
3
P0972UN (GRAY, 50 cm) SEC PWR ADDED EQUIPMENT

OPTICAL
SPLITTER
P0972VG (ORANGE, 50 cm) LAST OF BASEPLATES HOLDING UP TO 32 FBMs
FEM100
FEM100

P0973BU (GRAY, 25 cm)

P0973CA
P0973CA

FIELDBUS 2 HDLC CABLES:

P0926AH P0972ZQ (ORANGE, 25 cm) SEC PWR 2
TERMINATOR CABLE GROUP E
I/A Series I/A Series
P0916RB
BASEPLATE FBM FBM
HORIZONTAL = P0926HC BASEPLATE 2-SLOT 1 BASE- BASE-
VERTICAL = P0926HW POWER P0973CG FEM100 BASEPLATE PLATE PLATE
FBM
FBM
FBM
FBM

MODULE TERMINATOR
200 Series
200 Series
200 Series
200 Series

CABLE GROUP B
FPS400-24 P0916RB
I/A Series I/A Series I/A Series I/A Series
P0917LY/ See Note 3 See Note 2
P0922YU

CABLE GROUP D
Appendix B. FEM100 and FBI100 Connection Diagrams
 Overview Cabling Diagram For Connecting FCP270s with FEM100
FIBER CABLE GROUP A FPS400 POWER CABLES FIBER CABLE GROUP C FPS400 LINE CORDS
MMF with MT-RJ/LC GROUP B MMF w/MTRJ CABLES GROUP D Up to 4 Baseplates each; 128 FBM modules total
Adjust power supply loading accordingly CABLE GROUP C
CABLES P0926KK = 16" P0972KV = 3 m P0926CN = 11"
P0972TR = 3 m P0926KL = 36" P0972KW = 10 m P0923DA = 15"
P0972TS = 15 m P0926KM = 48" P0972KX = 50 m P0926CM = 33" HDLC CABLES
P0972TT = 50 m P0926KN = 60" CUSTOMER GROUP E
CUSTOMER SUPPLIED = P0926KP = 72" SUPPLIED = >50m, < 2 km P0916ND = 0.25 m
>50m, < 2 km P0926KQ = 84" P0917JJ = 0.5 m
P0916MZ = 1.0 m POWER
TO OTHER MESH P0916NC = 3.0 m MODULE

FBM
FBM
FBM
FBM
COMPONENTS

I/A Series
I/A Series
I/A Series
I/A Series

MESH P0916NB = 5.0 m FPS400-24

CABLE GROUP C P0916NA = 10 m P0922YU /
NETWORK OPTIONAL 1 GBit UPLINK. P0916UH = 20 m P0917LY
REQUIRES UPLINK CARDS P0916UJ = 30 m
P0916UK = 60 m
P0972YC (EXAMPLE) P0972WP (EXAMPLE)

FBM
FBM
FBM
FBM

I/A Series
I/A Series
I/A Series
I/A Series

24-PORT, 100Base-FX SWITCH 24-PORT, 100Base-TX SWITCH

W/MTRJ CONNECTORS W/RJ-45 CONNECTORS
SWITCH GROUP A SWITCH GROUP A POWER
MODULE

FBM
FBM
FBM
FBM

TO OTHER MESH FPS400-24

I/A Series
I/A Series
I/A Series
I/A Series

COMPONENTS P0922YU /
P0917LY

P0972WP (EXAMPLE)

FBM
FBM
FBM
FBM

I/A Series
I/A Series
I/A Series
I/A Series

24-PORT, 100Base-TX SWITCH

P0972YC (EXAMPLE) W/RJ-45 CONNECTORS
24-PORT, 100Base-FX SWITCH SWITCH GROUP B CABLE GROUP D
W/MTRJ CONNECTORS P0916RB
SWITCH GROUP B Terminator
POWER MODULE NOTES:
See Note 1., Note 2. and P0922YC available with
Appendix B. FEM100 and FBI100 Connection Diagrams

cable group E.
24 Vdc INPUT
P0922YU and P0917LY =
85-240 Vac INPUT
or 125 Vdc INPUT

