I/A Series® HARDWARE

Product Specifications

PSS 21H-1B10 B3
Z-Module Control Processor 270 (ZCP270)

The Z-Module Control Processor 270 is a distributed, optionally fault-tolerant controller that performs
process control and alarming functions according to a user-defined control strategy.

FEATURES  Performs data acquisition and alarm detection

 Performs regulatory, logic, timing, and sequential and notification
control together with connected Fieldbus  Offers unique, patented, fault-tolerant operation
Modules using two control modules to greatly improve
 Supports up to 128 of the 200 Series Fieldbus reliability relative to other process controllers
Modules (FBMs - Compact or standard types)  Connects to The MESH control network via
when using the FCM100Et Fieldbus standard fiber optic 100 Mbps Ethernet
Communications Module  Uses versatile control algorithms and a wide
 Supports up to 128 of the 200 Series FBMs variety of FBMs to provide control capabilities for
(Compact or standard types), 100 Series FBMs, a broad range of process applications
or a combination 100 Series and 200 Series  Supports time synchronization using optional
FBMs when using the FCM100E Fieldbus external time from GPS satellites
Communications Module  Offers on-line image update of a fault-tolerant
ZCP270 without shutting down the process
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 Uses soft letterbugs configurable via the ENHANCED RELIABILITY (FAULT-

I/A Series® system Letterbug Configurator. TOLERANCE)
The unique and patented fault-tolerant operation of
 Supports self-hosting mode with I/A Series
the ZCP270 greatly improves reliability relative to
software v8.4-v8.8 or Foxboro Evo™ Control
other process controllers. The fault-tolerant version of
Core Services v9.0 or later
the ZCP270 consists of two modules operating in
OVERVIEW parallel, with two sets of Ethernet connections to The
MESH network, two for the control network and two
The Z-Module Control Processor 270 (ZCP270) is an
for the fieldbus network. The two ZCP270 modules,
optionally fault-tolerant, Z-form factor controller. The
married together as a fault-tolerant pair, provide
ZCP270 performs regulatory, logic, timing, and
continuous operation of the controller in the event of
sequential control together with connected Fieldbus
virtually any hardware failure occurring within one
Communications Modules (FCMs) and Fieldbus
module of the pair.
Modules. It also performs data acquisition and alarm
detection and notification. The ZCP270 connects to Both modules receive and process information
The MESH control network and simultaneously, and faults are detected by the
FCM100Ets/FCM100Es via standard fiber optic 100 modules themselves. One of the significant methods
Mbps Ethernet. The FCM100Et interfaces the of fault detection is comparison of communication
2 Mbps Module Fieldbus used by the 200 Series messages at the module external interfaces.
FBMs and the FCM100E interfaces the 2 Mbps Messages only leave the controller when both
Module Fieldbus used by the 200 Series FBMs or the controllers agree on the message being sent (bit for
268 Kbps Fieldbus used by 100 Series FBMs. bit match). Upon detection of a fault, self-diagnostics
Depending on sizing considerations, the ZCP270 can are run by both modules to determine which module
be used with a mix of FCM100E and FCM100Et is defective. The non-defective module then assumes
modules. control without affecting normal system operations.
The fault-tolerant version of the ZCP270 consists of This fault-tolerant solution has the following major
two single-width processor modules. These modules advantages over controllers that are merely
install in adjacent ZCP270 slots in a 1x8 or 2x8 redundant:
mounting structure and connect to a fault-tolerant
 No bad messages are sent to the field or to
connector to allow for high-speed communication
applications using controller data because no
between the modules (see Figure 1).
message is allowed out of the controller unless
both modules match bit for bit on the message
EQUIPMENT MOUNTING
being sent.
The Foxboro Evo architecture requires workstations
 The secondary controller is synchronized with the
and commercial-off-the-shelf (COTS) Ethernet
primary one, which ensures up to the moment
switches, a rack room for the ZCP270 and Ethernet
data in the event of a primary controller failure.
switches, and a field enclosure for the
FCM100Ets/FCM100Es, FBMs, and other I/O  The secondary controller will have latent flaws
hardware. For more information on The MESH detected prior to any switchover because it is
control network architecture, refer to performing exactly the same operations as the
PSS 21H-7C2 B3. primary controller.
 PSS 21H-1B10 B3
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Fault-tolerant ZCP270 Modules

