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IA系统FCP270说明书


B0700AR REV C

I/A Series? System Field Control Processor 270 (FCP270) User’s Guide
May 31, 2007

Invensys, Foxboro, FoxCom, Spec 200, SPECTRUM and I/A Series are tr

ademarks of Invensys plc, its subsidiaries, and affiliates. All other brand names may be trademarks of their respective owners. Copyright 2004-2007 Invensys Systems, Inc. All rights reserved

Contents
Figures................................................................................................................................... vii Tables..................................................................................................................................... ix Preface.................................................................................................................................... xi Who This Book Is For ............................................................................................................. xi What You Should Know .......................................................................................................... xi Revision Information ............................................................................................................... xi Reference Documents .............................................................................................................. xi Glossary of Terms .................................................................................................................. xiii 1. Introduction ...................................................................................................................... 1 Overview ................................................................................................................................... 1 Features ..................................................................................................................................... 2 Fault-Tolerance ......................................................................................................................... 3 Traditional Redundant Systems ............................................................................................ 3 FCP270 Fault-tolerant Operation ........................................................................................ 3 On-Line Image Update ............................................................................................................. 4 FCP270 Network Configuration .............................................................................................. Network Path Switching ...................................................................................................... Splitter/Combiner ................................................................................................................ Fieldbus Expansion Module 100 (FEM100) ........................................................................ 4 4 4 6

I/O Communications ................................................................................................................ 6 Communication to 200 Series Fieldbus Modules ................................................................. 7 Communication to Y-Module Fieldbus Modules ................................................................. 7 Time Synchronization ............................................................................................................... Overview .............................................................................................................................. Internal Source Time Synchronization ............................................................................ External Source Time Synchronization ............................................................................ 7 7 7 8

FCP270 Sizing Constraints ....................................................................................................... 8 FCP270 Supported Block Processing Cycles ........................................................................ 8 2. Installing the Field Control Processor 270 ........................................................................ 9 Overview ................................................................................................................................... 9 System Definition ................................................................................................................ 9 Installing a Single or Primary FCP270 Module ....................................................................... 10 Installing a Shadow FCP270 Module ...................................................................................... 13
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Cabling a Single (Non-Fault-Tolerant) FCP270 Module ........................................................ 14 Cabling a Fault-Tolerant FCP270 Module Pair ...................................................................... 14 Boot-Up Sequence .................................................................................................................. Case 1 – Rebooting a Commissioned FCP270 ................................................................... Case 2 – Connecting an FCP270 with the Same Letterbug ................................................ Case 3 – Connecting an FCP270 with a New Letterbug .................................................... Case 4 – Connecting a Shadow Module with Same Software Image ................................... Case 5 – Connecting a Shadow Module with Different Software Image ............................. 18 18 19 19 19 19

Cabling Y-Module FBMs to an FCP270 Baseplate ................................................................. 20 Remote Fieldbus Extension, Cable Connections ................................................................ 20 3. Configuration Information.............................................................................................. 27 System Definition .............................................................................................................. 27 System Definition Procedure .............................................................................................. 27 Integrated Control Configuration ........................................................................................... Off-Line Control Configuration .................................................................................... On-Line Control Configuration .................................................................................... Available I/A Series System Control Blocks ................................................................... 28 29 30 30

4. System Management ....................................................................................................... 31 Overview ................................................................................................................................. 31 Operating Status ..................................................................................................................... 31 System Management Displays for the FCP270 ........................................................................ Equipment Information Display for FCP270 ..................................................................... Configuration Information Display for FCP270 ................................................................ Equipment Change Display for FCP270 ............................................................................ Reboot Station Procedure .............................................................................................. Image Update Procedure for a Non-Fault-Tolerant FCP270 ......................................... Image Update Procedure for a Fault-Tolerant FCP270 ................................................. On-line Image Update Procedure for a Fault-Tolerant FCP270 .................................... System Management Displays – Primary ECB (FBM0) .......................................................... Equipment Information Display for Primary ECB (FBM0) ............................................... Equipment Change Display for Primary ECB (FBM0) ...................................................... Overview of Fieldbus Switching Mode .......................................................................... Using the Fieldbus Switching Options .......................................................................... Overview of the General Download ............................................................................... Downloading all FBM Images ....................................................................................... On-Line Diagnostics (PIO) Display for Primary ECB (FBM0) .......................................... 31 31 36 37 39 39 40 41 42 43 46 48 49 49 49 50

5. Troubleshooting.............................................................................................................. 53 Overview ................................................................................................................................. 53 LED Indicators, Reset Button, and Infrared Ports ................................................................... 53 Operational Status LED Indicators .................................................................................... 55 FCP270 Troubleshooting ....................................................................................................... 55
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Using the Operational Status LEDs .................................................................................... Red off, Green off .......................................................................................................... Red on, Green off .......................................................................................................... Red on, Green on .......................................................................................................... Cycling Red, Red/Green ................................................................................................ Red off, Green on .......................................................................................................... Using the Ethernet Tx and Rx/Link Status LEDs ............................................................... Using the Fieldbus Tx and RX Status LEDs ....................................................................... Fault-Tolerant FCP270 Troubleshooting Addenda ............................................................ Replacing a Failed Module ............................................................................................

56 56 56 57 57 57 58 58 58 59

Memory Dumps and Last Gasp Messages ............................................................................... 59 Last Gasp Messages ............................................................................................................ 59 Memory Dumps ................................................................................................................. 60 Diagnostics ............................................................................................................................. Start-Up Diagnostics .......................................................................................................... Error Recovery Local Diagnostics ....................................................................................... Error Recovery Cooperative Diagnostics ............................................................................ 61 61 62 62

Appendix A. Upgrade Diagrams .......................................................................................... 63 Index .................................................................................................................................... 73

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Figures
1-1. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 3-1. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 5-1. A-1. A-2. A-3. A-4. A-5. A-6. A-7. A-8. A-9. Typical FCP270 Network Configuration (Simplified) .................................................. 5 FCP270 Module Installation (Typical) ....................................................................... 10 Cabling the FCP270 Fault-tolerant Controllers (Two-Position Baseplate Example) .... 15 Cabling the FCP270 Fault-tolerant Controllers (Four-Position Baseplate Example) ... 16 Cabling Y-Module FBMs to an FCP270 Baseplate ..................................................... 21 TCA Cable Connection to 268 Kbps Fieldbus Splitter/Terminator ............................ 22 TCA Termination Block Assembly Mounting ............................................................. 22 TCA Termination Block Removal .............................................................................. 23 Remote Redundant Fieldbus Cabling (FCP270 End) ................................................. 24 Example of Extending Fieldbus in Two Directions from FCP270 ............................... 25 Typical Control Scheme Using an FCP270 and 200 Series FBMs ............................... 29 Equipment Information Display for FCP270 – Typical (1 of 2) ................................. 32 Equipment Information Display for FCP270 – Typical (2 of 2) ................................. 32 Configuration Information Display for FCP270 ......................................................... 36 Equipment Change Display for FCP270 ..................................................................... 37 REBOOT STATION Dialogue Box – Fault-Tolerant FCP270 .................................. 39 IMAGE UPDATE Dialogue Box – Non-Fault-Tolerant FCP270 .............................. 40 IMAGE UPDATE Dialogue Box – Fault-Tolerant FCP270 ....................................... 41 ON-LINE IMAGE UPDATE Dialogue Box – Fault-Tolerant FCP270 ..................... 41 REBOOT STATION Dialogue Box – Fault-Tolerant FCP270 .................................. 42 Equipment Information Display for Primary ECB (FBM0) – Typical (1 of 2) ............ 43 Equipment Information Display for Primary ECB (FBM0) – Typical (2 of 2) ............ 44 Equipment Change Display for Primary ECB (FBM0) ............................................... 47 On-line Diagnostics Display for Primary ECB (FBM0) .............................................. 50 FCP270 LED Indicators, Reset Button, and Infrared Port .......................................... 54 Equipment Replacement Order for CP60-to-FCP270 Conversions ............................ 64 Converting CP10/30/40 with Local I/O to FCP270s .................................................. 65 Converting CP60 with DCM10E to FCP270 ............................................................. 66 Converting CP60 with DCM10Ef to FCP270 ............................................................ 67 Converting CP60 with DCM10Ef with Fiber Optic Hub to FCP270 ........................ 68 Converting CP60 with FBI10E and 100 Series FBMs to FCP270s ............................. 69 Converting CP60 with 200 Series DIN Rail Mounted Equipment to FCP270 ........... 70 Converting Micro-I/A Station to FCP270 .................................................................. 71 Converting AW51/AW70 to FCP270s ....................................................................... 72

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Figures

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Tables
2-1. 2-2. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 5-1. 5-2. Cables for Connecting the FCP270 or Splitter/Combiners to the Ethernet Switches .. Cables for Connecting the Splitter/Combiners to the FCP270 .................................... Equipment Information Display Fields for FCP270 .................................................... Configuration Information Display Fields for FCP270 ............................................... Equipment Change Display Fields for FCP270 ........................................................... Equipment Information Display Fields for Primary ECB (FBM0) .............................. Equipment Change Display Fields for Primary ECB (FBM0) ..................................... Equipment Change Display Fields for Primary ECB (FBM0) ..................................... FCP270 LED Indicators, Reset Button, and Infrared Communication Ports .............. FCP270 Operational Status LEDs .............................................................................. 14 18 33 36 37 44 47 50 54 55

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Tables

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Preface
This document describes how to configure and install the Field Control Processor 270 (FCP270) in an I/A Series? system with The MESH control network. It also describes how the FCP270 functions in The MESH control network. Finally, it describes how to troubleshoot system problems.

Who This Book Is For
This book is intended 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 I/A Series MESH control network.

What You Should Know
Prior to using this book, you should be generally familiar with the I/A Series system, and with DIN Rail Mounted FBM Subsystem User’s Guide (B0400FA). Detailed information relating to the various I/A Series software and hardware elements is found in the reference documents listed below.

Revision Information
For Revision C of this document, the following changes were made to this document: Chapter 1 “Introduction” ? Added the Fieldbus Expansion Module 100 (FEM100) to the introduction and “Fieldbus Expansion Module 100 (FEM100)” on page 6. ? Added “FCP270 Supported Block Processing Cycles” on page 8. Chapter 5 “Troubleshooting” ? Added “Memory Dumps” on page 60. Appendix A “Upgrade Diagrams” ? Added the Appendix.

Reference Documents
The following documents provide additional and related information. For information about defining control blocks and compounds, refer to: Integrated Control Block Descriptions (B0193AX) ? Integrated Control Software Concepts (B0700AG) For information about configuring and managing the FCP270, refer to: ? CP 270 On-Line Upgrade (B0700BY) ? System Definition: A Step-by-Step Procedure (B0193WQ)
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Letterbug Configurator User’s Guide (B0700AY) ? Integrated Control Configurator (B0193AV) ? I/A Series Configuration Component (IACC) User’s Guide (B0400BP) ? Process Operations and Displays (B0700BN) ? System Management Displays (B0193JC) ? Field Control Processor 270 (FCP270) Sizing Guidelines and Excel Workbook (B0700AV). For information about associated DIN Fieldbus Modules and the Fieldbus Expansion Module 100, refer to: ? DIN Rail Mounted FBM Subsystem User’s Guide (B0400FA). For information about Y-module Fieldbus Modules, refer to: ? I/A Series System Equipment Installation (B0193AC). For information about system power and earthing (grounding), refer to: ? Power, Earthing (Grounding), EMC and CE Compliance (B0700AU) For information about supported migration products, refer to: ? 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). ? 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 MESH control network, refer to: The MESH Control Network Architecture Guide (B0700AZ) Most of these documents are available on the I/A Series Electronic Documentation CD-ROM (K0173TQ or K0173WT). The latest revisions of each document are also available through our Global Product Support at http://support.ips.invensys.com.
? ?

?