Extension
Extension
Extension
Extension

FIELDBUS 4
Equipment
FIELDBUS 3
Equipment
FIELDBUS 2
Equipment
FIELDBUS 1
Equipment

POWER
FIBER OPTIC
MODULE

2Mbit HDLC Fiber

2Mbit HDLC Fiber
2Mbit HDLC Fiber
2Mbit HDLC Fiber

CABLE GROUP A
FPS400-24
P0922YU /
P0917LY
CABLE GROUP D
CABLE GROUP B

FAULT TOLERANT PAIR CABLE GROUP E

See Note 2
PRI PWR BASEPLATE: P0973CG
BASEPLATE: P0926KH BASEPLATE: P0926KH
or P0926KE or P0926KE
PRI PWR
4

A A 2Mbit HDLC Fiber

Extension Equipment P0916RB

OPTICAL
Cable group E Terminator

SPLITTER
3

RX RX RX RX
FEM100
FEM100

TX TX TX TX
P0973CA
P0973CA

Cable group E

FCP270
FCP270
2

P0917YZ
P0917YZ
P0916RB FCM FCM FCM FCM

SOCKETS
2f2/4/10 2f2/4/10 2f2/4/10 2f2/4/10 I/A Series I/A Series

FIELDBUS &
Terminator I/A Series I/A Series I/A Series I/A Series

TIME STROBE
B B
1

SEC PWR 2-SLOT

Up to 10Km FEM100 BASEPLATE
P0972UN (GRAY, 50 cm) See Note 2

OPTICAL
SPLITTER
P0972VG (ORANGE, 50 cm)
P0973BU (GRAY, 25 cm)
P0972ZQ (ORANGE, 25 cm) SEC PWR
P0926AH

BASEPLATE CABLE GROUP B NOTES:

HORIZONTAL = P0926HC 1. Remote HDLC cable can be eliminated if remote FBM2F* modules are
mouted on the 200 Series baseplates.
VERTICAL = P0926HW POWER
2. The total cable length of the Module Fieldbus (shielded twisted-pair segment) cannot exceed 60 m (198 ft) between the FCP, FEM100 or FCM2F2/4/10 and the end of the baseplate chain.
MODULE 3. The cable length between the FCP and FEMs cannot exceed 60 m (198 ft). See “FCP270 Product Sizing” in B0400FA for the list of cabling restrictions.
FPS400-24

Figure B-2. Overview for Expanded Fieldbus Cabling (FCP270 to Four FEM100s)
CABLE GROUP D P0922YU /
CYAN P0917LY
COPPER (ie, TP) ETHERNET CABLE

MAGENTA FIBER (ie, FO) ETHERNET CABLE

B0700AR – Rev N

103
104
Overview Cabling Diagram For FEM100s w/FBI100s
For Dual-Baud Systems
B0700AR – Rev N

FIBER OPTIC FIBER CABLE GROUP A FIBER CABLE GROUP C HDLC CABLES
TO OTHER MESH
CABLE GROUP A MMF with MT-RJ/LC CABLES MMF w/MTRJ CABLES GROUP E
COMPONENTS
P0972TR = 3 m P0972KV = 3 m P0916ND = 0.25 m
CABLE GROUP C P0972TS = 15 m P0972KW = 10 m P0917JJ = 0.5 m
OPTIONAL 1 GBit UPLINK.
TO OTHER MESH P0972TT = 50 m P0972KX = 50 m P0916MZ = 1.0 m
REQUIRES UPLINK CARDS
DEVICES CUSTOMER SUPPLIED = CUSTOMER P0916NC = 3.0 m
MESH P0972YC (EXAMPLE) P0972YC (EXAMPLE) >50m, < 2 km SUPPLIED = >50m, < 2 km P0916NB = 5.0 m
24-PORT, 100Base-FX SWITCH 24-PORT, 100Base-FX SWITCH P0916NA = 10 m
NETWORK FPS400 LINE CORDS P0916UH = 20 m
W/MTRJ CONNECTORS W/MTRJ CONNECTORS FPS400 POWER CABLES GROUP D P0916UJ = 30 m
SWITCH GROUP A SWITCH GROUP A GROUP B P0926CN = 11" P0916UK = 60 m
P0926KK = 16" P0923DA = 15"
P0926KL = 36" P0926CM = 33"
P0926KM = 48"
P0926KN = 60"
P0972YC (EXAMPLE) P0972YC (EXAMPLE) P0926KP = 72"
24-PORT, 100Base-FX SWITCH 24-PORT, 100Base-FX SWITCH P0926KQ = 84"
W/MTRJ CONNECTORS W/MTRJ CONNECTORS
SWITCH GROUP B SWITCH GROUP B