1x8 Mounting Structure Fault-tolerant Connector

To/From Ethernet Fieldbus A To/From Ethernet Fieldbus B

Ethernet Fiber Switch 1 Ethernet Fiber Switch 2

100 Mbps Duplex Fiber Cable

-Orange for Ethernet Switch 1
Fault-tolerant ZCP270 Modules -Gray for Ethernet Switch 2 Splitter/Combiner
Pair in Bracket
DIN Rail

To/From MESH Control

Network B
Ethernet Fiber Switch 2

To/From MESH Control

Network A
Ethernet Fiber Switch 1

Figure 1. Fault-Tolerant ZCP270 Module Pair Mounted in 1x8 Mounting Structure

PSS 21H-1B10 B3
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SPLITTER/COMBINER ON-LINE IMAGE UPDATE

Fault-tolerant ZCP270 modules connect to two pair For fault-tolerant ZCP270 modules, on-line image
of fiber optic splitter/combiners (see Figure 1). One update replaces the executable image (operating
splitter/combiner pair connects redundant Ethernet system) of a running ZCP270 with a newer image
ports on the front of each module to redundant without having to shut down the equipment being
Ethernet switches in the control network. The other controlled by the ZCP270. New product
splitter/combiner pair connects redundant Ethernet enhancements can be brought on-line in
fieldbus ports on the top of each module to 1.5 seconds for heavily loaded controllers; less for
redundant Ethernet switches in the control network. lightly loaded controllers.
For each module, the splitter/combiners provide Because the ZCP270 contains its executable image
separate transmit/receive fiber connections for each in internal flash memory, and has sufficient RAM to
Ethernet control network and Ethernet fieldbus port. hold a new executable image at the same time, on-
Fiber cables are connected so that splitter/combiners line image updates are now much easier to perform.
pass inbound traffic from a switch to both modules,
and pass outbound traffic from the primary module TIME SYNCHRONIZATION, SOE, TDRA
to a switch. The Foxboro Evo system supports time
Each splitter/combiner pair mounts in an assembly synchronization using either an externally maintained
that either mounts in a chassis assembly for 19-inch optional source of Universal Coordinated Time (UTC)
racks or fastens to the DIN rail in the enclosure. The from GPS satellites or an internal source using
splitter/combiner is a passive device that does not proprietary software. ZCP270s and their FCM100Ets
require electrical power. receiving time updates via the external time source
synchronize their FBMs to 1 ms. For more
ENHANCED COMMUNICATIONS information, refer to PSS 21S-1C2 B3.
The Foxboro Evo architecture uses an Ethernet Time stamping is used for alarm messages, values
control network with 100 Mbps data sent to the historian, and the new Sequence Of
communications between the ZCP270s and the Events (SOE) and Transient Data Recorder and
Ethernet switches (see Figure 2). Analyzer (TDRA) features.
The ZCP270 can also communicate with serial and SOE data are discrete points that are time stamped
Ethernet devices, such as PLCs, via Field Device at the FBM, optionally to 1 ms, and sent to the
System Integrators and FCM100Ets/FCM100Es. This workstation on a change basis. TDRA data are
allows connection to new device interfaces without analog points that are time stamped at the FBM and
any changes to the controller software. sent to the workstation every 10 ms. These new
features are supported by client software in the
workstation. To support SOE and TDRA, the
FCM100Et must be installed on the same network as
the workstation collecting the data. For information
on this software, refer to PSS 21S-2B9 B4 and
PSS 21S-2B10 B4.
 PSS 21H-1B10 B3
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SOFTWARE FEATURES Self-Hosting Feature, Available with 200 Series

The ZCP270 performs regulatory, logic, timing, and FBMs Only
sequential control, as well as data acquisition, alarm The self-hosting feature is recommended only for use
detection, and alarm notification. Process variables in ZCP270s which are used with 200 Series FBMs.
are controlled using time-proven algorithms All of the information necessary to reboot 200 Series
(mathematical computations performing specific FBMs is included in non-volatile flash memory on the
functions). The algorithms are contained in functional ZCP270. However, the flash memory on the
control blocks, which are configured by on-site 100 Series FBMs and related products on the 268k
process engineers to implement the desired control fieldbus does not include this information, and they
strategies. The versatility of the algorithms, coupled require the workstation host to be present to reboot.
with the variety of FBMs available, provides control More details on the self-hosting feature are available
capabilities suited to a broad range of process in DIN Rail Mounted FBM Subsystem User’s Guide
applications. Control strategies ranging from simple (B0400FA).
feedback and cascade loops to highly sophisticated
feedforward, nonlinear, and complex characterization
control schemes are readily implemented.
The ZCP270 also provides the following features:
 Infrared communications with the controller
enables you to set and read the controller
letterbug via the Letterbug Configurator.
 Alarm enhancements to the function blocks:
re-alarming on changes to alarm priority,
re-alarming based upon a configurable time delay
deadband, and alarm suppression based upon
time.
 Optional UTC external time synchronization.