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Glossary of Terms
The following terminology, used throughout this user’s guide, relates to the FCP270 controller and associated equipment. Name AI APACS+? AW BPC CP60 CSD DIN ECB EEPROM FBM FCM FCP270 FDSI FEM GMT GPS HART HDLC I/A Series? IACC ICC IR LC LED Letterbug Letterbug Configurator MMF MTK MT-RJ Meaning Analog input Siemens? Process Automation System Application Workstation Block Processing Cycle Control Processor 60 Control Strategy Diagram DIN is a non-governmental organization established to promote the development of standardization and related activities in Germany. Equipment Control Block Electrically erasable programmable read-only memory I/A Series system Fieldbus Module Fieldbus Communication Module Field Control Processor 270 Foreign Device Systems Integrator Fieldbus Expansion Module Greenwich Meridian Time (GMT) is an international time standard Global positioning system HART Field Communications Protocol is a standard for digitally enhanced 4 to 20 mA smart instrument communication. High-level Data Link Control protocol - Master/Slave Protocol used on top of several physical layers for FBM communication Intelligent Automation Series I/A Series Configuration Component Integrated Control Configurator Infrared Connector for fiber optic cable connection to the ZCP270 or splitter/combiner Light-emitting diode Alphanumeric string that the user defines to identify a station in an I/A Series control system. Handheld device for setting, modifying and reading the controller letterbug and reading controller status information Multimode fiber cable Master Timekeeper Connector for fiber optic cable connection to Ethernet switches

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Name ROM Rx SMDH SOE STK SysDEF TDA TDR The MESH Tx UTC

Meaning Read only memory Receive System Management Display Handler, the user interface for equipment status and change actions Sequence of Events Slave Timekeeper System Definition Transient Data Analyzer Transient Data Recorder The MESH Control Network Transmit Universal Coordinated Time

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1. Introduction
This chapter describes the main features, fault-tolerant operation, network configuration, and time synchronization of the Field Control Processor 270.

Overview
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. 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. Refer to 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.

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NOTE

The FCP270 supports either the 2 Mbps or the 268 Kbps HDLC fieldbus, but not both at the same time. For the maximum number of devices supported by each fieldbus, refer to the device specific Product Specification Sheets.

Features
The FCP270 provides the following new features and improvements. ? A direct 100 Mbps Ethernet fiber connection to the The MESH 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 and safety using unique, dual controller comparison on all outgoing messages. ? 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, Series 200 DIN rail mounted FBMs, Termination Assemblies, and FPS400-24 power supply). The new configuration eliminates the need for a rack room (you only need a control room and a field enclosure). ? Supports up to 128 Series 200 DIN rail mounted FBMs, or equivalent modules (depending on the sizing guidelines), when connected to an optional Fieldbus Expansion Module 100 (FEM100).
? ? ? ?

? ? ? ?

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. Sequence of Events (SOE) are optionally time stamped at the FBM (200 Series FBMs only) to 1 ms1 accuracy throughout the system for later analysis of events. Optional Transient Data Recorder (TDR) allows 10 ms sampling of analog data for later analysis of events using Transient Data Analyzer (TDA). TDR data is optionally time stamped (200 Series FBMs only) to 1 ms1 accuracy. 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.
1.

Time stamping has 1 ms accuracy only when using the optional GPS external time synchronization.

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?

Foundation Fieldbus, FoxCom?, HART, Profibus, and Modbus FBMs are supported. ? 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.

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 critical systems, the FCP270 uses a patented method of faulttolerance.

FCP270 Fault-tolerant Operation
The fault-tolerant version of the FCP270 consists of two modules operating in parallel, with two separate connections to the The MESH control network. The two control processor modules, married together as a fault-tolerant pair, provide continuous operation of the unit 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’s external interface. Upon detection of a fault, the communication message is aborted, and 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. An aborted control network communication message is then sent by the non-defective 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 61.

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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. Because the FCP270 contains its executable image in internal flash memory, and has sufficient RAM to hold a new executable image at the same time, on-line image updates are now much easier to perform.

FCP270 Network Configuration
The MESH 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 I/A Series workstations connected to Ethernet switches in The MESH. For information about general guidelines and specific requirements for designing The MESH above the FCP270 level, including site planning and network installation guidelines, see The MESH 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 MESH control network provides redundant communications paths. The MESH architecture and the software in the controller allow it to switch paths when a communications path fails 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 MESH 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 MESH. One splitter/combiner in the pair is connected to one Ethernet switch, the other is connected to another Ethernet switch. The splitter/combiner is connected via fiber optic cables. Inbound traffic from The MESH is split and sent to each FCP270 controller. Output traffic is sent from the primary module, which can be either physical module, to The MESH.

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The MESH Control Network
Ethernet Fiber 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

Ethernet Fiber 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

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1 Gbps Ethernet Fiber Optic Cables
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

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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

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100 Mbps Ethernet Fiber Optic Cables (Redundant) Splitter* Splitter* Splitter* FCP270 Only Baseplate F C P 2 7 0 F C P 2 7 0 F C P 2 7 0 F C P 2 7 0 Splitter*

Splitter* Splitter* F C P 2 7 0 F C P 2 7 0

FCP270 Control Processor (Fault-Tolerant)

FCP270 Control Processor (Fault-Tolerant) FCP270 Only Baseplate

FCP270 Control Processor (Fault-Tolerant) FCP270 Only Baseplate 268 Kbps HDLC Module Fieldbus (Shielded Twisted Pair Cables)

2 Mbps HDLC Module Fieldbus (Shielded Twisted Pair Cables)

IPM2

IPM2

FBI

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

Up to 8 FBMs per Baseplate (See B0400FA) DIN Rail Mounted 200 Series FBMs Up to 32 per FCP270 or FCP270 Pair (See Note)

Competitive Migration Modules (See “Overview” on page 1)

1x8 FBM Mounting Structure

* Splitter/Combiner. Note: For additional sizing information, refer to Field Control Processor 270 (FCP270) Sizing Guidelines (B0700AV). Figure 1-1. Typical FCP270 Network Configuration (Simplified)

Y-module FBMs or Migration Modules Up to 64 Y-module FBMs per FCP270 or FCP270 Pair (See Note below and “Overview” on page 1)

IPM2

FBI

100 SERIES FBM

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F B M

Equipment Rack

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1. Introduction

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. (Refer to 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 case of a module’s failure, the other provides backup coverage until the failed module is returned to service. The failure is reported as an interruption to one path of the redundant fieldbus network. Additional information on the FEM100 is provided in the DIN Rail Mounted FBM Subsystem User’s Guide (B0400FA).

I/O Communications
The FCP270 contains several I/O communication features and functions: ? Dual channel HDLC at either 2 Mbps or 268 Kbps for redundant fieldbus connection to the FCP270 module ? Simultaneous support of 200 Series FBM types and protocols (HART, Foundation Fieldbus, Profibus, Modbus, FoxCom, FDSI and standard 200 Series FBMs) ? A maximum of 32 DIN railed mounted 200 Series FBMs 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. ? A maximum of 39 Siemens APACS+ DCS migration FBMs 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 FBMs 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 FBMs and/or DCS migration FBMs 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) data2 ? I/O maintenance activity ? Pass-through activity for device configuration, and so forth.
2.

Using the new SOE feature or the original SOE via ECB6.

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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 fails (see Figure 1-1). For complete information on DIN Rail mounted devices, see DIN Rail Mounted FBM Subsystem User’s Guide (B0400FA).

Communication to Y-Module 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 fails (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 DIN Rail Mounted FBM Subsystem User’s Guide (B0400FA).

Time Synchronization
The I/A Series 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 an I/A Series 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 Master Timekeeper (MTK), residing in an Application Workstation (AW), maintains the time source and distributes the system time to all other stations in The MESH control network. A Slave Timekeeper (STK) receives time information from the MTK and keeps itself synchronized with the MTK, and thus with all other stations in The MESH. STKs reside in all controllers. The MTK determines the time for synchronizing all slave 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, refer to Time Synchronization User’s Guide (B0700AQ).

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 MESH. This time is displayed as local time.

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1. Introduction

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, refer to 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
The number of 200 Series FBMs hosted by an FCP270 (or fault-tolerant FCP270 pair) is 32 maximum alone, 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 faulttolerant 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. For complete sizing information, see Field Control Processor 270 (FCP270) Sizing Guidelines and Excel Workbook (B0700AV).

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: 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 the user 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.
?

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2. Installing the Field Control Processor 270
This chapter provides installation and cabling information for the Field Control Processor 270.

Overview
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 prevents accidental installation of a module in the wrong baseplate location. ? The FCP270 is designed for installation in I/A Series equipment enclosures. For general information on installing equipment into these enclosures, refer to Enclosures and Mounting Structures (B0700AS).
?

The FCP270 installs on DIN Rail mounted baseplates. For complete information on these baseplates, refer to DIN Rail Mounted FBM Subsystem User’s Guide (B0400FA).

System Definition
System Definition identifies the I/A Series 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 the user defines to identify a station in an I/A Series control 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. For a step-by-step procedure for defining an I/A Series system configuration using the System Definition (SysDEF) software, refer to System Definition: A Step-By-Step Procedure (B0193WQ). IACC allows you to import system configuration information from an I/A Series system using SysDEF Export disks created with the System Definition configuration application. For importing procedures, refer to I/A Series Configuration Component (IACC) User’s Guide (B0400BP).

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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)

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! WARNING For safety reasons, always consider the possible impact on plant operations before removing an FCP270 module from a baseplate in an active control system. 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 DIN Rail Mounted Subsystem User’s Guide (B0400FA). Connection to an external time strobe generator is optional. ! CAUTION Observe the signal and power cable separation and segregation guidelines in DIN Rail Mounted Subsystem User’s Guide (B0400FA). 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 prevent 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). ! CAUTION 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. 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). ! WARNING 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.

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5. Connect the FCP270 module to Ethernet switches in The MESH: ? To connect a single (non-fault-tolerant) module to Ethernet switches in The MESH, see “Cabling a Single (Non-Fault-Tolerant) FCP270 Module” on page 14. ? To connect a fault-tolerant module to Ethernet switches in The MESH, see “Cabling a Fault-Tolerant FCP270 Module Pair” on page 14. The module follows one of the following boot-up sequences: ? “Case 2 – Connecting an FCP270 with the Same Letterbug” on page 19 ? “Case 3 – Connecting an FCP270 with a New Letterbug” on page 19 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 39.

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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 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. 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 14. 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). ! CAUTION 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. 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 19 ? “Case 5 – Connecting a Shadow Module with Different Software Image” on page 19 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 31.

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Cabling a Single (Non-Fault-Tolerant) FCP270 Module
! CAUTION When installing fiber optic cable, do not exceed the minimum bend radius of 5 cm (2 in). To connect a single (non-fault-tolerant) FCP270 module to Ethernet switches in The MESH: 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 MESH 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 MESH 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 P0972TR P0972TS P0972TT
1.

Length 3 m (9.8 ft) 5 m (16.4 ft) 50 m (164 ft)1

Material MMF 62.5/125 ?m, orange riser. Two ceramic type LC connectors on one end with an MT-RJ connector on the other end. MMF 62.5/125 ?m, orange riser. Two ceramic type LC connectors on one end with an MT-RJ connector on the other end. MMF 62.5/125 ?m, orange riser. Two ceramic type LC connectors on one end with an MT-RJ connector on the other end.

For fiber optic cable lengths greater than 50 m (164 ft), use a customer-supplied cable up to a maximum 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 MESH using fiber optic cables. The cabling scheme for an FCP270 on a two-position baseplate is shown in Figure 2-2, while the cabling scheme for an FCP270 on a four-position baseplate is shown in Figure 2-3. 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.

