schneiderFoxboro Evo™ Process Automation System Product Specifications

The Field Control Processor 280 is a distributed, optionally fault-tolerant, field-mounted controller that 

performs process control and alarming functions according to a user-defined control strategy.

FEATURES

 Performs regulatory, logic, timing, and sequential 

control together with connected Fieldbus 

Modules (FBMs)

 Performs data acquisition and alarm detection 

and notification

 Supports up to 128 Compact or standard 

200 Series FBMs, or up to 128 of a combination 

of 100 Series FBMs and 200 Series FBMs (with 

no more than 64 100 Series FBMs in this 

configuration)

No Fieldbus Communication Module is required.

 No Fieldbus Expansion Module is required for 

Expanded fieldbus support.

 Supports self-hosting mode, which allows the 

FCP280 to boot itself with a valid control 

database even without its host workstation

 Offers unique, patented, fault-tolerant operation 

using two control modules to greatly improve 

reliability relative to other process controllers

 Offers on-line image upgrade (OLUG) of a faulttolerant FCP280 without shutting down the 

process

 Liquid Crystal Display (LCD) displays letterbug 

and real-time roles and statuses

 Connects to The Mesh control network via 

standard fiber optic or copper 100 Mbps 

Ethernet cables

 Uses a rugged, die cast aluminum housing for 

mounting in a non-vented field enclosure

 Can operate in Class G3 harsh environments

 CE certified for field mounting in enclosures

 Each Fieldbus port on FCP280 baseplates 

supports either a 2 Mbps or 268 Kbps HDLC 

fieldbus exclusively

 Uses versatile control algorithms and a wide 

variety of FBMs to provide control capabilities for 

a broad range of process applications

 Supports time synchronization using optional 

external time from GPS satellites

 Uses soft letterbugs configurable via the keys on 

the FCP280 faceplate.

OVERVIEW

The Field Control Processor 280 (FCP280) is a 

distributed, optionally fault-tolerant, field-mounted 

controller module. The FCP280 performs regulatory, 

logic, timing, and sequential control together with 

connected Fieldbus Modules. It also performs data 

acquisition and alarm detection and notification. 

The FCP280 connects to The Mesh control network 

via standard fiber optic or copper 100 Mbps Ethernet 

cables from network adapters installed on its 

baseplate (shown in Figure 1).

The FCP280 requires Foxboro Evo Control Core 

Services v9.0 or later. A system with the FCP280 and 

this software is called a Foxboro Evo Process 

Automation System

Figure 1. Fault-Tolerant FCP280 Module Pair Mounted on Vertical Mounted 2-Position FCP280 Baseplate

The fault-tolerant version of the FCP280 consists of 

two processor modules. These modules are installed 

in adjacent FCP280 slots in a baseplate for high 

speed communication between the modules.

The FCP280 accepts four PIO channels (that is, four 

separate HDLC fieldbuses) via the four Fieldbus ports 

on its baseplate. These four Fieldbuses are referred 

to collectively as the “Expanded fieldbus.” For a 

description of the FCP280 baseplates, refer to DIN 

Rail Mounted Modular Baseplates

(PSS 21H-2W6 B4).

The number of FBMs which an FCP280 can support 

varies depending on the types of FBMs used:

 200 Series FBMs exclusively used with FCP280 - 

Each Fieldbus port on the FCP280 baseplate can 

connect to a baseplate chain with up to 32 

Compact or standard 200 Series FBMs per chain 

via the 2 Mbps HDLC fieldbus (up to 128 

modules).

 200 Series and 100 Series FBMs (dual baud 

configurations) used with FCP280 - The FCP280 

can support a total of 64 100 Series FBMs (Ymodule) or competitive devices (such as Foxboro 

Evo System migration FBMs) in one or more 

baseplate chains, with the remainder of the 

FCP280’s 128 module limit being 200 Series 

FBMs, depending on the Fieldbus loading of the 

FCP280. For example, an FCP280 could support 

64 100 Series FBMs and 64 200 Series FBMs (as 

128 - 64 = 64). See Figure 2 and Figure 3 below.

NOTE

Certain competitive migration or supported 

third-party modules such as DCS Migration 

fieldbus Modules and Pepperl+Fuchs™ I/O 

modules may increase this 128 module 

maximum per FCP280. For the maximum 

numbers of each of these migration/thirdparty modules supported by the FCP280, 

refer to the supported migration products 

books in Field Control Processor 280 

(FCP280) User’s Guide (B0700FW).

When supporting 200 Series and 100 Series FBMs, 

each Fieldbus port (PIO channel) is dedicated to 

supporting either a 268 Kbps HDLC fieldbus (for 

100 Series FBMs) or a 2 Mbps HDLC fieldbus (for 

200 Series FBMs) - not both.

For connections to 100 Series FBMs over 60 m 

(198 ft), an FBI200 pair is required to extend 

communications up to 1830 m (6000 ft). See 

Figure 2 below.

