Category: Foxboro

APACS+ Subsystems

An FCP280. FCP270 or FCM100Et/FCM100E

baseplate is installed in the MODULPAC enclosure

with single or redundant modules. The baseplate has

a built-in Fieldbus termination assembly. The

I/O module power supplies and MODULRACs are

retained in the cabinet.

The MODULRACS, used to house I/O modules, are

reused to house the DCS FBMs. All termination

assemblies in the local, adjacent, and remotely

marshalled MODULPACs remain intact with their

termination cables and field wiring.

APACS+ I/O modules are removed from the

MODULRAC and replaced by a corresponding DCS

FBM that mates to the original power/signal

connector and termination cable connector on the

back of the MODULRAC. This DCS FBM provides

original I/O functionality of the process inputs and

outputs.

Ladder Logic Implementation

Ladder logic for an APACS+ system is implemented

in the ACM controllers, not in the I/O modules. Thus,

any digital I/O point in the system can be used as an

input or output to the ladder logic running in the

ACM. A similar capability exists with the migrated

APACS+ system through the use of sequence control

logic in the FCP280. FCP270 or ZCP270 Control

Processor.

Foxboro control block ladder logic is implemented by

using a combination of logic which executes directly

in the digital I/O modules and sequence control logic

in the Control Processor. This same capability exists

in the AID115. AID230. AOD115. and ADO125

APACS+ migration modules. The channel

configurable ASAM01. AEAM01. ASDM24 and

ASDM48 I/O modules implement ladder logic only by

using sequence control logic in the Control Processor

similar to the original APACS+ system.

Migration with FCP280 and DCS FBMs

The Field Control Processor 280 (FCP280) is a

distributed, field-mounted controller module that

supports up to 128 DCS FBMs – 32 per HDLC

fieldbus. The FCP280 connects to the control

network via optionally redundant 100 Mbps Ethernet

fiber optic cables and Ethernet fiber switches. The

FCP280 is an optionally fault-tolerant controller that

communicates with connected DCS FBMs to

perform data acquisition and control using Foxboro

Evo control algorithms.

The FCP280 mounts in a 2-position baseplate that

supports a single module or a fault-tolerant module

pair. The baseplate accepts only FCP280 modules.

The FCP280 connects to an optionally redundant

2 Mbps HDLC I/O Fieldbus for communications to

the DCS FBMs and provides galvanic isolation

between the 100 Mbps Ethernet Fieldbus and the

2 Mbps local Fieldbus.

FCP280 modules connect to a pair of copper or fiber

optic network adapters that connect to Ethernet

switches in a redundant control network. The

network adapter pair mounts to the FCP280

baseplate.

To support redundancy, a pair of FCP280s must be

used for each DCS FBM grouping. In non-redundant

configurations, only a single FCP280 is required for

each grouping.

The maximum total cable length for the 2 Mbps

Fieldbus is 60 m (198 ft) within a grouping.

I/O Modules

FEATURES

 Migration from proprietary DCS to a

state-of-the-art open Foxboro Evo system

 Advanced Foxboro Evo control with a single point

of configuration

 More direct control performance than any

gateway device could offer

 Cost savings over total system replacement by

preserving the existing process interface and

wiring and minimizing process downtime

 Single vendor service and supply.

FUNDAMENTAL PRINCIPLE

Foxboro® believes that it is only acceptable to

interface with competing manufacturers’ operating

systems in two ways:

 Through high level public gateways

 At the lowest level directly to field devices without

communicating with proprietary buses or

components.

The Foxboro migration product offerings adhere to

this principle.

PRODUCT DESCRIPTIONS

The Foxboro Evo migration strategy replaces the

APACS+ process control system with a 2 Mbps

Fieldbus connection to a Field Control Processor

(FCP280 or FCP270), provides a module-for-module

replacement of I/O modules, but leaves the original

process interface wiring and cabinets in place.

To replace the APACS+ control and I/O modules

mounted in MODULRAC, SIXRAC or UNIRAC

assemblies, the APACS+ migration consists of new

Foxboro Evo DCS FBMs, FCP280/FCP270 and

baseplate. The baseplate supports either a single

FCP280/FCP270 module or a pair of fault-tolerant

FCP280/FCP270 modules. The FCP280/FCP270

provides the control algorithms and interface

between the FBMs and the 100 Mbps/1 Gbps

Ethernet control network. This allows migration to

Foxboro Evo control, display and application

products while retaining the original process

termination and field I/O wiring. All original process

I/O capability of the APACS+ module functions is

replaced by FBMs and direct Foxboro Evo control

processor scanning and control. For more

information on the FCP270. refer to

PSS 21H-1B9. For more information on the FCP280.

refer to PSS 31H-FCP280.