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2. Installing the Field Control Processor 270

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To/From To/From The MESH Control Network The MESH Control Network Ethernet Fiber Switch 1 Ethernet Fiber Switch 2 100 Mbps Orange MMF Fiber Cables See Table 2-1 Splitter/Combiner Pair Baseplate Position 1

DC Power Connector Baseplate Position 2

FCP270 Fault-Tolerant Module 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 2-2. Cabling the FCP270 Fault-tolerant Controllers (Two-Position Baseplate Example)

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2. Installing the Field Control Processor 270

To/From The MESH Control Network Ethernet Fiber Switch 1 100 Mbps Orange MMF Fiber Cables See Table 2-1

To/From The MESH Control Network Ethernet Fiber Switch 2

FCP270 Fault-Tolerant Module Pair Baseplate Baseplate Position 1 Position 2

DC Power Connector

Splitter/ Combiner Pair

Optional Splitter/ Terminator P0916RB/ P0926KZ

To/From Expanded Fieldbuses 3-4

To/From Expanded Fieldbuses 1-2

FEM100 Module (Bus A)

FEM100 Module (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 2-3. Cabling the FCP270 Fault-tolerant Controllers (Four-Position Baseplate Example)

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2. Installing the Field Control Processor 270

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! CAUTION 1. Failure to properly connect the cables will result in the modules not being able to operate in a fault-tolerant mode. 2. When installing fiber optic cable, do not exceed the minimum bend radius of 5 cm (2 in). The splitter/combiners (P0926AH) install in an I/A Series enclosure on the following: ? DIN rail mounted modular baseplate ? DIN rail ? Chassis assembly. For detailed mounting procedures for the splitter/combiners, refer to DIN Rail Mounted FBM Subsystem User’s Guide (B0400FA). To connect the splitter/combiners to The MESH Ethernet switches and fault-tolerant FCP270 modules, see Figure 2-2 and proceed as follows: 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 MESH 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 MESH 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).

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2. Installing the Field Control Processor 270

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

Part Number P0972UN P0972VG

Length 0.5 m (1.6 ft) 0.5 m (1.6 ft)

Material MMF 62.5/125 ?m, gray riser. Ceramic type LC connectors with clip on each end. MMF 62.5/125 ?m, 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. ? 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).

Case 1 – Rebooting a Commissioned FCP270
When a Reboot command is issued to a commissioned FCP270 controller running non-faulttolerant, 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. The controller loads the checkpoint file (control database) from the host server as indicated by the Tx and Rx/Link LEDs flashing for either Control Network A or B. 5. The controller initializes on-control as defined by the control database.

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2. Installing the Field Control Processor 270

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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 MESH network cables connected, the operational sequence is the same as for Case 1.

Case 3 – Connecting an FCP270 with a New Letterbug
When connecting an FCP270 module with a new letterbug to the baseplate, with The MESH 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, 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: 1. The shadow module boots up as described in Steps 1 through 3 in Case 1. 2. If the letterbug of the shadow module differs from the primary module, the shadow copies the primary’s letterbug to flash memory. 3. The shadow module marries the primary module, as indicated by the red Operational Status LED flashing on both modules, then the modules run fault tolerant.

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 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 red Operational Status LED flashing on both modules, then the modules run fault tolerant.

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2. Installing the Field Control Processor 270

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 in Figure 4-2 on page 32.

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 2-4). 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). If the fieldbus is non-redundant, only one TCA is connected to the fieldbus splitter/terminator (P0926LC) which is shown in Figure 2-5. 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 2-4 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).

Remote Fieldbus Extension, Cable Connections
Remote fieldbus extension cable connections are implemented as shown in Figure 2-4 and Figure 2-8. For cable connections to the Fieldbus Isolator TCA, refer to “Remote Fieldbus Extension, Cable Connections” in I/A Series System Equipment Installation (B0193AC). To make the remote fieldbus extension cable connections: 1. Referring to Figure 2-6, assemble the termination blocks associated with the termination cable assemblies (P0903VY) for the FCP270 baseplate, snap them onto the mounting rails (DIN rails) in the enclosure, and connect the ground wires. (For future reference, Figure 2-7 illustrates how to remove the TCA termination blocks.) 2. Connect the fieldbus splitter/terminator (P0926LC) to the “Fieldbus and Time Strobe” connector on the FCP270 baseplate (see Figure 2-4). 3. Make cable connection(s) to the fieldbus splitter/terminator as shown in Figure 2-5. 4. Make the fieldbus cable connections between termination cable assemblies (see Figure 2-8). 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 FPC270. (Refer to Figure 2-9.) 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 I/A Series system earthing requirements, refer to Power, Earthing (Grounding), EMC and CE Compliance (B0700AU).
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2. Installing the Field Control Processor 270

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Customer Installed Label Fieldbus A

Termination Cable Assemblies (P0903VY)

Vertical DIN Rail Mounted 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 2-4. Cabling Y-Module FBMs to an FCP270 Baseplate

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2. Installing the Field Control Processor 270

Fieldbus A TCA Cable Connector

Baseplate (P0926HW)

268 Kbps Fieldbus Splitter/Terminator (P0926LC)

Fieldbus B TCA Cable Connector Figure 2-5. TCA Cable Connection to 268 Kbps Fieldbus Splitter/Terminator

1

Slide strain relief bracket onto TCA termination block. Snap assembled termination block onto DIN rail.

3

Connect ground wire to DIN rail using screw, lock washer and nut (customer supplied).

2

TCA Termination Block

Earth (Ground) Wire Screw Lock Washer DIN Rail Ring Lug Strain Relief Bracket

Figure 2-6. TCA Termination Block Assembly Mounting

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2. Installing the Field Control Processor 270

B0700AR – Rev C

1

Disconnect the earth wire from from the DIN rail. Insert a medium-size flat-head screw driver as shown.

3

Move the screw drive handle in the direction shown, while lifting the TCA termination block from the DIN rail.

2

Lift

Earth (Ground) Wire Screw Washer Move TCA Termination Block

Figure 2-7. TCA Termination Block Removal

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2. Installing the Field Control Processor 270

Termination Cable Assemblies (2) (P0903VY) 100 Ohm Twinaxial Cable P0170GF, P0170GG, or Equivalent

Note 1 Note 2 Note 3 BK W SH F F- S F F- S Fieldbus B Note 4 F F- S F F- S Fieldbus A Note 4 BK W SH Note 3

Fieldbus A Fieldbus B To Fieldbus Isolator TCA (See B0193AC)

Note 5

B BR G/Y

B 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, refer to 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 2-8. Remote Redundant Fieldbus Cabling (FCP270 End)

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2. Installing the Field Control Processor 270

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Termination Cable Assembly (P0903VY)

SH To Next Fieldbus Isolator Termination Cable Assembly (See Notes 1 and 2) W BK BK W SH F F- S F F- S Fieldbus A To Next Fieldbus Isolator Termination Cable Assembly (See Notes 1 and 2)

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. Figure 2-9. Example of Extending Fieldbus in Two Directions from FCP270

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26

3. Configuration Information
This chapter provides system configuration information (System Definition) and control configuration information. In general, “configuration” means specifying, to the I/A Series system software, 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
You can use either the SysDEF or IACC application to identify the I/A Series 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 either SysDEF or IACC produces a Commit disk, 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 SysDEF or IACC 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 SysDEF or IACC, 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 I/A Series system software.

System Definition Procedure
To perform system definition, choose either SysDEF or IACC and configure the I/A Series system as described in the corresponding document: ? System Definition: A Step-By-Step Procedure (B0193WQ) ? I/A Series Configuration Component (IACC) User’s Guide (B0400BP) After you have completed system definition, install the system software. Refer to Hardware and Software Specific Instructions for Model P92*A Workstation (PW340) (B0400HD). To use Y-module FBMs (100 Series FBMs) with your FCP270s, use the Integrated Control Configurator (ICC) to create and configure the required ECBs. For more information on the ICC, refer to Integrated Control Configurator (B0193AV) or IACC, refer to I/A Series Configuration Component (IACC) User’s Guide (B0400BP).

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Integrated Control 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. Control 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.
NOTE

The IACC allows you to import Save and SaveAll backup files from an I/A Series control database containing compounds and blocks configured with the Integrated Control Configurator (ICC). The IACC also allows you to export a control database containing compounds and blocks configured with the IACC to Save and SaveAll files for import by the ICC. For import/export IACC, refer to I/A Series Configuration Component (IACC) User’s Guide (B0400BP). The ICC allows you to save control configuration database files to diskette via the Save and SaveAll functions. The ICC also allows you to load Save and SaveAll control configuration database files to an ICC database via the LoadAll function. For Save, SaveAll and LoadAll details, refer to Integrated Control Configurator (B0193AV). You must select one of the following two Foxboro applications for developing your control strategy and configuring the required compounds and blocks ? ICC ? IACC for Windows XP? Professional Edition For information on configuring and downloading the control database, refer to the following: ? Integrated Control Configurator (B0193AV) describes how to use the ICC to implement your process control strategy by configuring compounds, blocks and equipment control blocks, and downloading the configuration database to an FCP270. ? I/A Series Configuration Component (IACC) User’s Guide (B0400BP) describes how to use IACC to develop process control strategy diagrams (CSD), implement CSD templates, configure the required compounds, blocks and equipment control blocks, and download the configuration database to an FCP270. As a compound/block editor, the IACC or ICC provides 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 ICC or IACC. 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.

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4-20 MA

Remote Setpoint

AIN

4-20 MA FBM204 4-20 MA To/From Process Contact Out ECB5 ECB2

Meas. AIN PID

Output AOUT

Alarm Status High COUT FBM241 Alarm Status Low COUT Control Compound

Contact Out

Primary ECB

<Letterbug>_ECB Compound

FCP270 Controller

I/A Series System Enclosure

Notes: 1. For ECB parameters definitions and ECB to FBM assignments, refer to 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

Off-Line Control Configuration
The IACC can run on a PC for off-line configuration of control schemes prior to installation of the actual equipment. The generated control database is easily loaded into the system’s control processor once the I/A Series system is installed. Off-line control configuration is intended for use when a new system is being configured.

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On-Line Control Configuration
The IACC or ICC allow you to modify configuration data for on-line control stations (for example, an FCP270) and configure off-line configuration databases (called library volumes in the ICC). When you have completed creating and editing the off-line configuration database, you can download it to the FCP270. On-line control configuration is intended for use for when a previous I/A Series configuration is being updated to include new equipment.

Available I/A Series System Control Blocks
The I/A Series system offers 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, refer to Integrated Control Block Descriptions (B0193AX). You can use the following control blocks in conjunction with the FCP270: ACCUM AIN AI AINR ALMPRI AO AOUT AOUTR BIAS BIN BINR BLNALM BOOL BOUT BOUTR CALC CALCA CHARC CIN CINR CMP COUT COUTR DEP DGAP DI DO DPIDA DSI DTIME ECBP EVENT EXC FBTUNE FFTUNE GDEV IIN IND IOUT LIM LLAG LOGIC LONG MAIN MATH MCIN MCOUT MDACT MEALM MON MOVLV MSG MTR OUTSEL PACK PAKIN PAKOUT PATALM PATT PID PIDA PIDE PIDX PIDXE PLSOUT PLB PTC RAMP RATIO REAL REALM RIN RINR ROUT ROUTR SIGSEL STA STALM STATE STRIN STRING STROUT SWCH TIM VLV

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This chapter provides general system management information for the Field Control Processor 270. It also provides references to the manuals that describe the tools you use to perform in-depth system management tasks.

Overview
The general I/A Series system management philosophy applies to the Field Control Processor 270 in the I/A Series system.Through the System Management Displays, you can receive status information on the FCP270 and send change requests to the FCP270.

Operating Status
The operating status of the FCP270 is reported by the I/A Series system using on-screen and printed messages. Refer to the following documents for information on the reporting of equipment operating status and errors:
?

I/A Series System Management Displays (B0193JC) ? I/A Series System V8.x System Error Messages (B0700AF) ? I/A Series Process Operations and Displays (B0700BN).

System Management Displays for the FCP270
The I/A Series System Management Display Handler (SMDH) allows 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 SMDH screens, see System Management Displays (B0193JC).