To connect a Fieldbus port to a 268 Kbps HDLC 

fieldbus directly, the Fieldbus splitter (RH928CV) 

provides a connector for any Fieldbus port on the 

FCP280 baseplate, and two Termination Cable 

Assembly (TCA) termination blocks for the twinaxial 

cabling from the 100 Series FBMs.

The FCP280 can also communicate with serial and 

Ethernet devices, such as PLCs, via Field Device 

System Integrators. This allows you to connect to 

new device interfaces without any changes to the 

controller software.

To estimate the FCP280’s processor load, refer to 

Field Control Processor 280 (FCP280) Sizing 

Guidelines and Excel Workbook (B0700FY)

FIBER AND COPPER NETWORK ADAPTERS

FCP280 modules connect to a pair of fiber or copper 

adapters (see Figure 4) which each connect to one 

Ethernet switch in The Mesh control network. The 

FCP280 baseplate passes inbound traffic from either 

of the two switches to both FCP280s, and pass 

outbound traffic from the primary FCP280 module to 

either switch.

Figure 4. Fiber Optic and Copper Network Adapters

The fiber or copper adapters mount on the FCP280 

baseplate as shown in Figure 1 on page 2. They 

receive their power from the baseplate.

REMOTE MOUNTING

The FCP280 simplifies the Foxboro Evo Process 

Automation System architecture, maintaining control 

while only requiring housing (via field enclosures), 

host workstations with Foxboro Evo Control Core 

Services v9.0 or later, and Ethernet switches for 

communication via The Mesh control network 

architecture, described in PSS 21H-7C2 B3.

The field-mounted FCP280 is an integral part of the 

highly-distributed control network where controllers 

are closely aligned to specific process units mounted 

in close proximity to their I/O and the actual 

equipment being controlled. Coordination between 

process units takes place via a fiber optic 100 Mbps 

Ethernet network.

The FCP280 and its network adapters are packaged 

in a rugged, die cast aluminum housing that does not 

require venting due to its efficient design. The 

FCP280 and its network adapters are CE certified, 

and it can be mounted without expensive special 

cabinets to prevent electronic emissions. The 

FCP280, network adapters, and baseplate can be 

mounted in Class G3 harsh environments.

ENHANCED RELIABILITY (FAULTTOLERANCE)

The unique and patented fault-tolerant operation of 

the FCP280 improves reliability relative to legacy 

process controllers. The fault-tolerant version of the 

FCP280 consists of two modules operating in 

parallel, with two Ethernet connections to The Mesh 

control network. The two FCP280 modules, married 

together as a fault-tolerant pair, provide continuous 

operation of the controller in the event of virtually any 

hardware failure occurring within one module of the 

pair.

Both modules receive and process information 

simultaneously, and faults are detected by the 

modules themselves. One of the significant methods 

of fault detection is comparison of communication 

messages at the module external interfaces. 

Messages only leave the FCP280 when both 

FCP280s agree on the message being sent (bit for 

bit match). Upon detection of a fault, self-diagnostics 

are run by both modules to determine which module 

is defective. The non-defective module then assumes 

control without affecting normal system operations.

This fault-tolerant solution has the following major 

advantages over controllers that are merely 

redundant:

 No bad messages are sent to the field or to 

applications using controller data because no 

message is allowed out of the controller unless 

both modules match bit for bit on the message 

being sent.

 The secondary controller is synchronized with the 

primary one, which ensures up to the moment 

data in the event of a primary controller failure.

 The secondary controller will have latent flaws 

detected prior to any switchover because it is 

performing exactly the same operations as the 

primary controller.

UPGRADE OPTIONS

Multiple options are available for replacing existing 

control processors with the FCP280. A fault-tolerant 

FCP280 may replace a fault-tolerant FCP270 or 

ZCP270. It may import the CP database from the 

CP270 it is replacing, for compatibility and minimal 

configuration time.

As well the FCP280 provides an increase in 

performance and block processing capacity over the 

CP270s. When replacing FCP270s, the FCP280 

eliminates the need for FEM100 hardware.

For ease of replacement, the fault-tolerant or nonfault-tolerant FCP280 in its baseplate has the same 

dimensions as the fault-tolerant or non-fault-tolerant 

FCP270 in its baseplate.

Cabling the 100 Series FBMs or Migration products 

to an FCP280 baseplate consists of extending the 

remote 268 Kbps fieldbus between enclosures. This 

is accomplished using termination cable assemblies 

(TCAs) and Fieldbus Isolators (FBIs) to provide 

connections between primary and extended fieldbus 

segments.

The optional FBI200 can extend the 2 Mbps HDLC 

fieldbus between 200 Series FBMs from 60 m (198 ft) 

up to 305 m (1000 ft). As well, it can extend the 

268 Kbps HDLC fieldbus between 100 Series FBMs 

from 60 m (198 ft) up to 1830 m (6000 ft).

