Foxboro FCP270 P0917YZ Field Control Processor

Functional Features

• Control and Data Processing: Executes regulation, logic, timing, and sequential control together with connected Fieldbus Modules (FBMs). It also performs data acquisition, alarm detection, and notification, processing large volumes of data and complex algorithms to ensure efficient system operation.

• Communication Capability: Connects to the MESH control network via standard 100Mbps fiber Ethernet, while supporting 2Mbps or 268Kbps HDLC fieldbus with FBI200 or FBI100. This allows connection to Series 200 and Series 100 FBMs, and may also support various data communication interfaces (Ethernet, RS232, RS485, etc.) for easy data exchange with other devices and systems.

• I/O Expansion: Supports up to 32 Series 200 FBMs; with the Fieldbus Expansion Module 100 (FEM100), it can support up to 128 Series 200 FBMs and up to 64 Series 100 FBMs.

• Reliability Design: Features a rugged die-cast aluminum housing for operation in G3-level harsh environments. It uses two control modules to provide unique, patented fault-tolerant operation, significantly enhancing reliability compared to other process controllers.

• Programming and Configuration: Supports multiple programming languages/methods (FBD, LD, ST, etc.), enabling users to write custom control logic. It offers flexible configuration options for customization based on specific application requirements.

• Time Synchronization: Supports time synchronization with optional external time from GPS satellites.

Technical Parameters

• Memory: 16MB SDRAM, 32MB flash.

• Power Supply: Input voltage is typically 24V DC (redundant voltage); maximum power consumption per non-fault-tolerant module is 8.5W.

• Dimensions and Weight: 14.7cm×5.15cm×11.4cm, 0.6kg (shipping weight: 1.5kg).

• Operating Environment: Working temperature 0 to +60°C, adaptable to certain industrial temperature conditions.

Working Principle

I. System Architecture and Core Components

• Hardware Architecture

• Processor Core: Uses high-performance processors (e.g., PowerPC series) with multitasking capabilities to run control logic, communication protocol stacks, and system management tasks simultaneously.

• Memory System

• 16MB SDRAM: Stores runtime data (process variables, intermediate calculation results).

• 32MB Flash: Stores the operating system, control programs, configuration parameters, and historical data.

• Communication Interfaces

• MESH Control Network: Connects to upper-level control systems (operator stations, engineer stations) via 100Mbps fiber Ethernet.

• Fieldbus Interface: Supports 2Mbps/268Kbps HDLC protocol to connect Fieldbus Modules (FBMs) for data exchange with I/O devices.

• Expansion Interfaces: Supports auxiliary communications (RS232/RS485, etc.) for debugging or third-party device integration.

• Software Architecture

• Real-Time Operating System (RTOS): Ensures deterministic execution of control tasks, supporting priority scheduling and interrupt handling.

• Control Engine: Runs user-programmed control logic (algorithms written in FBD, LD, ST, etc.).

• Communication Stack: Implements MESH network protocols, HDLC fieldbus protocols, and other communication standards.

• Configuration Management: Stores and loads configurations for FCP and connected FBMs.

II. Workflow and Data Processing

1. Data Acquisition and Input Processing

• Field Signal Collection: FBMs (analog/digital input modules) convert field sensor signals (temperature, pressure, switch states) to digital signals, transmitted to FCP270 via HDLC fieldbus.

• Data Preprocessing: FCP270 performs signal conditioning (linearization, filtering, engineering unit conversion), validates data (range check, quality code judgment), and marks abnormal data.

• Data Storage: Processed data is stored in SDRAM's real-time database for control algorithms, while critical data (alarm values, historical trends) is backed up to flash.

2. Control Logic Execution

• Control Algorithm Parsing: FCP270 parses user-programmed control logic (PID loops, sequential control, logic interlocks) and executes algorithms cyclically at preset periods (10ms, 50ms, etc.).

• Real-Time Calculation: Calculates based on current input values and set parameters (PID’s Kp, Ki, Kd), generating control outputs (valve openings, motor speeds).

• Fault-Safe Handling: Triggers preset fault-safe strategies (maintain output, switch to backup values) if anomalies (sensor disconnection, communication failure) are detected.

3. Output Control and Execution

• Output Data Generation: Converts control algorithm results to FBM-recognizable formats (analog output currents, digital switch signals).

• Output Signal Transmission: Sends output commands to corresponding FBMs via HDLC bus; FBMs convert digital signals to physical outputs (drive actuators, relays).

• Feedback Verification: Some FBMs support output status readback (relay contact monitoring); FCP270 compares expected/actual values to ensure control implementation.

4. Communication and Coordination

• Communication with Upper Systems: Uploads real-time data (process variables, alarms) to operator/engineer stations via MESH network and receives configuration updates (parameter modifications, program downloads).

• Collaboration with Other FCPs: In redundant/distributed control scenarios, multiple FCP270s sync data via MESH network for load sharing or hot standby switching.

• Time Synchronization: Ensures consistent timing across system devices via GPS or internal clock synchronization to avoid control timing conflicts.

III. Core Differences from FCP280

IV. Application Scenarios

• Chemical Production: Precise control and monitoring of reaction processes, material transportation, etc.

• Power Generation: Control of boilers, turbines, generators, etc.

• Metallurgy, Mining, and Minerals: Precise control and monitoring of equipment during ore mining, beneficiation, smelting, etc.

• Water and Wastewater Treatment: Control of water pumps, valves, and water quality monitoring.

• Food and Beverage Industry: Precise control and monitoring of production equipment to ensure stable product quality.