 Improved controller performance.

 Optional self-hosting mode (I/A Series software

v8.4-v8.8 or Control Core Services v9.0 or later)
allows the ZCP270 to start up and run, executing
its configured control scheme using the
checkpoint file stored in flash memory. This
allows the ZCP270 to boot itself with a valid
control database even if its host workstation is
not present.
PSS 21H-1B10 B3
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The MESH
Control Network
(See Note 1)

100 Mbps Ethernet Fiber Optic

Cables (Redundant)

ZCP270 Control Processor

(Fault-Tolerant)

100 Mbps Ethernet Fiber Optic

Fieldbus (Redundant)

The MESH
Control Network
(See Note 1)

100 Mbps Ethernet

Fiber Optic Fieldbus
(Redundant)

F F 268 Kbps Module Fieldbus

F F Modular C C (Shielded Twisted
C C Baseplate M M Pair Cables)
M M 100 100 Other FBIs
100 100 Fieldbus E E (Note 2)
E E Communications
t t Modules
(Fault-Tolerant) Mounting Structure or
OR
Equipment Rack
2 Mbps Module Fieldbus
IPM2
IPM2

FBI

100 Series
100 Series

100 Series
100 Series

100 Series

(Shielded Twisted Pair Cables)

100 Series
100 Series

FBM

FBM

FBM
FBM
FBM

FBM
FBM
FBI
IPM2
IPM2

Modular
Baseplate
or 100 Series FBMs
Equipment or Competitive Migration
Rack Modules (See “Devices
F F F 200 Series Supported”)
F F F
B B B FBMs or B B B
M M M Competitive
M M M Other FBIs
Migration Modules
(See “Devices (Note 2)
Supported”)
Notes:
1. These networks can be part of the same network.
2. For sizing constraints, refer to the functional specifications at the end of this document.

Figure 2. Typical ZCP270 Network Configuration (Simplified)

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DEVICES SUPPORTED The ZCP270 with FCM100Es supports the following

The ZCP270 with FCM100Ets supports the following devices on the 268 Kbps Fieldbus:
devices:  100 series FBMs (FBM01, FBM02, and so forth)
 All 200 series FBMs (FBM201, FBM202, and so  Fieldbus Cluster I/O via FBP10 Fieldbus
forth) processor module
 Field Device Systems Integrator (FDSI) modules  Foxboro® Hydrostatic Interface Unit (HIU)(1)
 Intrinsically Safe I/O Subsystem (ISCM)  Foxboro Mass Flowmeter
 DCS Fieldbus Modules for Siemens APACS+™  Foxboro Panel Display Stations
Systems
 SPECTRUM™ Migration Integrators
 DCS Fieldbus Modules for Westinghouse
 SPEC 200™ Control Integrators
WDPF® Systems.
 DCS Fieldbus Modules for Fisher's PROVOX®  SPEC 200 MICRO™ Control Integrators
Series 20 Migration with HART.  SPEC 200 CCM Control Integrators
 DCS Fieldbus Modules for Honeywell® TDC  DCS Fieldbus Modules for Honeywell® TDC 2000
2000 Systems with HART. and TDC 3000 systems

 DCS Fieldbus Modules for Bailey® Net90 and

The ZCP270 with FCM100Es supports the following Infi90 systems
devices on the 2 Mbps module Fieldbus:
 DCS Fieldbus Modules for Fisher’s PROVOX®
 All 200 Series FBMs (FBM201, FBM202, and so Series 10, Series 20 and Controller Series
forth) - both Compact or standard types systems.
 Field Device Systems Integrator (FDSI) modules
MOUNTING STRUCTURE
 Intrinsically Safe I/O Subsystem (ISCM)
The ZCP270 are installed in the 1x8 and 2x8
 DCS Fieldbus Modules for Siemens APACS+™ mounting structures. The two modules of a fault-
Systems tolerant ZCP270 must be mounted in adjacent
 DCS Fieldbus Modules for Westinghouse mounting structure slots to allow for installation of the
WDPF® Systems. interconnecting fault-tolerant connector.

 DCS Fieldbus Modules for Fisher's PROVOX®

Series 20 Migration with HART.
 DCS Fieldbus Modules for Honeywell® TDC
2000 Systems with HART.