AN EXPANDED FIELDBUS SEGMENT

HDLC CABLES:
CABLE GROUP E
See Note 1

FBM
FIBER OPTIC

FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM

BASE-
CABLE GROUP A PLATE TERMINATOR

200 Series
200 Series
200 Series
200 Series
200 Series
200 Series
200 Series
200 Series

P0916RB
I/A Series I/A Series I/A Series I/A Series I/A Series I/A Series I/A Series I/A Series

POWER
MODULE LAST BASEPLATE
HDLC CABLES:
FPS400-24 CABLE GROUP E
P0917LY/ See Note 1
P0922YU
CABLE FBM
GROUP D BASE-
PLATE

FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM

TERMINATOR

CABLE
200 Series
200 Series
200 Series
200 Series
200 Series
200 Series
200 Series
200 Series

GROUP B
FCP270 FBM EXPANSION SYSTEM P0916RB
I/A Series I/A Series I/A Series I/A Series I/A Series I/A Series I/A Series I/A Series

A A
CP FIELDBUS

CABLE GROUP E AN EXPANDED FIELDBUS SEGMENT FBI TERMINAL ASSEMBLIES

P0800DC

FCP270
FCP270

P0917YZ
P0917YZ

OPTICAL
OPTICAL
TWINAX (P/N P0170GF/GG )

SPLITTER
SPLITTER
FBI TERMINAL ASSEMBLIES
B B TERMINATOR (P0916RB) 6000 FT (MAX) [ALL SEGMENTS, END TO END]
OR OPTIONAL
P0800DC 110 O TERMINATOR
FBI100 SYSTEM (USE AT END OF FIELDBUS)
TIME STROBE ADAPTER TO OTHER REMOTE I/O
BASEPLATE TERMINAL
(P0916KZ)
ASSEMBLY KITS
FIELDBUS 1 P0903VY x 2 1 x 8 STRUCTURE 1 x 8 STRUCTURE
3 1

FEM100
FEM100

P0973CA
P0973CA
FBI
FBI

FIELDBUS 2
4 2

FBI100
FBI100

I/A Series I/A Series CABLE GROUP E

P0923LN
P0923LN
FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM
FBM

See Note 1
P0400VE
P0400VE

I/A Series I/A Series

100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES
100 SERIES

4-SLOT FEM100 BASEPLATE

FBI
FBI

FBI100 BASEPLATE = P0923LR 110 O TERMINATORS

BASEPLATE: P0973CN (USE AT END OF FIELDBUS)
FBI = P0903ZE or
FBI = P0903ZE or

FIELDBUS 4
TERMINATOR
FIELDBUS 3 P0916RB TO OTHER REMOTE I/O 110 O TERMINATOR
POWER FBI TERMINAL ASSEMBLIES (USE AT END OF FIELDBUS)
MODULE P0800DC TWINAX (P/N P0170GF/GG )

Figure B-3. Overview for Dual Baud Cabling (FCP270 to FEM100 and FBI100)
6000 FT (MAX) [ALL SEGMENTS, END TO END]
FPS400-24
CABLE FBI TERMINAL ASSEMBLIES
P0917LY/
P0922YU GROUP B P0800DC
NOTE 1:
TThe total cable length of the Module Fieldbus (shielded twisted-pair segment) cannot exceed 60 m (198 ft) between the FCP, FEM100 or FCM2F2/4/10 and the end of the baseplate chain.
NOTE 2:
CABLE GROUP D The cable length between the FCP and FEMs cannot exceed 60 m (198 ft). See “FCP270 Product Sizing” in B0400FA for the list of cabling restrictions.
Appendix B. FEM100 and FBI100 Connection Diagrams
Glossary