Equipment Information Display for FCP270
The Equipment Information display pages (Figure 4-1 and Figure 4-2) 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.

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Figure 4-1. Equipment Information Display for FCP270 – Typical (1 of 2)

Figure 4-2. Equipment Information Display for FCP270 – Typical (2 of 2)

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Table 4-1. Equipment Information Display Fields for FCP270

Field STATION NAME RUN MODE

Description Controller letterbug assigned during definition of system hardware. On-line or Off-line. This field is initially Off-line. It changes to Online 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 fail the station. However, a failed 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 failure ? Any station hardware failure or communication failure 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. 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 faulted 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. Fault-Tolerant State is Operational or Non-Operational for faulttolerant controllers only. FT STATE indicates Non-Operational if the shadow module is not installed/configured. 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 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, refer to the PRIMARY MODE and SHADOW MODE fields for the current EEPROM Updating State. For more information, see “Image Update Procedure for a Non-FaultTolerant FCP270” on page 39.

FAIL ACK STATE

FT STATE

FAIL DEV ACK

EE UPDATE STATE

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

Field SM REPORT STATE

Description 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 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. 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 fail 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 failure or communication failure 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, refer to the PRIMARY MODE and SHADOW MODE fields for the current FAIL STATE of each module in the fault-tolerant pair. 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 failed or off-line. Additionally, when alarming is inhibited, System Alarm messages are not logged to the system printer, nor the Historian. Yes or No. Yes if one or more peripherals attached to the controller are failed. Not Active is always displayed because there are no off-line diagnostics for the FCP270 station. 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, refer to the PRIMARY MODE and SHADOW MODE fields for the current Downloading State. Both Cables Okay or Fault. This field indicates if there is a cable Fault on either The MESH control network cables A or B, or both. Single Primary, Married Primary, EE Updating, Downloading or Failed appears for fault-tolerant controllers.

TYPE

FAIL STATE

ALARMING STATE

FAIL DEV ATT DIAG STATE DOWNLOAD STATE

CABLE STATE PRIMARY MODE

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

Field PRIM ROM ADDRESS

Description 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 Figure 4-2. Primary controller hardware part number. Primary controller hardware revision number. Typically, for an FCP270 this part number is P0917YZ. Primary controller hardware manufacturing date. Primary controller EEPROM revision level. Six-octet MAC address. This field specifies a unique MAC address that other stations in the system use to communicate with the FCP270. Married Shadow, EE Updating, Downloading, Failed, or Off-line appears for fault-tolerant controllers. A non-existent shadow module is marked as Off-line. 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. Last known shadow controller hardware part number. This field is blank if the shadow controller does not exist. Last known shadow controller hardware revision number. This field is blank if the shadow controller does not exist. Last known shadow controller hardware manufacturing date. This field is blank if the shadow controller does not exist. Last known shadow controller EEPROM revision level. This field is blank if the shadow controller does not exist. Indicates the status of UTC time and time strobe from the Master Timekeeper (MTK), as received by the FCP270. STATE Pulsed STK Sync_A_In_Fail Sync_B_In_Fail Sync_AB_In_Fail Sync_not_Cfg Description FCP270 is receiving UTC time from MTK and time strobe from both ports A and B. FCP270 is receiving UTC time from MTK and time strobe only from port B. FCP270 is receiving UTC time from MTK and time strobe only from port A. FCP270 is receiving UTC time from MTK, but lost time strobe from ports A and B. FCP270 is not configured as a Sync Pulse station.

PRIM HARD PART PRIM HARD REV PRIM HARD DATE PRIM EEPROM REV STATION ADDRESS SHADOW MODE

SHD ROM ADDRESS

SHAD HARD PART SHAD HARD REV SHAD HARD DATE SHAD EEPROM REV MT REPORT STATE

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Configuration Information Display for FCP270
The Configuration Information display (Figure 4-3) 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.

Figure 4-3. Configuration Information Display for FCP270

Table 4-2. Configuration Information Display Fields for FCP270

Field STATION NAME SMON NAME LI NAME IP ADDR SW CONNECTION TYPE SMON AP NAME BOOT HOST
36

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

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

Figure 4-4. Equipment Change Display for FCP270

! CAUTION Only designated personnel who are aware of the effects of making equipment changes should initiate equipment changes.

Table 4-3. Equipment Change Display Fields for FCP270

Action CHECKPOINT COMMAND

Description Saves operator set values and process tuning changes for a controller 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.

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

Action ENABLE STATION ALARMING INHIBIT STATION ALARMING REBOOT STATION

Description Enables the controller system alarms to be propagated up the equipment hierarchy and enables controller system alarm messages. This action does not affect process alarms. Prevents the controller system alarms from being propagated up the equipment hierarchy and disables controller system alarm messages. Does action not affect process alarms. 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. 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. Enables uploading of the station image to a file on the host file server if the controller fails. Disables uploading of the station image to a file on the host file server if the controller fails. Enables download of files needed for REBOOT STATION, IMAGE UPDATE and ON-LINE IMAGE UPDATE actions. Disables download of files needed for REBOOT STATION, IMAGE UPDATE and ON-LINE IMAGE UPDATE actions. Enables reporting of all status for the controller and any attached devices, and reporting of system and peripheral counters to the System Monitor. Disables reporting of all status for the controller and any attached devices and reporting of system and peripheral counters to the System Monitor. Allows you to update the software image on a fault-tolerant FCP270, safely and with minimum hold-control time. For more information, refer to “On-line Image Update Procedure for a FaultTolerant FCP270” on page 41.

IMAGE UPDATE

ENABLE UPLOAD DISABLE UPLOAD ENABLE DOWNLOAD DISABLE DOWNLOAD ENABLE ALL REPORTS

DISABLE ALL REPORTS

ON-LINE IMAGE UPDATE

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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, refer to I/A Series 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 (refer to I/A Series System Management Displays (B0193JC). 2. In the Equipment Change Display, ensure that the Enable Download state is active. If it is not, click ENABLE DOWNLOAD. To ensure 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 (Figure 4-5) offers choices for primary module, shadow module, or both. The dialog box displays the MAC address and status of the primary and shadow modules.

Figure 4-5. REBOOT STATION Dialogue Box – Fault-Tolerant FCP270

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 an error, the system displays a message on the screen and/or at the system printer. Refer to I/A Series System V8.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.
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To update the existing image in flash memory for a non-fault tolerant FCP270 station: 1. Access the Equipment Change Display for the desired FCP270 (refer to I/A Series System Management Displays (B0193JC). 2. To ensure that all changes to the station are recorded in the host server, click Checkpoint COMMAND. 3. Ensure that download is currently enabled. If it is not, click ENABLE DOWNLOAD. To ensure that download is currently enabled, verify that the ENABLE DOWNLOAD button is back-lighted dark cyan. 4. Click IMAGE UPDATE, then click Yes in the dialog box (Figure 4-6) that appears.

Figure 4-6. IMAGE UPDATE Dialogue Box – Non-Fault-Tolerant FCP270

While IMAGE UPDATE runs, the system sends standard update progress messages to the system printer. IMAGE UPDATE takes approximately 1 minute to 5 minutes depending on database size. 5. To verify the new image revision levels, use one of the following procedures: ? Enter the Command Prompt window on the Application Workstation hosting the updated FCP270, and start the Frev utility by typing the following command:
/usr/fox/bin/tools/frev >/usr/tmp/frev.log
?

Use the Equipment Information display to view the updated EEPROM version in the PRIM EEPROM REV field. You can also use the Station display, selectable via FoxSelect, to view the updated software version.

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. To update the existing image in flash memory for a fault-tolerant FCP270 station: 1. Access the Equipment Change Display for the desired FCP270 (refer to System Management Displays (B0193JC). 2. Ensure that download is currently enabled. If it is not, click ENABLE DOWNLOAD. To ensure that download is currently enabled, verify that the ENABLE DOWNLOAD button is back-lighted dark cyan. 3. Click IMAGE UPDATE, then click Yes in the dialog box (Figure 4-7) that appears.

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Figure 4-7. IMAGE UPDATE Dialogue Box – Fault-Tolerant FCP270

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 process is entirely automatic.

On-line Image Update Procedure for a Fault-Tolerant FCP270
The ON-LINE IMAGE UPDATE action allows you to upgrade the existing image (operating system software) in an on-line, fault-tolerant FCP270, safely and with minimum hold-control time. For more information, refer to Control Processor 270 (CP270) On-Line Upgrade (B0700BY). To update the existing image in flash memory for a fault-tolerant CP270 while it is on-line: 1. Access the Equipment Change Display for the desired CP270 (refer to System Management Displays (B0193JC)). 2. Ensure that download is currently enabled. If it is not, click ENABLE DOWNLOAD. To ensure that download is currently enabled, verify that the ENABLE DOWNLOAD button is back-lighted dark cyan. 3. Click ON-LINE IMAGE UPDATE, then click COLD START or WARM START in the dialog box (Figure 4-8) that appears. For information on Cold Start and Warm Start, refer to Control Processor 270 (CP270) On-Line Upgrade (B0700BY).

Figure 4-8. ON-LINE IMAGE UPDATE Dialogue Box – Fault-Tolerant FCP270

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While the ON-LINE IMAGE UPDATE runs, the system sends standard update progress messages to the system printer. ON-LINE IMAGE UPDATE takes approximately 1 minute to 5 minutes depending on database size. 4. On the Equipment Change Display, click REBOOT STATION. For a fault-tolerant station, a dialog box (Figure 4-9) appears with choices for primary module, shadow module, or both.

Figure 4-9. REBOOT STATION Dialogue Box – Fault-Tolerant FCP270

The module operational statuses that can be displayed are listed in “Reboot Station Procedure” on page 39. 5. Click PRIMARY or SHADOW based on one of the following conditions: ? If you are satisfied with the behavior of the controller running the new image, reboot the Shadow module to complete the update process. ? If you do not want to continue running the new software image, reboot the Primary module to resume fault-tolerant operation running the old software image. For more information, refer to Control Processor 270 (CP270) On-Line Image Update (B0700BY). If there is an error, the system displays a message on the screen and/or at the system printer. Refer to I/A Series System V8.x System Error Messages (B0700AF). This completes the On-line Image Update of the CP270 station.

System Management Displays – Primary ECB (FBM0)
The I/A Series 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).

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Equipment Information Display for Primary ECB (FBM0)
The Equipment Information display pages (Figure 4-10 and Figure 4-11) for the Primary ECB (FBM0) contain operational status, equipment change action status, device status, and power status fields. The following fields are updated when a status change occurs:
?

RUN MODE ? FAIL ACK STATE ? CP POWER 1 ? SWITCHING MODE

?

DEVICE STATE ? ALARMING STATE ? ACTIVE PIO BUS ? CP POWER 2 ? DIAG STATUS 1

All other fields are either static, updated when the display is recalled, or unused. Table 4-1 describes the available text fields in the order that they appear on the display pages, from left column to right column.

Figure 4-10. Equipment Information Display for Primary ECB (FBM0) – Typical (1 of 2)

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Figure 4-11. Equipment Information Display for Primary ECB (FBM0) – Typical (2 of 2)

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

Field NAME RUN MODE

Description The letterbug of the FCP270 in which the primary ECB (FBM 0) is located. 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 fail. As a result, a number of messages appear at the printer indicating communication failures and peripheral equipment failures. 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.

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

Field FAIL ACK STATE

Description 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 faulted 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 failure. To clear, click ACK or ACK ALL on the configured application workstation (AW). This field does not apply to FBM0. It displays “Not Downloading”. This field does not apply to FBM0. It displays “No”. OK or Failed indicates the state of primary power to FCP270. 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. This field does not apply to FBM0. It displays “0”. This field does not apply to FBM0. It displays “0”. This field does not apply to FBM0. It displays “0”. This field does not apply to FBM0. It displays “0”. This field does not apply to FBM0. It displays “0”. This field does not apply to FBM0. It displays “00”. This field does not apply to FBM0. This field does not apply to FBM0. FBM0 represents the primary ECB. 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 are not guaranteed to be good. ? Comm Failures: No real device information is available. ? Failed: Fatal hardware or other fatal fault reported by the device. Presupposes that communication has not failed. ? 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.