(1) Although FBM23 (HIU) IOM software is included with I/A Series software v8.x or Control Core Services v9.0 or later, the module’s con-
figurator, Intelligent Transmitter Maintenance Workbench (IT_Maint), is not supported. You must configure all FBM23s with the hand-
held terminal FIU. Refer to Configuration - Handheld Terminal (FIU), Foxboro M&I document number MI 020-065.
PSS 21H-1B10 B3
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LED INDICATORS
Light-emitting diodes (LEDs) on the front of the
ZCP270 module provide visual indication of the:
 ZCP270 operational status

 Communications activity of Ethernet control

network A and B links
 Communications activity of Ethernet fieldbus A
and B.
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.
 PSS 21H-1B10 B3
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F U N C T I O N A L S P E C I F I C AT I O N S

Processor Type WITH FCM100E (CONT.)

CONTROL PROCESSOR 100 Series FBMs
Microprocessor-based AMD Elan SC520 (running 64 (maximum) per ZCP270 Ethernet trunk
at 100 MHz) with stored programs, using high- 128 (maximum) Fieldbus Modules depending
speed communication capability. on the number of FCM100Es implemented
and control processor sizing constraints
Memory (per processor) (refer to ZCP270 Sizing Guidelines
SIZE [B0700AW]).
16 MB SDRAM
32 MB flash memory Maximum Number of Blocks Configured
The maximum number of blocks that can be
ERROR DETECTION
configured for the ZCP270 (or fault-tolerant ZCP270
ECC providing single-bit error detection and
pair) is 4000.
correction as well as multiple-bit error detection.
Memory Allocation for Blocks
Process I/O Communications (with FCMs)
5.8 MB
100 MBPS FAST ETHERNET
Transmission Rate Block Executions Per Second
100 Mbps to the FCM100Et or FCM100E 10,000 blocks/second, maximum

Cable Lengths Maximum Blocks Processed

The number of blocks that can be processed per
ZCP270, FCM100Et or FCM100E TO
basic processing cycle (BPC) time interval depends
ETHERNET SWITCH
on control processor sizing constraints and block
2 km (1.24 mi) maximum
type selection. These blocks include all types (control
Process I/O Capacity blocks, ECBs, compounds, data blocks, and so
WITH FCM100Et forth). For sizing guidelines, refer to ZCP270 Sizing
FCM100Et Modules Guidelines (B0700AW).
32 (maximum) per ZCP270 Ethernet trunk Minimum Block Processing Cycle (BPC)
fieldbus 50 ms
200 Series FBMs
128 (maximum) Fieldbus Modules depending
Sequence Block Size
on the number of FCM100Ets implemented 32 KB maximum for each block
and control processor sizing constraints Maximum Number of IPC Connections
(refer to ZCP270 Sizing Guidelines 131; 100 connections for source points; 30
[B0700AW]). connections for sink points; 1 connection for internal
WITH FCM100E use only.
FCM100E Modules 30 IPC connections 100 IPC connections
32 (maximum) per ZCP270 Ethernet trunk ZCP270
fieldbus
200 Series FBMs
128 (maximum) Fieldbus Modules depending Maximum Number of OM Sink Lists
on the number of FCM100Es implemented 50
and control processor sizing constraints Maximum OM Scanner Database
(refer to ZCP270 Sizing Guidelines 12,000 points for BPC ≥ 200 ms
[B0700AW]). 5,000 points for BPC ≤ 100 ms
PSS 21H-1B10 B3
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F U N C T I O N A L S PE CI F I C AT I O N S ( C O N T I N U E D )

Maximum Number of OM Sink Points Regulatory Compliance (Continued)