Name Meaning
AI Analog input
APACS+™ Siemens® Process Automation System
AW Application Workstation (For I/A Series software v8.8 and Foxboro
DCS Control Core Services v9.0+, WSTA70 and WSVR70)
BPC Block Processing Cycle
Checkpoint File The Control Database, that resides on the host workstation, which is
downloaded to the FCP270.
Commissioned A commissioned control processor is a control processor for which all
the steps required to place the device into service have been performed.
This includes:
♦ Connecting to the baseplate and power
♦ Setting the letterbug
♦ Connecting to the Foxboro DCS Control Network
♦ Receiving and storing the IP address, MAC address, and control
database from its host workstation in the CP's Serial SPI flash
memory
Once these steps have been completed the CP becomes operational.
Control Core Services See “Foxboro DCS Control Core Services”.
CP60 Control Processor 60
CSD Control Strategy Diagram
DIN DIN is a non-governmental organization established to promote the
development of standardization and related activities in Germany.
ECB Equipment Control Block
EEPROM Electrically erasable programmable read-only memory
FBM Foxboro DCS Fieldbus Module
FCM Fieldbus Communication Module
FCP270 Field Control Processor 270
FDSI Foreign Device Systems Integrator
FEM Fieldbus Expansion Module
Fault Tolerant (FT) A station that is running with two FCP270 controllers.
Foxboro DCS Control Core software environment, formerly known as “I/A Series (Intelligent
Core Services Automation Series) software”. A workstation which runs this software is
known as a “Foxboro DCS Control Core Services workstation”.
Foxboro DCS Control Formerly known as “FCS Configuration Tools”, “InFusion Engineering
Editors Environment”, or “IEE”, these are the Control software engineering and
configuration tools built on the ArchestrA Integrated Development
Environment (IDE).

105
B0700AR – Rev N Glossary

Name Meaning
Foxboro DCS Control Formerly known as “Foxboro Control Software (FCS)” and “InFusion”,
Software a suite of software built on the ArchestrA Integrated Development
Environment (IDE) to operate with the Foxboro DCS Control Core
Services.
Foxboro DCS Process An overall term used to refer to a system which may include either, or
Automation System both, Foxboro DCS Control Software and Foxboro DCS Control Core
Services.
Foxboro DCS System Foxboro-provided control and interface modules to third-party control
Fieldbus Modules solutions, such as Fisher's PROVOX® Series 20 or Honeywell® TDC
2000 systems. Formerly known as Distributed Control System (DCS)
FBMs.
GMT Greenwich Meridian Time (GMT) is an international time standard
GPS Global positioning system
HART HART Field Communications Protocol is a standard for digitally
enhanced 4 to 20 mA smart instrument communication.
HDLC High-level Data Link Control protocol - Main/Secondary Protocol used
on top of several physical layers for FBM communication
IACC I/A Series Configuration Component
ICC Integrated Control Configurator
IR Infrared
LC Connector for fiber optic cable connection to the FCP270 or
splitter/combiner
LED Light-emitting diode
Letterbug Alphanumeric string that you define to identify a station in a Foxboro
DCS Process Automation System.
Letterbug Configurator Handheld device for setting, modifying and reading the controller
letterbug and reading controller status information
Married FT Station Two healthy FCP270 controllers operating as one station.
MMF Multimode fiber cable
MTK Main Timekeeper
MT-RJ Connector for fiber optic cable connection to Ethernet switches
OLUG On-Line Image Upgrade; the procedure that allows a fault tolerant
FCP270 to update to the latest image with minimal I/O down time.
Remarry When a newly booted FCP270 module marries with a FCP270 running
in Single Primary mode.
ROM Read only memory
Rx Receive
Single Primary A FCP270 module that is running as a single module.
SMDH System Management Display Handler, the user interface for equipment
status and change actions
SOE Sequence of Events