DOWNLOAD STATE FAIL DEV ATT CP POWER 1 SWITCHING MODE

DIAG STATUS 2 DIAG STATUS 4 SOFTWARE TYPE PRIM CMD STAT FBM STATUS HARDWARE REV SERIAL NUMBER EEPROM REV TYPE DEVICE STATE

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

Field ALARMING STATE

Description

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 failed 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. SOFTWARE REV This field does not apply to FBM0.

Equipment Change Display for Primary ECB (FBM0)
You can use the Equipment Change display (Figure 4-12) 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 secured actions on this FCP270 can access the equipment change actions for FBM0. Table 4-5 describes the actions that are available for this display. In Figure 4-12, the following fields are not used:
?

DOWNLOAD ? EEPROM UPDATE

?

RESET ATTENTION BIT ? SWITCH ROLES

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Figure 4-12. Equipment Change Display for Primary ECB (FBM0)

! CAUTION Only designated personnel who are aware of the effects of making equipment changes should initiate equipment changes.

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

Action GO OFF-LINE

Description 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. Starts Fieldbus communication to all attached FBMs. The system sends a message to the designated printer. 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.

GO ON-LINE GENERAL DOWNLOAD

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

Action SELECT BUS A ONLY

Description 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 an error, the system displays a message. 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 an error, the system displays a message. 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 an error, the system displays a message. Enables device alarming from FBMs attached to the Fieldbus. System alarm messages are logged to the system printer or Historian. Prohibits device alarming for FBMs attached to the Fieldbus. 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.

SELECT BUS B ONLY

BUS AUTO SELECT

ENABLE DEVICE ALARMING INHIBIT DEVICE ALARMING

NOTE

For more information and procedures for performing equipment change actions, refer to I/A Series System Management Displays (B0193JC).

Overview of Fieldbus Switching Mode
The FCP270 records the number of FBM access failures per Fieldbus A and/or B and determines whether switching occurs. The system checks the other bus (cable) to eliminate switching to a bad or worse bus. The following scenarios can occur: ? If the current Fieldbus has a failure(s) and the other bus has fewer or no failures, 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 failures, 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 failure.

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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 maintained. If there is an 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 an 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 an error occurs. 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 defective cable or Modular Baseplate).

Overview of the General Download
The GENERAL DOWNLOAD action downloads FBM images for all off-line/failed 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, failed 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 Equipment Change display, select GENERAL DOWNLOAD. This loads the FBM images to all off-line/failed FBMs. Messages indicating the success or failure of the action for each downloaded FBM appear. If the GENERAL DOWNLOAD action is successful, each FBM goes on-line. If there is a failure, 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 37.

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On-Line Diagnostics (PIO) Display for Primary ECB (FBM0)
You can use the On-line Diagnostics (PIO) display (Figure 4-13) for the Primary ECB (FBM0) to inhibit or enable PIO bus (Fieldbus) cable alarms. Only workstations designated (during System Monitor configuration) to perform secured actions on this FCP270 can access the on-line diagnostics actions for FBM0. Table 4-6 describes the actions that are available for this display.

Figure 4-13. On-line Diagnostics Display for Primary ECB (FBM0)

! CAUTION Only designated personnel who are aware of the effects of running on-line diagnostics should initiate diagnostic actions.

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

Action ENABLE PIO BUS CABLE A ALARMS ENABLE PIO BUS CABLE B ALARMS

Description Enables PIO Bus A (Fieldbus A) cable alarms to monitor cable faults. System alarm messages are logged to the system printer or Historian. Enables PIO Bus B (Fieldbus B) cable alarms to monitor cable faults. System alarm messages are logged to the system printer or Historian.

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

Action INHIBIT PIO BUS CABLE A ALARMS INHIBIT PIO BUS CABLE B ALARMS
NOTE

Description Prohibits PIO Bus A (Fieldbus A) cable alarms. System alarm messages are not logged to the system printer or Historian. Prohibits PIO Bus B (Fieldbus B) cable alarms. System alarm messages are not logged to the system printer or Historian.

For more information and procedures for performing on-line diagnostic actions, refer to I/A Series System Management Displays (B0193JC).

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5. Troubleshooting
This chapter describes possible FCP270 failure situations and provides diagnostic routines that allow you to locate and resolve unit failures quickly.

Overview
In most cases, problems occur because the controller is misconfigured or there are faulty network connections. In the event of a true hardware failure, the I/A Series 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, refer to 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 MESH 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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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 The MESH Control Network A or B Tx The MESH Control Network A or B Rx/Link

Description LED is on when the primary controller is transmitting data over control network A or B. LED is active only on the primary controller. LED is blinking when the controller is receiving data 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. LEDs indicate the health of the controller. See “Using the Operational Status LEDs” on page 56.

Green and Red Operational Status LEDs

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

Item Reset Button

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

IR Active LED

Fieldbus A or B Tx

Fieldbus A or B Rx Infrared communication port

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 OFF OFF ON

Green LED ON OFF ON

Status Module is on-line and functional. (This is the normal run state.) No power, or a fault exists in which the green or red LED is not turned on. Start-up, or a fault 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. Module is in failed state, or it is running on-line diagnostics during boot up.

ON

OFF

FCP270 Troubleshooting
The following troubleshooting information is intended as a service guide for some of the most commonly encountered system problems. 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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! CAUTION 1. Do not attempt to repair modules in the field! 2. To reboot the FCP270, use System Management displays if possible.

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 failed 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 Failed Module” on page 59). ? Replace the failed FCP270 module with a known good module to test that slot in the baseplate (see “Replacing a Failed Module” on page 59). ? Remove the FCP270 module and check the connector for bent pins. For module removal procedures, see “Replacing a Failed Module” on page 59). 2. Verify that the operational status LEDs on the front of the Invensys 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, refer to DIN Rail Mounted 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 failed 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, refer to DIN Rail Mounted Subsystem User’s Guide (B0400FA). If none of the above checks resolve the failure, 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 hardware fault of some kind. Hardware faults are typically internal to the FCP270 module, but you can try the following 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 39). 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 Failed Module” on page 59).
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3. If the module is part of a fault-tolerant pair, replace it and verify that the new module marries successfully. ! WARNING If the failed FCP270 module is part of a fault-tolerant module pair, disconnecting the time strobe cable from the baseplate causes the primary FCP270 module on control to loose time synchronization. 4. Check for insufficient voltage, as shown in Steps 1 through 4 in the previous section.

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 processor fault probably exists. 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. Processor faults can occur for several reasons when fault-tolerant modules are married, but such faults are unlikely to occur when the module is operating single. 1. Verify that the module is properly configured using System Management. 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 MESH control network A and B cables on one module. If these steps fail to 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 failing or the cooperative diagnostics between the two processors reaches 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 Failed Module” on page 59). If these steps fail to 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.

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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: 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 failure, 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, refer to DIN Rail Mounted FBM Subsystem User’s Guide (B0400FA). If none of the above issues caused the failure, 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.

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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 fails, the failed 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 network fiber cables are correctly connected. 2. Check for error messages at the system printer. 3. Replace the module if all else fails.

Replacing a Failed Module
To replace a failed module in 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 defeated. 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 13. 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.

Memory Dumps and Last Gasp Messages
The following sections describe memory dumps and last gasp messages.

Last Gasp Messages
Last gasp messages are a way of sending information about a failure before the FCP270 restarts. Last gasp messages contain the controller ID and error code. In the case of a failed module within a fault-tolerant pair, the failed 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.

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Memory Dumps
There are two kinds of memory dumps. If the module experiences a SW error while running (such as WDT time-out or a memory violation), it saves a memory image of the FCP270 so that a thorough failure analysis 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 failed 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 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 hardware failures 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 Invensys 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 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. 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 primary to upload the memory dump. To make the shadow module become primary, 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

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?

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 Invensys 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 fault occurred while the modules were married, you can now restart the off-line module, which remarries its partner. To restart the module, use the “Reboot Station Procedure” on page 39.
NOTE

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

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
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approximately five seconds. A failure is indicated by the Operational Status LEDs (red LED remains on and green LED remains off ).

Error Recovery Local Diagnostics
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). These diagnostics attempt to identify any faults 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 failure is indicated by the Operational Status LEDs (red LED is on and green LED is off ) and by messages at the system printer.

Error Recovery Cooperative Diagnostics
Error recovery cooperative diagnostics run when a fault is detected by the run-time mechanisms (output miscompare, sync time-out, and so forth). These diagnostics tests work cooperatively to identify any faults that inhibit normal fault-tolerant operations. If a failure is localized to a particular controller, that controller is sent to the failed state. An example of this type of failure 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 fails due to a miscompare. If a fault 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 inter-link exchange failure. If no fault is detected 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. A failure is indicated by the Operational Status LEDs (red LED is on and green LED is off ) and by messages at the system printer.

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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 an I/A Series 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 65 ? Figure A-3 “Converting CP60 with DCM10E to FCP270” on page 66 ? Figure A-4 “Converting CP60 with DCM10Ef to FCP270” on page 67
? ? ? ? ?

Figure A-5 “Converting CP60 with DCM10Ef with Fiber Optic Hub to FCP270” on page 68 Figure A-6 “Converting CP60 with FBI10E and 100 Series FBMs to FCP270s” on page 69 Figure A-7 “Converting CP60 with 200 Series DIN Rail Mounted Equipment to FCP270” on page 70 Figure A-8 “Converting Micro-I/A Station to FCP270” on page 71 Figure A-9 “Converting AW51/AW70 to FCP270s” on page 72
NOTE

Systems with combinations of FCM10- and DCM10-type modules will not be supported until a later I/A Series software release. 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 64.

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CP60 CONFIGURATION

200 SERIES

200 SERIES or 100 SERIES

100 SERIES

FBM10E

FBM10E or FBM10Ef

FBM10Ef

DCM10E

DCM10E DCM10Ef or FBI10E

DCM10Ef

FBI10E ? Remove CP60 ? Remove Coax Cable ? Remove Cox ‘Tees’ ? Remove Terminators ? Remove any fiber extension equipment ? Remove FBM10E modules ? Remove CP60 ? Remove Coax Cable ? Remove Cox ‘Tees’ ? Remove Terminators ? Remove Fiber Equip. ? Re-use Fiber Cable ? Remove FBM01Ef modules ? Remove CP60 ? Remove Coax Cable ? Remove Cox ‘Tees’ ? Remove Terminators ? Remove any fiber extension equipment ? Remove DCM10E modules ? Remove CP60 ? Remove Coax Cable ? Remove Cox ‘Tees’ ? Remove Terminators ? Remove any fiber extension equipment ? Replace FBI10e modules with Fieldbus Isolator modules ? Connect Fieldbus Terminal Assemblies ? Remove CP60 ? Remove Coax Cable ? Remove Cox ‘Tees’ ? Remove Terminators ? Remove Fiber Equip. ? Leave Fiber Cable

<20 m

<20 m or >20 m

>20 m

<975 m

<975 m or >975 m

>975 to 1830 m

<975 m

<975 m or >975 m

One FBM baseplate connection: ? FBM modules can be installed in FCM locations ? Install FCP270, baseplate & supplies ? Connect FCP270 baseplate to 200 Series baseplates with an HDLC cable ? Terminate the HDLC cables OR More than one FBM baseplate connection: ? FBM modules can be installed in FCM locations ? Install FCP270, baseplate & supplies ? Install FEM100 modules, baseplates & supplies near FBMs ? Connect FEM100 baseplate to 200 Series baseplate with HDLC cables ? Connect FEM100 baseplate to FCP270 baseplate with an HDLC cable ? Terminate the HDLC cables

