Foxboro ™ DCS Field Device Controller 280（FDC280）



Foxboro ™  DCS Field Device Controller 280（FDC280）

Product Overview and Core Positioning

FDC280 is a distributed and optional fault-tolerant on-site installation controller, with the core function of implementing Foxboro ™  The integration of DCS and field devices does not require additional fieldbus modules (FBM), and it also undertakes process control and alarm tasks. It is mainly positioned as the "field device integration center", which is different from the same type of FCP280 (which does not support PIO bus and focuses on Ethernet/serial protocol integration).

1. Core functions

Device integration: Directly interface with Ethernet/serial field devices that support multiple protocols, collect device data for display, historical storage, and execute control tasks.

Control capability: Built in adjustment control, logic control, timing control, sequence control functions, supporting alarm detection and notification.

Hardware architecture: Adopting dual core ARM ®  SOC processor with clear dual core division of labor:

Core 1 (Control Core): Run control software and DCS control network communication software, supporting fault-tolerant operations.

Core 2 (I/O core): Run device integration software, independently handle on-site device connections and status diagnostics.

Basic requirements: A host workstation with Foxboro DCS Control Core Services v9.3 or higher must be installed, and connected to the control network via 100Mbps fiber/copper Ethernet. It must have obtained ISASecure EDSA Level 1 security certification.

2. Key difference: FDC280 vs FCP280

Comparison item FDC280 FCP280

Core positioning on-site equipment integration (Ethernet/serial port) universal process control

PIO bus support not supported

Core advantage: No FBM required, directly integrated with field devices compatible with traditional PIO bus devices

Network configuration plan

FDC280 supports both Ethernet and serial network configurations, divided into two modes: "simplex" and "fault tolerant", to meet the redundancy requirements of different field devices.

1. Ethernet network configuration

Support direct connection to Ethernet field devices or connection to serial devices through a "protocol specific gateway" (to achieve Ethernet serial bridging), with three core solutions:

Configuration Type Applicable Scenarios Key Features

Simplex, a single FDC280 module for scenarios with low reliability requirements, does not require redundant connections and saves wiring costs

Fault tolerant - Independent network with high reliability requirements, on-site equipment requires independent redundant network dual FDC280 modules (left/right), connected to two independent Ethernet networks provided by customers, with module IP addresses that can be the same or unique

Fault tolerant - Shared network field devices without independent redundancy requirements (such as single port devices). Dual FDC280 modules share one Ethernet network, supporting single port device access and reducing network complexity

Note: It is recommended to use a management switch for easy maintenance and troubleshooting; The device can also be directly connected to the FDC280 motherboard without the need for a switch.

2. Serial port network configuration

Each module of FDC280 contains 4 independently configurable serial ports (supporting RS232/RS422/RS485), with a maximum support of 128 serial field devices (up to 32 devices per RS485 port). The core solution is divided into 2 types:

Non fault-tolerant (Simplex): A single FDC280 can be connected to a single port serial device through a "Terminal Component (TA)", supporting RS485 multi station connection without a modem and RS232/RS422 direct connection.

Fault tolerant type: Dual FDC280 modules are connected to devices through TA and adapted to different port devices:

Dual port device: The left/right module connects the two ports of the device separately to achieve redundant communication.

Single port device: RS232 needs to be connected to two TAs through a Y-shaped cable; RS485/422 can be directly connected through a dual module TA sharing connection.

Core features and performance parameters

1. Key functional characteristics

Specific description of characteristic categories

The device and I/O capacity support a maximum of 256 field devices, 8000 soft I/O points, and 8252 total functional blocks (including Station blocks, ECB components, etc.). Please refer to the FDC280 sizing tool (B0700GS) to calculate the load

The protocol supports 6 core protocols, some of which support concurrent multi instance/multi version (see table below for details)

The diagnostic capability has a built-in "diagnostic driver" that can capture real-time communication messages with the device and send them to the workstation diagnostic application without physical interruption

Fault tolerance mechanism dual module "marriage" operation, Control Network communication requires dual module messages to be matched bit by bit before sending; Core 1 supports primary/backup switching, while Core 2 supports redundancy state comparison and role handover

In self hosted mode, the control database checkpoint file is stored in flash memory, and the host can autonomously start and execute control policies when offline

Software updates distinguish between "Major updates (new features, no online upgrade support)" and "Minor updates (only module switching, no process interruption)"

Environmental adaptability die-casting aluminum shell, no need for ventilation, supports Class G3 harsh environment (ISA S71.04 standard), CE certification for on-site installation

Time synchronization supports GPS satellite UTC time (external) or DCS internal TimeKeeper synchronization (internal), with data timestamp accuracy of 10 times/second (minimum scanning interval of 100ms)

2. Support protocols and concurrency capabilities

Protocol name, part number, multiple protocols, concurrent support, same protocol, multiple instances support