106
Glossary B0700AR – Rev N

Name Meaning
Station The virtual controller which runs as one or two CP modules. For
example, the station may exist on both fault-tolerant modules, but the
station itself is considered a single entity.
STK Secondary Timekeeper
SysDEF System Definition
System Configurator Software for configuring your system, such as the Foxboro DCS Control
Software, IACC, or ICC.
TDA Transient Data Analyzer
TDR Transient Data Recorder
Tx Transmit
UTC Universal Coordinated Time

107
B0700AR – Rev N Glossary

108
Index
A Primary ECB (FBM0) 69
Addresses Error recovery cooperative diagnostics 89
IP 6 Error recovery local diagnostics 89
MAC 6 External timing 16
Extracting memory dump information 87
B
Baseplates for FCP270 mounting 19 F
Block, defining 50 Failure messages 87
Boot-up sequence 34 Fault-tolerant operation 4
commissioned FCP270 35 hot remarry 85
FCP270 module with a new letterbug 36 FBI200A 9, 16
FCP270 module with the same letterbug 35 FBM
shadow module with the same letterbug and general download for off-line or failed 76
software image 36 FBMs
shadow module with the same letterbug but supported modules 1
different software image 38 Y-module 15
FBMs, supported 1
C FCP270
Cables, installing 29, 30 fault-tolerant operation 4
Cabling infrared communication ports 79
remote fieldbus extension 41 installing 20
Y-module FBMs 40 installing cables 29, 30
Communication to Series 200 FBMs 12, 15 installing secondary module 27
Configuration Information display, FCP270 58 installing single or primary module 21
Control block, defining 50 LED indicators 79
Control Configuration 50 letterbug installation 22
Control scheme, typical 51 network configuration 6
overview xiii
D replacing a failed module 86
Data stream types 10 reset button 79
Defining blocks 50 sizing constraints 16
Diagnostics Fiber optic cables, installing 30
error recovery cooperative diagnostics 89 Field Control Processor 270, overview xiii
error recovery local diagnostics 89 Fieldbus Expansion Module 100 (FEM100) 1, 9
start-up 89
Dual baud 10 H
cabling 104 Hosted FBMs and blocks 16
dual baud functionality 10, 40, 51 Hot remarry 85
E I
EEPROM Update procedure 63 I/O communications 9
Equipment Change display ICCPRT 27
FCP270 59 image 63
Primary ECB (FBM0) 73 Image Update procedure 63
Equipment Information display Infrared communication ports 79
FCP270 54 Installing

109
B0700AR – Rev N Index

cables 29, 30 Start-up diagnostics 89

FCP270 20 Supported products 1
secondary FCP270 module 27 Switching network paths 6
single or primary FCP270 module 21 System Definition 49
Internal timing 16 System Management displays
IP addresses 6 FBM0 69
FCP270 53
L
Last gasp messages 87 T
LED diagnostic indicators 79 Time synchronization 15
Letterbug installation 22 Timing
external 16
M internal 16
MAC addresses 6 Troubleshooting
MainTimeKeeper 15 failure messages 87
Memory dumps 87 fault-tolerant FCP270 failure 85
extracting 87 hot remarry 85
last gasp messages 87
N memory dumps 87
Network configuration, FCP270 6 Operational Status LEDs 81, 82
Network path switching 6
Y
O Y-module FBMs, cabling 40
On-line Diagnostics display, Primary ECB
(FBM0) 76
On-Line Image Update
Update 63
Operational Status LEDs, troubleshooting 81,
82

R
Reboot Station procedure 62
Reference documents xiv
Remote fieldbus extension 40
cable connections 41
Replacing a failed FCP270 module 86
Reset button 79
Reset button, location and operation 3
Revision information xiii

S
Secondary TimeKeeper 15
self-hosting 4
checkpoint invalidation 67
enabling or disabling 24
installation 21
messages 64
order of powering on 21
with fault-tolerance 39
Software installation 50
Splitter/combiner 6

110
Schneider Electric Systems USA, Inc.
38 Neponset Avenue
Foxboro, Massachusetts 02035–2037
United States of America

Global Customer Support: https://pasupport.schneider-electric.com

As standards, specifications, and designs change from time to time,

please ask for confirmation of the information given in this publication.

© 2004–2020 Schneider Electric. All rights reserved.

B0700AR, Rev N