One FBM baseplate connection: ? Install FCM2f modules in FCM locations ? Install FCP270, baseplate & supplies ? Install FCM2f*, baseplate & supplies near FCP270s ? Connect FCP270 baseplate to FCM2f* baseplate with an HDLC cable ? Connect FCM2f* modules with fiber cables ? Terminate the HDLC cables OR More than one FBM baseplate connection: ? FBM modules can be installed in FCM locations ? Install FCP270, baseplate & supplies ? Install FCM2f*, baseplate & supplies near FCP270s ? Connect FCP270 baseplate to the FCM2f* baseplate with an HDLC cable ? Install FEM100 modules, baseplates & supplies near FBMs ? Connect FEM100 baseplate to the 200 Series baseplate with an HDLC cable ? Install FCM2f*, baseplate & supplies near FEM100s ? Connect FEM100 baseplate to the FCM2f* baseplate with an HDLC cable ? Connect FCM2f* modules with fiber cables ? Terminate the HDLC cables

>975 to 2000 m

? Install FCP270 modules, baseplate & supplies ? Connect terminal assemblies to FCP270 baseplate ? Connect FCP270 terminal assemblies to 100 Series terminal assemblies with Twinaxial cables ? Terminate the HDLC cables

? Install FCP270 modules, baseplate & supplies ? Install FBI100 modules, baseplate & supplies near the FCP270 modules ? Connect FBI100 baseplate to FCP270 baseplate with an HDLC cable ? Connect FBI100 baseplate to Fieldbus Isolator terminal assemblies with Twinaxial cables ? Terminate the HDLC cables

? Install FCP270 modules, baseplate & supplies ? Connect terminal assembly to FCP270 baseplate ? Install fiber optic modems, baseplate & supplies near the FCP270 modules ? Connect fiber modems to FCP270 terminal assemblies using Twinaxial cables ? Install fiber optic modems, baseplate & supplies near the 100 Series nest ? Connect the remote fiber modems to FBI terminal assembly using Twinaxial cables ? Connect the fiber modems near the FCP270 modules to the fiber modems near the 100 Series nest using the existing fiber cables ? Terminate the HDLC cables

Transfer the control scheme to the FCP270

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

64

Appendix A. Upgrade Diagrams

B0700AR – Rev C

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

65

IPM2

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

10Base-2 COAX

IPM2

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS
SWITCH GROUP B

NODEBUS CP60 CONNECTION TO EXISTING NODEBUS DCM 10E

TWINAXIAL CABLE

SWITCH GROUP B

IPM2

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS

6000 ft/1830 m (max)

FBI

TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES

FIBER OPTIC CABLE GROUP A CABLE GROUP E POWER MODULE PRI PWR FPS400-24 P0917LY/ P0922YU CABLE GROUP D CABLE GROUP B

TO OTHER DCMs

END-OF-LINE TERMINATOR

FAULT TOLERANT PAIR

TO OTHER REMOTE I/O

UPGRADED EQUIPMENT
ADD EQUIPMENT WHICH IS HIGHLIGHTED IN GREEN

FBI TERMINAL ASSEMBLY

OPTICAL SPLITTER

FIELDBUS & TIME STROBE SOCKET

A

A

P0800DC

TERMINATOR (USE AT END OF LINE)

1 x 8 STRUCTURE

IPM2

FCP270

P0917YZ

FCP270

P0917YZ

TO BE RELEASED
BASEPLATE TERMINAL ASSEMBLY KITS

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

OPTICAL SPLITTER

FBI100

FBI100

TERMINATOR P0916RB

"Y" ADAPTER MAY BE NEEDED IF STARTING WITH "LOCAL" I/O
TWINAX

IPM2

FBI

B
P0903VY x 2

B

P0972UN P0972VG P0973BU P0972ZQ
I/A Series I/A Series

(GRAY, 50 cm) (ORANGE, 50 cm) (GRAY, 25 cm) (ORANGE, 25 cm)
BASEPLATE

FBI = P0903ZE or P0400VE
EXISTING TWINAXIAL CABLES 3200 to 6000 ft (975 to 1830 m)

TERMINATOR (USE AT END OF LINE)

P0926AH

FBI TERMINAL ASSEMBLIES

BASEPLATES HORIZONTAL = P0926HC VERTICAL = P0926HW
PRI PWR
BASEPLATE TERMINAL ASSEMBLY KITS

P0800DC

TO OTHER REMOTE I/O

FAULT TOLERANT PAIR

TERMINATOR (USE AT END OF LINE)

IPM2

OPTICAL SPLITTER

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

FCP270

P0917YZ

FCP270

P0917YZ

IPM2

CABLE GROUP B

B

B

SEC PWR

POWER MODULE FPS400-24 P0917LY/ P0922YU CABLE GROUP D CYAN MAGENTA

"Y" ADAPTER MAY BE NEEDED IF STARTING WITH "LOCAL" I/O

IPM2

FBI

OPTICAL SPLITTER

COPPER (ie, Cu) ETHERNET CABLE FIBER (ie, FO) ETHERNET CABLE

FBI = P0903ZE or P0400VE

TERMINATOR (USE AT END OF LINE)

Appendix A. Upgrade Diagrams

P0926AH

P0972UN P0972VG P0973BU P0972ZQ

(GRAY, 50 cm) (ORANGE, 50 cm) (GRAY, 25 cm) (ORANGE, 25 cm)

FIELDBUS & TIME STROBE SOCKET

100 SERIES FBM

ADAPTER P0926LC

EXISTING TWINAXIAL CABLES 3200 ft/975 m (Max - all segments)

IPM2

FBI

Figure A-3. Converting CP60 with DCM10E to FCP270

RECOMMENDED FOR SHORTER RUNS (UP TO 3200 FT)

1 x 8 STRUCTURE

A

A

P0903VY x 2

100 SERIES FBM

SEC PWR

RECOMMENDED FOR LONGER RUNS (3200 TO 6000 FT)

IPM2

FBI

TO OTHER REMOTE I/O

TO OTHER REMOTE I/O

100 SERIES FBM

POWER CABLES

IPM2

FBI

66
EXISTING CP60 EQUIPMENT
REMOVE EQUIPMENT HIGHLIGHTED IN YELLOW
185 m/607 ft (max) END TO END
10Base-2 COAX

B0700AR – Rev C

Overview Cabling Diagram For Converting CP60 w/DCM10e To FCP270s
TO OTHER MESH COMPONENTS

FIBER CABLE GROUP A MMF with MT-RJ/LC CABLES P0972TR = 3 m P0972TS = 15 m P0972TT = 50 m CUSTOMER SUPPLIED = >50m, < 2 km FIBER CABLE GROUP C FPS400 LINE CORDS GROUP D MMF w/MTRJ CABLES P0926CN = 11" P0972KV = 3 m P0923DA = 15" P0972KW = 10 m P0926CM = 33" P0972KX = 50 m CUSTOMER SUPPLIED = >50m, < 2 km TO OTHER DCMs
NOTE: OTHER WELL FILTERED 24 TO 39 Vdc POWER SOURCES MAY BE SUBSTITUTED FOR THE P0904AU PDU.

FPS400 POWER CABLES GROUP B P0926KK = 16" P0926KL = 36" P0926KM = 48" P0926KN = 60" P0926KP = 72" P0926KQ = 84" OPTIONAL 1 GBit UPLINK. REQUIRES UPLINK CARDS DCM 10E P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS
SWITCH GROUP A TWINAXIAL CABLE 6000 ft (max)

END-OF-LINE TERMINATOR TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES

CABLE GROUP C

MESH NETWORK

HDLC CABLES GROUP E P0916ND = 0.25 m P0917JJ = 0.5 m P0916MZ = 1.0 m P0916NC = 3.0 m P0916NB = 5.0 m P0916NA = 10 m P0916UH = 20 m P0916UJ = 30 m P0916UK = 60 m

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS

SWITCH GROUP A

1 x 8 STRUCTURE

TO OTHER MESH COMPONENTS

PDU P0904AU

Overview Cabling Diagram For Converting CP60 w/DCM10Ef To FCP270s
EXISTING CP60/DCM10Ef EQUIPMENT
REMOVE EQUIPMENT HIGHLIGHTED IN YELLOW
10Base-2 COAX 185 m /607 ft (max) END-OF-LINE TERMINATOR TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES

FIBER CABLE GROUP A MMF with MT-RJ/LC CABLES P0972TR = 3 m P0972TS = 15 m P0972TT = 50 m CUSTOMER SUPPLIED = >50m, < 2 km
TO OTHER MESH COMPONENTS BNC to FIBER CONVERTER NOTE: OTHER WELL FILTERED 24 TO 39 Vdc POWER SOURCES MAY BE SUBSTITUTED FOR THE P0904AU PDU.
2 km (max)
TWINAXIAL CABLE

FPS400 POWER CABLES GROUP B P0926KK = 16" P0926KL = 36" P0926KM = 48" P0926KN = 60" P0926KP = 72" P0926KQ = 84" FIBER CABLE GROUP C MMF w/MTRJ CABLES P0972KV = 3 m P0972KW = 10 m P0972KX = 50 m CUSTOMER SUPPLIED = >50m, < 2 km FPS400 LINE CORDS GROUP D P0926CN = 11" P0923DA = 15" P0926CM = 33"

MESH NETWORK
OPTIONAL 1 GBit UPLINK. REQUIRES UPLINK CARDS
ST/ST MMF FIBER CABLE

Appendix A. Upgrade Diagrams

CABLE GROUP C

1 x 8 STRUCTURE
IPM2 IPM2

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

TWINAXIAL CABLE
6000 ft (max)

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS
SWITCH GROUP B

NODEBUS CP60 CONNECTION TO EXISTING NODEBUS DCM 10Ef

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS

2 km (max) TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES

SWITCH GROUP B

ST/ST MMF FIBER CABLE

BNC to FIBER CONVERTER

IPM2

FBI

END-OF-LINE TERMINATOR 10Base-2 COAX 185 m/607 ft (max)

POWER MODULE

FIBER OPTIC CABLE GROUP A FPS400-24 P0917LY/ P0922YU

UPGRADED EQUIPMENT
ADD EQUIPMENT HIGHLIGHTED IN GREEN
P0973EE P0973ED

FBI TERMINAL ASSEMBLY

P0800DC

1 x 8 STRUCTURE
P0904AT
TWINAX IPM2 IPM2

PRI PWR BASEPLATE TERMINAL ASSEMBLY KIT

CABLE GROUP B

OR
FIBER OPTIC MODEM

EXISTING ST/ST MMF FIBER CABLE 2 km (max)

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

P0903QF OR
EXISTING TWINAXIAL CABLE

P0903QF OR
3200 ft/975 m (Max - all segments)

OPTICAL SPLITTER

P0903VY ADAPTER P0926LC
SEC PWR

FBI TERMINAL ASSEMBLY

FCP270 P0917YZ

FCP270 P0917YZ

P0800DC
TERMINATOR (USE AT END OF LINE)

TWINAX

B

B

IPM2

A

A

FBI

OPTICAL SPLITTER

FIELDBUS & TIME STROBE SOCKET

IPM2

OR
P0903VY CABLE GROUP B POWER MODULE FPS400-24 P0917LY/ P0922YU P0973EE FIBER OPTIC MODEM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

BASEPLATE HORIZONTAL = P0926HC VERTICAL = P0926HW

P0973ED

P0903QF

P0903QF

EXISTING TWINAXIAL CABLE

OR

2 km (max)

FIBER OPTIC MODEM

IPM2

EXISTING ST/ST MMF FIBER CABLE

FBI

TERMINATOR (USE AT END OF LINE)

CYAN

COPPER (ie, Cu) ETHERNET CABLE

100 SERIES FBM

OR

IPM2

FBI

Figure A-4. Converting CP60 with DCM10Ef to FCP270
SWITCH GROUP A 10Base-2 COAX

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS DCM 10Ef
6000 ft (max)