New DCS FBMs plug directly into existing

MODULRACs, SIXRACS or UNIRACs in place of

APACS+ I/O modules.

The Fieldbus connects the DCS FBM subsystem to

the FCP280. FCP270 or ZCP270. I/O from the

subsystem is connected to the control strategy using

standard Foxboro Evo system I/O type blocks. The

DCS FBMs pass process measurement and output

signals and digital I/O signals to and from the control

processor.

All process signals are fully integrated into the

Foxboro Evo system, allowing direct Foxboro Evo

system monitoring and control of the process.

Migration using theFCP280. FCP270 or

FCM100Et/FCM100E and baseplate is accomplished

using the DCS Fieldbus Module Migration Kit

(P0922TL).

Foxboro Evo™ system Field Control Processor 280 (FCP280)

and Field Control Processor 270 (FCP270) modules mounted

on a baseplate and distributed control system (DCS) Fieldbus

Modules replace the APACS+ Control and I/O modules and

connect existing field devices to the Foxboro Evo system via

a 2 Mbps HDLC Fieldbus and high-speed Ethernet network.

OVERVIEW

The Foxboro Evo system DCS Fieldbus Modules

(FBMs) are for migration of APACS+™ automation

systems manufactured by Siemens® Energy &

Automation, Inc. and Moore Products Co. The FBMs

plug directly into an existing electronic nest to replace

process input and output modules.

The Foxboro Evo system DCS FBM family provides a

migration path from APACS+ process I/O

components to Foxboro Evo display and supervisory

functions. No additional communication devices are

required. No multi-vendor communication software

licensing is required.

The DCS FBM family replaces the APACS+ I/O

modules. Once integrated, the process is controlled

entirely by the advanced Foxboro Evo algorithm set.

The Foxboro Evo DCS FBM product includes

connectors to enable integration of original process

signals to Foxboro Evo systems while keeping the

field interface and wiring. It provides access to all

process signals connected to the APACS+ system by

providing the connection between the Field

Termination Assemblies (FTAs) and the Foxboro Evo

system. All process signals become fully integrated

into the Foxboro Evo system through the use of

process data for operator display, history, alarming

and control.

Operator functions and engineering configuration are

accomplished by the Foxboro Evo system at any

Foxboro Evo operator workstation. Because all

process values become part of the Foxboro Evo

system, all configuration data is maintained by the

system as native Foxboro Evo configurations.

This migration path provides plant operations with all

the power and flexibility of the Foxboro Evo system.

FIELD I/O TERMINATIONS

Field I/O signal connections are made at termination

assemblies (TAs) mounted on DIN rails within or

external to the enclosure. Termination assemblies are

connected to the associated baseplate by dedicated

cables, which can be 0.5 m (1.7 ft) up to 30 m

100 ft) in length. These various cable lengths allow

the termination assemblies to be mounted in the

same enclosure as the FBMs, or in an adjacent

enclosure.

Analog and discrete I/O FBMs are used with specific

termination assemblies to handle a variety of

input/output signals. When used in high voltage

applications, discrete I/O termination assemblies

adapt the module to 120 V ac, 125 V dc, or 240 V ac

inputs.Termination assemblies (TAs) with built-in

relays are available for switching high voltage and

high current digital outputs. Some TAs readback the

state of the contacts to confirm the state of the relay.

INTRINSICALLY SAFE TERMINATION

ASSEMBLY – BASEPLATE (ISTA-*BP*)

The ISTA-*BP* is a combination of a baseplate with

integrated terminals fitted with one or two Fieldbus

modules (FBMs) and eight galvanic isolators. This

solution consists of a printed circuit board and

therefore does not require any additional wiring on

the board, offering a reliable interface between the

control processor and field I/O sensors and

actuators. As a result this compact packaging offers

a noticeable space saving in the interface cabinet.

This is a joint Foxboro® / Pepperl+Fuchs product.

For details, refer to PSS 31H-2Y12.

ENCLOSURES

Enclosures extend the design of the 200 Series

FBMs by providing a range of mounting options to

match application requirements.

Figure 2. Dual or Redundant ISTA-*BP*

The G-Series enclosures are floor-standing units

which accommodate 200 Series baseplates for

mounting FBMs, FEMs, FCMs, and CPs, and/or

termination assemblies or terminal blocks for

marshalling. Most are available for use in ordinary

(IP 43/54) or harsh (IP 55/65) rated environments.

