FOXBORO Z-Module Control Processor 270 (ZCP270)

FOXBORO Z-Module Control Processor 270 (ZCP270)

Z-Module Control Processor 270 (ZCP270)

The Z-Module Control Processor 270 is a distributed, optionally fault-tolerant 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

 Supports up to 128 of the 200 Series Fieldbus

Modules (FBMs - Compact or standard types)

when using the FCM100Et Fieldbus

Communications Module

 Supports up to 128 of the 200 Series FBMs

(Compact or standard types), 100 Series FBMs,

or a combination 100 Series and 200 Series

FBMs when using the FCM100E Fieldbus

Communications Module

 Performs data acquisition and alarm detection

and notification

 Offers unique, patented, fault-tolerant operation

using two control modules to greatly improve

reliability relative to other process controllers

 Connects to The MESH control network via

standard fiber optic 100 Mbps Ethernet

 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

 Offers on-line image update of a fault-tolerant

ZCP270 without shutting down the process

Uses soft letterbugs configurable via the

I/A Series® system Letterbug Configurator.

 Supports self-hosting mode with I/A Series

software v8.4-v8.8 or Foxboro Evo™ Control

Core Services v9.0 or later

OVERVIEW

The Z-Module Control Processor 270 (ZCP270) is an

optionally fault-tolerant, Z-form factor controller. The

ZCP270 performs regulatory, logic, timing, and

sequential control together with connected Fieldbus

Communications Modules (FCMs) and Fieldbus

Modules. It also performs data acquisition and alarm

detection and notification. The ZCP270 connects to

The MESH control network and

FCM100Ets/FCM100Es via standard fiber optic 100

Mbps Ethernet. The FCM100Et interfaces the

2 Mbps Module Fieldbus used by the 200 Series

FBMs and the FCM100E interfaces the 2 Mbps

Module Fieldbus used by the 200 Series FBMs or the

268 Kbps Fieldbus used by 100 Series FBMs.

Depending on sizing considerations, the ZCP270 can

be used with a mix of FCM100E and FCM100Et

modules.

The fault-tolerant version of the ZCP270 consists of

two single-width processor modules. These modules

install in adjacent ZCP270 slots in a 1x8 or 2x8

mounting structure and connect to a fault-tolerant

connector to allow for high-speed communication

between the modules (see Figure 1).

EQUIPMENT MOUNTING

The Foxboro Evo architecture requires workstations

and commercial-off-the-shelf (COTS) Ethernet

switches, a rack room for the ZCP270 and Ethernet

switches, and a field enclosure for the

FCM100Ets/FCM100Es, FBMs, and other I/O

hardware. For more information on The MESH

control network architecture, refer to

PSS 21H-7C2 B3.

ENHANCED RELIABILITY (FAULT

TOLERANCE)

The unique and patented fault-tolerant operation of

the ZCP270 greatly improves reliability relative to

other process controllers. The fault-tolerant version of

the ZCP270 consists of two modules operating in

parallel, with two sets of Ethernet connections to The

MESH network, two for the control network and two

for the fieldbus network. The two ZCP270 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 controller when both

controllers 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.

SPLITTER/COMBINER

Fault-tolerant ZCP270 modules connect to two pair

of fiber optic splitter/combiners (see Figure 1). One

splitter/combiner pair connects redundant Ethernet

ports on the front of each module to redundant

Ethernet switches in the control network. The other

splitter/combiner pair connects redundant Ethernet

fieldbus ports on the top of each module to

redundant Ethernet switches in the control network.

For each module, the splitter/combiners provide

separate transmit/receive fiber connections for each

Ethernet control network and Ethernet fieldbus port.