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS

P0904AT
BASEPLATE TERMINAL ASSEMBLY KIT EXISTING TWINAXIAL CABLE 3200 ft/975 m (Max - all segments)

P0926AH

P0972UN P0972VG P0973BU P0972ZQ

(GRAY, 50 cm) (ORANGE, 50 cm) (GRAY, 25 cm) (ORANGE, 25 cm)

OPTIONAL 2nd 1 x 8 STRUCTURE

TO OTHER REMOTE I/O

TO OTHER REMOTE I/O

MAGENTA

FIBER (ie, FO) ETHERNET CABLE
CABLE GROUP D

100 SERIES FBM

FIBER OPTIC MODEM

PDU P0904AU

FBI

FAULT TOLERANT PAIR

CABLE GROUP D

100 SERIES FBM

TO OTHER MESH COMPONENTS

PDU P0904AU

FBI

SWITCH GROUP A

B0700AR – Rev C

67

IPM2

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS DCM 10Ef NODEBUS CP60 CONNECTION TO EXISTING NODEBUS
ST CONNECTORS SWITCH GROUP B

TWINAXIAL CABLE
6000 ft (max)

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS

SWITCH GROUP B

ST/ST MMF FIBER CABLE 2 km/6562 ft (max)

IPM2

TO OTHER MESH COMPONENTS

FBI

TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES

FIBER OPTIC HUB P0922KS

END-OF-LINE TERMINATOR

POWER MODULE

TWINAX

FBI TERMINAL ASSEMBLY

FIBER OPTIC CABLE GROUP A FPS400-24 P0917LY/ P0922YU

UPGRADED EQUIPMENT
ADD EQUIPMENT HIGHLIGHTED IN GREEN
P0973EE P0973ED PDU P0904AU

P0800DC

1 x 8 STRUCTURE

IPM2

FAULT TOLERANT PAIR

CABLE GROUP D

OR
CABLE GROUP B FIBER OPTIC MODEM

EXISTING ST/ST MMF FIBER CABLE 2 km/6562 ft (max)

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

OR
A A

P0903QF
EXISTING TWINAXIAL CABLE 3200 ft/975 m (Max - all segments) EXISTING TWINAXIAL CABLE 3200 ft/975 m (Max - all segments)

P0903VY ADAPTER P0926LC P0903VY

TWINAX

P0903QF

OR

IPM2

PRI PWR

FBI

FBI TERMINAL ASSEMBLY

OPTICAL SPLITTER

P0800DC OR
EXISTING ST/ST MMF FIBER CABLE TWINAX TERMINATOR (USE AT END OF LINE)

FCP270 P0917YZ

FCP270 P0917YZ

OR
SEC PWR BASEPLATE TERMINAL ASSEMBLY KIT x 2

B

B

FIBER OPTIC MODEM

2 km/6562 ft (max)

FIBER OPTIC MODEM

P0904AT

OPTIONAL 2nd 1 x 8 STRUCTURE
IPM2 TWINAX TWINAX IPM2

OPTICAL SPLITTER

FIELDBUS & TIME STROBE SOCKET

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

Figure A-5. Converting CP60 with DCM10Ef with Fiber Optic Hub to FCP270

FPS400-24 P0917LY/ P0922YU

P09 73E D P09 73E E

BASEPLATE HORIZONTAL = P0926HC VERTICAL = P0926HW
CABLE GROUP B POWER MODULE

TERMINATOR (USE AT END OF LINE)

CYAN

COPPER (ie, TP) ETHERNET CABLE

IPM2

FBI

TO OTHER REMOTE I/O

MAGENTA

FIBER (ie, FO) ETHERNET CABLE
CABLE GROUP D

100 SERIES FBM

Appendix A. Upgrade Diagrams

P0926AH

P0972UN P0972VG P0973BU P0972ZQ

(GRAY, 50 cm) (ORANGE, 50 cm) (GRAY, 25 cm) (ORANGE, 25 cm)

OR

FBI

P0903QF

P0903QF

100 SERIES FBM

FIBER OPTIC MODEM

IPM2

P0904AT

FBI

100 SERIES FBM

SWITCH GROUP A

SWITCH GROUP A

10Base-2 COAX

POWER CABLES

IPM2

FBI

68
EXISTING CP60/DCM10Ef EQUIPMENT
REMOVE EQUIPMENT HIGHLIGHTED IN YELLOW
10Base-2 COAX

B0700AR – Rev C

Overview Cabling Diagram For Converting CP60 w/DCM10Ef To FCP270s
FPS400 LINE CORDS GROUP D P0926CN = 11" P0923DA = 15" P0926CM = 33"
FIBER OPTIC HUB P0922KS

FIBER CABLE GROUP A MMF with MT-RJ/LC CABLES P0972TR = 3 m P0972TS = 15 m P0972TT = 50 m CUSTOMER SUPPLIED = >50m, < 2 km
ST CONNECTORS ST/ST MMF FIBER CABLE 2 km/6562 ft (max)
TWINAXIAL CABLE

FPS400 POWER CABLES GROUP B P0926KK = 16" P0926KL = 36" P0926KM = 48" P0926KN = 60" P0926KP = 72" P0926KQ = 84" FIBER CABLE GROUP C MMF w/MTRJ CABLES P0972KV = 3 m P0972KW = 10 m P0972KX = 50 m CUSTOMER SUPPLIED = >50m, < 2 km
TO OTHER MESH COMPONENTS NOTE: OTHER WELL FILTERED 24 TO 39 Vdc POWER SOURCES MAY BE SUBSTITUTED FOR THE P0904AU PDU.

END-OF-LINE TERMINATOR TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES

MESH NETWORK
OPTIONAL 1 GBit UPLINK. REQUIRES UPLINK CARDS DCM 10Ef
PDU P0904AU
6000 ft (max)

CABLE GROUP C

1 x 8 STRUCTURE

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS

Appendix A. Upgrade Diagrams

B0700AR – Rev C

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

69

OPTICAL SPLITTER

FCP270 P0917YZ

FCP270 P0917YZ

FIELDBUS & TIME STROBE SOCKETS

OPTICAL SPLITTER

70
EXISTING CP60-200 SERIES EQUIPMENT
REMOVE EQUIPMENT HIGHLIGHTED IN YELLOW
Fiber Extension Equipment (Optional) REDUNDANT FCMs Cable Group B

B0700AR – Rev C

Overview Cabling Diagram For Converting CP60-200 Series To FCP270s
FIBER CABLE GROUP C MMF w/MTRJ CABLES P0972KV = 3 m P0972KW = 10 m P0972KX = 50 m CUSTOMER SUPPLIED = >50m, < 2 km FPS400 LINE CORDS GROUP D P0926CN = 11" P0923DA = 15" P0926CM = 33"

FIBER CABLE GROUP A MMF with MT-RJ/LC CABLES P0972TR = 3 m P0972TS = 15 m P0972TT = 50 m CUSTOMER SUPPLIED = >50m, < 2 km
TO OTHER MESH COMPONENTS

FPS400 POWER CABLES GROUP B P0926KK = 16" P0926KL = 36" P0926KM = 48" P0926KN = 60" P0926KP = 72" P0926KQ = 84" FBM FCM OPTIONAL 1 GBit UPLINK. REQUIRES UPLINK CARDS
I/A Series I/A Series I/A Series

FBM
I/A Series

MESH NETWORK
FCM

CABLE GROUP C

POWER MODULE FPS400-24 P0922YU/ P0917LY

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS
SWITCH GROUP A

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS

Up to 4 Baseplace each with 30 FBMs

SWITCH GROUP A

TO OTHER MESH COMPONENTS

FBM FCM
I/A Series

FBM FCM
I/A Series I/A Series I/A Series

POWER MODULE FPS400-24 P0922YU/ P0917LY

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS
SWITCH GROUP B

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS NODEBUS
DNBT CP60
OR

CP60

REDUNDANT FCMs

SWITCH GROUP B

CONNECTION TO EXISTING NODEBUS

P0916RB Terminator

Cable Group D

FIBER OPTIC CABLE GROUP A FPS400-24

POWER MODULE

UPGRADED EQUIPMENT
ADD EQUIPMENT HIGHLIGHTED IN GREEN
P0916RB Terminator CABLE GROUP B Up to 20 meters, total lenght

POWER MODULE NOTES:

P0917LY/ P0922YU CABLE GROUP D

P0922YC available with 24 Vdc INPUT P0922YU and P0917LY = 85-240 Vac INPUT or 125 Vdc INPUT Cable Group B

FAULT TOLERANT PAIR PRI PWR
RX TX RX TX

FBM FCM FCM
2f2/4/10
I/A Series

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

A

A

POWER MODULE FPS400-24

OR
RX TX RX TX

Up to 10Km
FCM 2f2/4/10
I/A Series

Up to 4 Baseplace each; with 30 FBMs Total

P0922YU/ P0917LY Cable Group C

P0916RB Terminator
FCM 2f2/4/10
I/A Series

B

B

RX TX

RX TX

FBM FCM
To another FCP270 Controller
2f2/4/10
I/A Series

FBM FCM
2f2/4/10
I/A Series I/A Series I/A Series

P0926AH
CABLE GROUP B POWER MODULE CABLE GROUP D P0917LY/ P0922YU FPS400-24

P0972UN P0972VG P0973BU P0972ZQ
SEC PWR

(GRAY, 50 cm) (ORANGE, 50 cm) (GRAY, 25 cm) (ORANGE, 25 cm)

POWER MODULE FPS400-24 P0922YU/ P0917LY

BASEPLATE HORIZONTAL = P0926HC VERTICAL = P0926HW

CYAN

COPPER (ie, TP) ETHERNET CABLE

Figure A-7. Converting CP60 with 200 Series DIN Rail Mounted Equipment to FCP270

Appendix A. Upgrade Diagrams

MAGENTA

FIBER (ie, FO) ETHERNET CABLE

Overview Cabling Diagram For Converting Micro I/As To FCP270s
FPS400 LINE CORDS GROUP D P0926CN = 11" P0923DA = 15" P0926CM = 33"

EXISTING MICRO I/A EQUIPMENT
REMOVE EQUIPMENT WHICH IS HIGHLIGHTED IN YELLOW Micro I/A
TWINAXIAL CABLE 6000 ft/1830 m (max) TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES END-OF-LINE TERMINATOR

BER CABLE GROUP A MF with MT-RJ/LC ABLES 972TR = 3 m 972TS = 15 m 972TT = 50 m USTOMER SUPPLIED = 0m, < 2 km
TO OTHER MESH COMPONENTS

FPS400 POWER CABLES GROUP B P0926KK = 16" P0926KL = 36" P0926KM = 48" P0926KN = 60" P0926KP = 72" P0926KQ = 84" FIBER CABLE GROUP C MMF w/MTRJ CABLES P0972KV = 3 m P0972KW = 10 m P0972KX = 50 m CUSTOMER SUPPLIED = >50m, < 2 km HDLC CABLES GROUP E P0916ND = 0.25 m P0917JJ = 0.5 m P0916MZ = 1.0 m P0916NC = 3.0 m P0916NB = 5.0 m P0916NA = 10 m P0916UH = 20 m P0916UJ = 30 m P0916UK = 60 m OPTIONAL 1 GBit UPLINK. REQUIRES UPLINK CARDS P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS
IPM2 IPM2

CABLE GROUP C

MESH NETWORK

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS
SWITCH GROUP A

1 x 8 STRUCTURE
FBI

Appendix A. Upgrade Diagrams

SWITCH GROUP A

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS
TWINAXIAL CABLE SWITCH GROUP B 6000 ft/1830 m (max)

IPM2

FBI

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS

END-OF-LINE TERMINATOR

SWITCH GROUP B TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES

TO OTHER REMOTE I/O FBI TERMINAL ASSEMBLY

FIBER OPTIC CABLE GROUP A CABLE GROUP B POWER MODULE FPS400-24

FAULT TOLERANT PAIR
PRI PWR

P0800DC

TERMINATOR (USE AT END OF LINE)