As with earlier generations of control processors, up 

to 64 100 Series FBMs (including expansion 

modules) attach to Fieldbus ports through Fieldbus 

Isolators. (Up to 24 100 Series FBMs, excluding 

expansion modules, can connect to each isolator.

However, the expansion modules are considered 

100 Series FBMs in this “64 100 Series FBMs” 

maximum discussed in this PSS.)

Available upgrade scenarios are available in Field 

Control Processor 280 (FCP280) User’s Guide

(B0700FW).

FBI200 FIELDBUS ISOLATOR/FILTER

The FBI200 Fieldbus Isolator/Filter extends the length 

of the 268 Kbps module Fieldbus from the FCP280 

to 100 Series FBMs and similar competitive migration 

modules up to 1830 m (6000 ft) over a twinaxial 

Fieldbus cable. See Figure 2 on page 4.

It can also extend the 2 Mbps HDLC fieldbus to 

200 Series FBMs up to 305 m (1000 ft).

For more information on the FBI200, refer to FBI200 

Fieldbus Isolator/Filter (PSS 21H-2Y18 B4).

FIRMWARE UPGRADES WHILE ON-LINE

For fault-tolerant FCP280 modules, on-line image 

upgrade replaces the executable image (operating 

system) of a running FCP280 with a newer image 

without having to shut down the equipment being 

controlled by the FCP280. 

TIME SYNCHRONIZATION, SOE, TDR/TDA

The Foxboro Evo Process Automation System 

supports time synchronization using either an 

externally maintained optional source of Universal 

Coordinated Time (UTC) from GPS satellites or an 

internal source using proprietary software. FCP280s 

that receive time updates via the external time source 

synchronize their FBMs to 1 ms. For more 

information on time synchronization, refer to Time 

Synchronization Overview (PSS 21S-1C2 B3).

Time stamping is used for alarm messages, values 

sent to the historian, and the Sequence Of Events 

(SOE) and Transient Data Recorder (TDR), and 

Transient Data Analyzer (TDA) features.

SOE data are discrete points that are time stamped at the FBM, optionally to 1 ms, and sent to the workstation on a change basis. TDR/TDA data are analog or digital points that are time stamped at the FBM and sent to the workstation every 10 ms. These features are supported by client software in the workstation. For information on this new software, refer to Field Control Processor 280 (FCP280) Integrated Control Software (PSS 31S-3B3 B3). SOFTWARE CONTROL FEATURES The FCP280 performs regulatory, logic, timing, and sequential control, as well as data acquisition, alarm detection, and alarm notification. Process variables are controlled using time-proven algorithms (mathematical computations performing specific functions). The algorithms are contained in functional control blocks, which on-site process engineers configure to implement the desired control strategies. The versatility of the algorithms, coupled with the variety of FBMs available, provides control capabilities suited to a broad range of process applications. Control strategies ranging from simple feedback and cascade loops to highly sophisticated feedforward, nonlinear, and complex characterization control schemes are readily implemented. The FCP280 also supports the following features:  Setting and reading the FCP280 letterbug via the buttons on the faceplate  Alarm enhancements to function blocks: re-alarming on changes to alarm priority, re-alarming based upon a configurable time delay deadband, and alarm suppression based upon time  Optional UTC external time synchronization  Improved controller performance  Optional self-hosting mode allows the FCP280 to start up and run, executing its configured control scheme using the checkpoint file stored in flash memory. This allows the FCP280 to boot itself with a valid control database even if its host workstation is not present.  Support for high speed capabilities such as ladder logic, Motor Driven Actuator Controller (MDACT), and Distributed Proportional Integral Derivative functionality (DPIDA) DEVICES SUPPORTED The FCP280 supports the following devices on the 2 Mbps fieldbus:  All Compact and standard 200 Series FBMs (FBM201, FBM202, and so forth), which can support many types of intelligent field devices, including those on FOUNDATION fieldbus, PROFIBUS, HART, and DeviceNet networks  Field Device Systems Integrator (FDSI) modules  Intrinsically Safe I/O Subsystem (ISCM) - refer to PSS 21H-2Y6 B4).  DCS Migration fieldbus Modules for Siemens APACS+ Systems  DCS Migration fieldbus Modules for Westinghouse WDPF® Systems  DCS Migration fieldbus Modules for Fisher's PROVOX® Series 20 Migration with HART  DCS Migration fieldbus Modules for Honeywell® TDC 2000 Systems with HART. The FCP280 supports the following devices on the 268 Kbps fieldbus:  100 Series FBMs (FBM01, FBM02, and so forth)  SPECTRUM™ Migration Integrators  SPEC 200™ Control Integrators  SPEC 200 MICRO™ Control Integrators  SPEC 200 CCM Control Integrators