Modbus TCP Client K0177AH Yes Yes

Modbus RTU&ASCII Client K0177CV Yes

Triconex ™  TSAA Client K0177DE is

OPC UA Client K0177EC (single instance only)

Is EtherNet/IP Scanner Driver K0177EP

PROFINET IO Controller K0177FU No No (single instance only)

3. Functional specification parameters

Specific numerical values for parameter categories

The maximum execution speed of functional blocks with a processor performance of 16000 blocks per second, and the minimum block processing cycle (BPC) of 100ms

The maximum capacity of a single sequence block is 32KB

IPC connects 200 data source points (providing external data), 30 sink points (receiving external data), and 1 dedicated internal point

OM (Object Manager) can scan a database with a maximum capacity of 28000 points (18000 points when BPC ≥ 200ms, 7500 points when BPC=100ms); The maximum convergence point is 11250 points

Configurable block period of 0.1/0.2/0.5/0.6/1/2/5/6/10/30 seconds, 1/10/60 minutes

Fault tolerant module pairing time is less than 0.5 seconds

Hardware and environmental specifications

1. Core hardware components and parameters

The FDC280 hardware includes four categories: "module", "motherboard", "network adapter", and "terminal component". The key parameters are as follows:

Component type, model/part number, key specifications

FDC280 module RH101FQ size: height 105/116mm (including installation ears) x width 51.8mm x depth 147mm; single module weight 0.8kg

The base plate RH101KF (2 bits) supports 1 non fault tolerant module or 2 fault tolerant modules, including 2 10/100Mbps/1Gbps copper cable Ethernet RJ45 interfaces, 2 37 pin D-type serial port interfaces, and 2 time synchronization interfaces

Network adapter fiber optic: RH924WA (Rev. E+); Copper cable: RH924UQ (Rev. D+) takes power from the base plate, fiber supports multimode 62.5/125 μ m cable (maximum 2km), copper cable supports Cat5 (maximum 100m)

Serial terminal component ring terminal post: P0926PA; Tightening screws: RH926GH weighs 363g and 272g respectively, and needs to be paired with Type 5 terminal cables (such as RH100HV-1m and RH100HZ-5m)

2. Power and environmental requirements

Category specifications

Power requirement input voltage: 24VDC (redundant,+5%/-10%); The maximum power consumption of a single module is 8.5W

Working temperature -20~60 ℃ (-4~140 ℉)

Storage temperature -40~70 ℃ (-40~158 ℉)

Relative humidity 5%~95% (no condensation)

Altitude operation: up to 3000m; storage: -300~12000m

Anti pollution level Class G3 (ISA S71.04), supports 10-year mixed gas exposure testing (EIA 364-65A Class III), module with conformal coating (conformal coating: protective coating)

Vibration resistance 0.5g (5~500Hz)

3. Compliance certification

Electromagnetic Compatibility (EMC): Compliant with Directive 2014/30/EU, EN 61326-1 Class A (Emission and Industrial Immunity).

Product safety: UL/UL-C certification (applicable to Class I, Groups A-D, Zone 2), EU Low Voltage Directive (2014/35/EU), ATEX Directive (2014/34/EU, DEMKO Ex nA IIC T4 Gc, applicable to Zone 2).

Environmental compliance: Compliant with the EU RoHS Directive (2011/65/EU and revised versions 2015/863, 2017/2102).

California Proposition 65: Products containing lead and lead compounds may cause cancer or reproductive harm, details can be found at www.P65Warning.ca.gov.

Fault tolerance mechanism and reliability design

The "fault-tolerant" core of FDC280 consists of dual module redundancy, independent diagnosis, and seamless switching, covering the control network, CPU, and I/O levels to ensure uninterrupted processes

1. Three layer fault-tolerant/redundant design

Level fault tolerance/redundancy mechanism switching logic

The dual modules of the control network are connected through the backplane and share control network access (dual switches). Communication messages need to be matched bit by bit by the dual modules before being sent. When a fault is detected, the non faulty module takes over control without process interruption

Core 1 (control core) primary/backup mode, real-time synchronization status. When the primary core fails, the backup core immediately switches to primary dynamic mode

Core 2 (I/O core) independently diagnoses the connection status of dual core devices. When the main core fails and the backup core device is better connected compared to the backup core status, the main core resets and hands over the role

The main module on the I/O side is responsible for reading and writing I/O points, while the backup module monitors device connections through "heartbeat commands" and synchronizes I/O values in real-time. When the main module loses connection, the backup module seamlessly takes over without any process fluctuations

2. Maintain convenience

Hot plug support: Replacing the FDC280 module does not require disconnecting the backplane power supply, and does not affect the field I/O signal of another module.

Status visualization: The front of the module includes an LCD display screen (displaying module identification, role, hardware version, network status) and LED indicator lights (running status, Ethernet connection status), supporting the configuration of "letterbug" through panel buttons.