Several product lines of metal enclosures are offered

with the standard 200 Series subsystem:

 G-Series 800×800 Front and Rear Access

Enclosures (G10 system enclosure,

G11 termination enclosure, G12 system and

termination enclosure)

 G-Series 800×600 Front and Rear Access

Enclosures (G20 system enclosure,

G21 termination enclosure, G22 system and

termination enclosure)

 G-Series 800×800 Front-Only Access Enclosures

(G15 system enclosure, G16 termination

enclosure, G17 system and termination

enclosure)

The baseplates are backwards compatible with

existing I/O subsystems allowing for future expansion

without additional interface hardware and includes

the following:

 Primary and secondary 24 V dc power

connections

 Two Module Fieldbus connections (for A/B

Module Fieldbus daisy chain)

 Power/communication connection and field I/O

connection for each FBM

 DIP switch for baseplate identification

 A/B Module Fieldbus and optional time strobe

splitter/terminator connection

 Adding additional baseplates without removing

the system from service (requires redundant

Module Fieldbus).

The baseplates which support FBMs provide

increased overall system installation functionality by

providing unit increments of 2. 4. and 8 module

positions with various operational functionality in

combination with vertical and horizontal mounting.

Any FBM (except FBM232/233) can be removed

from a FBM-supporting baseplate without removing

or disturbing external field device wire terminations or

internal cable terminations or connections.

FCPs and FCMs require removal of wiring to the

control network.

Shielded twisted-pair cables for baseplate

interconnections are available in various lengths of

0.25 m (10 in) up to 60 m (198 ft). The maximum

twisted-pair cable length interconnecting all

baseplates is 60 m (198 ft).

Figure 1 shows selected vertical DIN rail mounted

baseplates. Horizontal DIN rail mounted baseplates

are available in similar styles as the vertical mounted

baseplates, but equivalents for each style are not all

available. Refer to PSS 31H-2SBASEPLT and

PSS 31H-2C200 B4 for additional information on the

remaining Standard and Compact 200 Series

baseplates.

200 SERIES BASEPLATE MODULE MOUNTING

The 200 Series Fieldbus Modules mount on

200 Series baseplates which have been specially

designed to support them (see Figure 1. only vertical

baseplates shown – also FBMs do not mount on the

FCP270-only, FCM-only, or FBI-only baseplates).

The baseplates shown in Figure 1 fasten to a

structurally supported non isolated DIN rail for

mounting inside or outside an enclosure. (As an

alternative to DIN rail mounting, a mounting plate can

be used for horizontal mounting of the 200 Series

baseplate on a 19-inch rack). These baseplates can

thus be mounted in small, distributed cabinets or in a

variety of other mounting configurations.

ENCLOSURES

Enclosures extend the design of the 200 Series

FBMs by providing a range of mounting options to

match application requirements.

Figure 2. Dual or Redundant ISTA-*BP*

The G-Series enclosures are floor-standing units

which accommodate 200 Series baseplates for

mounting FBMs, FEMs, FCMs, and CPs, and/or

termination assemblies or terminal blocks for

marshalling. Most are available for use in ordinary

(IP 43/54) or harsh (IP 55/65) rated environments.

Several product lines of metal enclosures are offered

with the standard 200 Series subsystem:

 G-Series 800×800 Front and Rear Access

Enclosures (G10 system enclosure,

G11 termination enclosure, G12 system and

termination enclosure)

 G-Series 800×600 Front and Rear Access

Enclosures (G20 system enclosure,

G21 termination enclosure, G22 system and

termination enclosure)

 G-Series 800×800 Front-Only Access Enclosures

(G15 system enclosure, G16 termination

enclosure, G17 system and termination

enclosure)

FEATURES

Key features for the standard 200 Series subsystem are:

 Allows you to locate control processor and field

input/output modules in strategic plant areas

 High performance Fieldbus Modules (FBMs)

 Enclosures to provide various levels of

environmental protection

 Optional redundant power

 Variety of modular mounting configurations

 High performance, high accuracy, fast updates

 Optional Intrinsically Safe baseplates for FBMs

 Reduced component count, for ultra-high

reliability and quality

 Optional redundancy

 Harsh (Class G3 – ISA S71.04) contamination

protection

 Distributed local and/or remote I/O

 Power security and alarming

 Electrical isolation and field device power

 High-speed system communication.

HIGH PERFORMANCE, HIGH ACCURACY,

FAST UPDATES

The 200 Series FBMs offer high resolution, high

accuracy, and repeatable design. The Sigma-Delta,

fast integrating converter used on the analog inputs

provides new readings as fast as every 25 ms,

suitable for high-speed regulatory control

applications. The analog inputs use a built-in

configurable moving average filter that efficiently

removes process noise and power line frequencies.

OPTIONAL REDUNDANCY

The standard 200 Series subsystem is optionally

available with total redundancy, for high reliability and

availability. Redundancy is available for; the power

supplies, the control network, the FCMs, the

FEMs(1)), the CPs, Modular Fieldbus cables between

baseplates, and certain FBM I/O module types.