7,500 CISPR 11, Industrial Scientific and Medical
Configurable Block Periods (ISM) Radio-frequency Equipment -
0.05, 0.1, 0.2, 0.5, 0.6, 1, 2, 5, 6, 10, 30 seconds Electromagnetic Disturbance Characteristics
1, 10, 60 minutes - Limits and Methods of Measurement
Meets: Class A Limits
Basic Processing Cycle IEC 61000-4-2 ESD Immunity
0.05, 0.1, 0.2, 0.5, and 1.0 seconds, selectable at Contact 6 kV, air 8 kV
system configuration time
IEC 61000-4-3 Radiated Field Immunity
Time to Marry Fault-Tolerant Modules 10 V/m at 80 to 1000 MHz
<1s IEC 61000-4-4 Electrical Fast
Internal Diagnostics Transient/Burst Immunity
Self-checking performed at power-up. Run-time ±2 kV on I/O, dc power and communication
checks and the watchdog timer function performed lines
during operation. IEC 61000-4-5 Surge Immunity
±2 kV on ac and dc power lines; ±1 kV on
Infrared Communications I/O and communications lines
Letterbug assignment via the Letterbug Configurator.
IEC 61000-4-6 Immunity to Conducted
Letterbug or Hardware ID readout via the Letterbug
Disturbances Induced by Radio-frequency
Configurator.
Fields
Power Requirements 10 V (rms) at 150 kHz to 80 MHz on I/O,
INPUT VOLTAGE (REDUNDANT VOLTAGE) dc power and communication lines
39 V dc typical IEC 61000-4-8 Power Frequency Magnetic
CONSUMPTION (PER NON-FAULT-TOLERANT Field Immunity
MODULE) 30 A/m at 50 and 60 Hz
15 W, maximum SECURITY
Wurldtech Achilles Certification™ Level One
Regulatory Compliance
CE CERTIFICATION
For the ZCP270 to meet CE certifications
required in European installations, shielded
enclosures are required as described in Power,
Earthing (Grounding), EMC and CE Compliance
(B0700AU).
ELECTROMAGNETIC COMPATIBILITY (EMC)
European EMC Directive 89/336/EEC
Meets: EN 50081-2 Emission standard
EN 50082-2 Immunity standard
EN 61326 Annex A for Industrial
Environments
 PSS 21H-1B10 B3
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E N V I R O N M E N TA L S P E C I F I C AT I O N S ( 2 )

Operating Storage
TEMPERATURE TEMPERATURE
0 to +60°C (+32 to +140°F) -40 to +70°C (-40 to +158°F)
RELATIVE HUMIDITY RELATIVE HUMIDITY
5 to 95% (Noncondensing) 5 to 95% (Noncondensing)
ALTITUDE ALTITUDE
-300 to +3,000 m (-1,000 to +10,000 ft) -300 to +12,000 m (-1,000 to +40,000 ft)
VIBRATION
0.5 g (5 to 500 Hz)

P H Y S I C A L S P E C I F I C AT I O N S

Configuration Fiber Optic Cabling – Ethernet Switch to

Single-width processor module. The fault-tolerant ZCP270
version consists of two single-width processor CONNECTORS
modules, with an interconnecting fault-tolerant Ethernet Switch Connector
connector. One MT-RJ Connector
Mass (Maximum) ZCP270 or Splitter/Combiner Connector
1.7 kg (3.75 lb) for a single, non-fault-tolerant module. Two ceramic type LC connectors with clip
Mounting Fiber Optic Cabling – Ethernet Switch to
May be placed in any of the following I/A Series ZCP270 (Continued)
mounting structures: FIBER OPTIC CABLE
 1x8 Mounting Structure Cable Material
 2x8 Mounting Structure(3) Multi-mode fiber (MMF) 62.5/125 µm plenum
In the fault-tolerant version, the two modules must be Cable Lengths
mounted in adjacent mounting structure slots to allow 3 m (9.9 ft), 15 m (49.5 ft), 50 m (165 ft)
for installation of the interconnecting fault-tolerant greater than 50 m – user supplied
connector. Maximum Length
Dimensions - Module 2 km (6,560 ft) from the Ethernet switch to
the ZCP270.
HEIGHT
228 mm (8.97 in)
WIDTH
34.3 mm (1.35 in)
DEPTH
447 mm (17.6 in)

(2) The environmental ranges can be extended by the type of enclosure containing the module. [Refer to the applicable Product Specifi-
cation Sheet (PSS) which describes the specific enclosure that is to be used.]
(3) The 2x8 mounting structure is shipped as part of the Industrial Enclosures - IE16 and IE32. This mounting structure cannot be ordered
as a separate structure.
PSS 21H-1B10 B3
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P H Y S I CA L S PE CI F I CAT I O N S ( CO N T I N U E D)

Fiber Optic Cabling – Splitter/Combiner to

ZCP270
CONNECTORS
Two ceramic type LC connectors with clip on
each end
FIBER OPTIC CABLE
Cable Material
Multi-mode fiber (MMF) 62.5/125 µm
Cable Lengths
0.5 m (1.6 ft), 1.0 m (3.3ft), 3.0 m (9.9 ft),
15 m (49.5 ft), 50 m (165 ft)
greater than 50 m – user supplied
Maximum Length
2 km (6,560 ft) total from the Ethernet switch
to the ZCP270, including the cabling to the
splitter/combiner.

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