UPGRADED EQUIPMENT
ADD EQUIPMENT WHICH IS HIGHLIGHTED IN GREEN
CABLE GROUP D

1 x 8 STRUCTURE

IPM2

IPM2

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

OPTICAL SPLITTER

IPM2

FCP270

P0917YZ

FCP270

P0917YZ

FIELDBUS & TIME STROBE SOCKET

TO BE RELEASED
SEC PWR

"Y" ADAPTER MAY BE NEEDED IF STARTING WITH "LOCAL" I/O
TWINAX

B

B

IPM2

FBI

FBI = P0903ZE or P0400VE

TERMINATOR (USE AT END OF LINE)

OPTICAL SPLITTER

FBI100

P0923LN

FBI100

P0923LN

EXISTING TWINAXIAL CABLES 3200 to 6000 ft (975 to 1830 m)

P0972UN P0972VG P0973BU P0972ZQ
I/A Series I/A Series

(GRAY, 50 cm) (ORANGE, 50 cm) (GRAY, 25 cm) (ORANGE, 25 cm)
BASEPLATE: P0923LR

FBI TERMINAL ASSEMBLIES

P0800DC

TO OTHER REMOTE I/O

P0926AH
CABLE GROUP E

TERMINATOR (USE AT END OF LINE)

BASEPLATES HORIZONTAL = P0926HC VERTICAL = P0926HW
PRI PWR
BASEPLATE TERMINAL ASSEMBLY KITS

1 x 8 STRUCTURE

IPM2

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

OPTICAL SPLITTER

FCP270

P0917YZ

FCP270

P0917YZ

ADAPTER P0926LC

EXISTING TWINAXIAL CABLES 3200 ft/975 m (Max - all segments)

"Y" ADAPTER MAY BE NEEDED IF STARTING WITH "LOCAL" I/O

CABLE GROUP B

IPM2

FBI

FBI = P0903ZE or P0400VE
CYAN MAGENTA

B

B

SEC PWR

POWER MODULE FPS400-24 P0917LY/ P0922YU

COPPER (ie, Cu) ETHERNET CABLE FIBER (ie, FO) ETHERNET CABLE
CABLE GROUP D

OPTICAL SPLITTER

B0700AR – Rev C

926AH

P0972UN P0972VG P0973BU P0972ZQ

(GRAY, 50 cm) (ORANGE, 50 cm) (GRAY, 25 cm) (ORANGE, 25 cm)

FIELDBUS & TIME STROBE SOCKET

TERMINATOR (USE AT END OF LINE)

100 SERIES FBM

A

A

P0903VY

IPM2

FBI

Figure A-8. Converting Micro-I/A Station to FCP270
TO OTHER MESH COMPONENTS

FAULT TOLERANT PAIR

100 SERIES FBM

P0917LY/ P0922YU

FBI

A

A

TO OTHER REMOTE I/O

TO OTHER REMOTE I/O

100 SERIES FBM

71

IPM2

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS
SWITCH GROUP B

TWINAXIAL CABLE 6000 ft/1830 m (max)

SWITCH GROUP B

IPM2

P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS

FBI

TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES END-OF-LINE TERMINATOR

FIBER OPTIC CABLE GROUP A CABLE GROUP B POWER MODULE FPS400-24 P0917LY/ P0922YU CABLE GROUP D

FAULT TOLERANT PAIR
PRI PWR

TO OTHER REMOTE I/O

UPGRADED EQUIPMENT
ADD EQUIPMENT WHICH IS HIGHLIGHTED IN GREEN

FBI TERMINAL ASSEMBLY

P0800DC

TERMINATOR (USE AT END OF LINE)

A

A

1 x 8 STRUCTURE

IPM2

OPTICAL SPLITTER

FCP270

P0917YZ

FCP270

P0917YZ

FIELDBUS & TIME STROBE SOCKET

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

IPM2

"Y" ADAPTER MAY BE NEEDED IF STARTING WITH "LOCAL" I/O
EXISTING TWINAXIAL CABLES 3200 to 6000 ft (975 to 1830 m)

OPTICAL SPLITTER

FBI100

P0923LN

FBI100

P0923LN

FBI TERMINAL ASSEMBLY

IPM2

B

B

SEC PWR

FBI

P0972UN (GRAY, 50 cm) P0972VG (ORANGE, 50 cm) P0972ZQ (GRAY, 25 cm)
I/A Series I/A Series

P0800DC

FBI = P0903ZE or P0400VE

TERMINATOR (USE AT END OF LINE)

P0926AH
CABLE GROUP E

BASEPLATE: P0923LR

FBI TERMINAL ASSEMBLY

BASEPLATES HORIZONTAL = P0926HC VERTICAL = P0926HW
PRI PWR
BASEPLATE TERMINAL ASSEMBLY KITS

P0800DC

TERMINATOR (USE AT END OF LINE)

1 x 8 STRUCTURE
FBI

IPM2

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

100 SERIES FBM

OPTICAL SPLITTER

FCP270

P0917YZ

FCP270

P0917YZ

"Y" ADAPTER MAY BE NEEDED IF STARTING WITH "LOCAL" I/O

CABLE GROUP B

IPM2

IPM2

ADAPTER P0926LC

EXISTING TWINAXIAL CABLES 3200 ft/975 m (Max - all segments)

FBI

B

B

SEC PWR

FBI = P0903ZE or P0400VE
CYAN MAGENTA

POWER MODULE FPS400-24 P0917LY/ P0922YU CABLE GROUP D

COPPER (ie, Cu) ETHERNET CABLE FIBER (ie, FO) ETHERNET CABLE

FBI TERMINAL ASSEMBLY

OPTICAL SPLITTER

Appendix A. Upgrade Diagrams

P0926AH

P0972UN (GRAY, 50 cm) P0972VG (ORANGE, 50 cm) P0972ZQ (GRAY, 25 cm)

FIELDBUS & TIME STROBE SOCKET

P0800DC

TERMINATOR (USE AT END OF LINE)

100 SERIES FBM

A

A

IPM2

Figure A-9. Converting AW51/AW70 to FCP270s

FAULT TOLERANT PAIR

P0903VY

100 SERIES FBM

TO BE RELEASED

IPM2

FBI

TO OTHER REMOTE I/O

TO OTHER REMOTE I/O

100 SERIES FBM

AW51 OR AW70 PROCESSOR

TERMINATION CABLE ASSY

IPM2

FBI

72

Overview Cabling Diagram For Converting AW51/70 To FCP270s
FPS400 LINE CORDS GROUP D P0926CN = 11" P0923DA = 15" P0926CM = 33"

B0700AR – Rev C

EXISTING AW51 0R AW70 EQUIPMENT
REMOVE EQUIPMENT WHICH IS HIGHLIGHTED IN YELLOW
END-OF-LINE TERMINATOR TO OPTIONAL ADDITIONAL 1 x 8 STRUCTURES

FIBER CABLE GROUP A MMF with MT-RJ/LC CABLES P0972TR = 3 m P0972TS = 15 m P0972TT = 50 m CUSTOMER SUPPLIED = >50m, < 2 km
TO OTHER MESH COMPONENTS

FPS400 POWER CABLES GROUP B P0926KK = 16" P0926KL = 36" P0926KM = 48" P0926KN = 60" P0926KP = 72" P0926KQ = 84" FIBER CABLE GROUP C MMF w/MTRJ CABLES P0972KV = 3 m P0972KW = 10 m P0972KX = 50 m CUSTOMER SUPPLIED = >50m, < 2 km OPTIONAL 1 GBit UPLINK. REQUIRES UPLINK CARDS FIELDBUS I/F CARD
TWINAXIAL CABLE 6000 ft/1830 m (max)

CABLE GROUP C

HDLC CABLES GROUP E P0916ND = 0.25 m P0917JJ = 0.5 m P0916MZ = 1.0 m P0916NC = 3.0 m P0916NB = 5.0 m P0916NA = 10 m P0916UH = 20 m P0916UJ = 30 m P0916UK = 60 m
FIELDBUS A FIELDBUS B

MESH NETWORK P0972WP (EXAMPLE) 24-PORT, 100Base-TX SWITCH W/RJ-45 CONNECTORS
SWITCH GROUP A

P0972YC (EXAMPLE) 24-PORT, 100Base-FX SWITCH W/MTRJ CONNECTORS

1 x 8 STRUCTURE

SWITCH GROUP A

TO OTHER MESH COMPONENTS

Index
A Addresses IP 4 MAC 4 B Baseplates for FCP270 mounting 9 Block, defining 28 Boot-up sequence 18 commissioned FCP270 18 FCP270 module with a new letterbug 19 FCP270 module with the same letterbug 19 shadow module with the same letterbug and software image 19 shadow module with the same letterbug but different software image 19 C Cables, installing 14 Cabling remote fieldbus extension 20 Y-module FBMs 20 Communication to Series 200 FBMs 7 Configuration Information display, FCP270 36 Control block, defining 28 Control scheme, typical 29 D Data stream types 6 Defining blocks 28 Diagnostics error recovery cooperative diagnostics 62 error recovery local diagnostics 62 start-up 61 E EEPROM Update procedure 39 Equipment Change display FCP270 37 Primary ECB (FBM0) 46 Equipment Information display FCP270 31 Primary ECB (FBM0) 43 Error recovery cooperative diagnostics 62
73

B0700AR – Rev C

Index

Error recovery local diagnostics 62 External timing 8 Extracting memory dump information 60 F Failure messages 59 Fault-tolerant operation 3 hot remarry 58 FBM general download for off-line or failed 49 FBMs supported modules 1 Y-module 7 FBMs, supported 1 FCP270 fault-tolerant operation 3 infrared communication ports 53 installing 10 installing cables 14 installing secondary module 13 installing single or primary module 11 LED indicators 53 letterbug installation 11 network configuration 4 overview 1 replacing a failed module 59 reset button 53 sizing constraints 8 Fiber optic cables, installing 14 Field Control Processor 270, overview 1 Fieldbus Expansion Module 100 (FEM100) 1, 6 G Global Product Support xii H Hosted FBMs and blocks 8 Hot remarry 58 I I/O communications 6 image 41 Image Update procedure 40 Infrared communication ports 53 Installing cables 14 FCP270 10
74

Index

B0700AR – Rev C

secondary FCP270 module 13 single or primary FCP270 module 11 Integrated control configuration, general 28 Internal timing 7 IP addresses 4 L Last gasp messages 59 LED diagnostic indicators 53 Letterbug installation 11 M MAC addresses 4 Master TimeKeeper 7 Memory dumps 60 extracting 60 N Network configuration, FCP270 4 Network path switching 4 O Off-line control configuration 29 On-line control configuration 30 On-line Diagnostics display, Primary ECB (FBM0) 50 On-Line Image Update 41 Operational Status LEDs, troubleshooting 55, 56 R Reboot Station procedure 39 Reference documents xi Remote fieldbus extension 20 cable connections 20 Replacing a failed FCP270 module 59 Reset button 53 Reset button, location and operation 3 Revision information xi S Slave TimeKeeper 7 Software installation 27 Splitter/combiner 4 Start-up diagnostics 61 Supported products 1 Switching network paths 4 System Definition 27
75

B0700AR – Rev C

Index

System Management displays FBM0 42 FCP270 31 T Time synchronization 7 Timing external 8 internal 7 Troubleshooting failure messages 59 fault-tolerant FCP270 failure 58 hot remarry 58 last gasp messages 59 memory dumps 60 Operational Status LEDs 55, 56 Y Y-module FBMs, cabling 20

33 Commercial Street Foxboro, Massachusetts 02035-2099 United States of America www.foxboro.com Inside U.S.: 1-866-746-6477 Outside U.S.: 1-508-549-2424 or contact your local Foxboro representative. Facsimile: 1-508-549-4999 Printed in U.S.A. 0507


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