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This Universal Instruction Manual is designed to provide the user with a single, concise, easy-touse manual that covers the key points needed for configuration, calibration, installation, and 

operation of I/A Series Pressure Transmitters.

It covers all models of single variable pressure transmitters in the I/A Series family, including 

absolute, gauge, and differential pressure transmitters, with FoxCom, HART, FOUNDATION

Fieldbus, or analog output electronics.

This universal manual, along with a DVD containing detailed information, is provided free of 

charge with every I/A Series Pressure Transmitter, unless the purchaser requests that these two 

items be omitted. 

For additional detailed information about each model, including dimensional prints, parts lists, 

and more detailed instructions, please refer to the standard DVD supplied or the optional paper 

instruction book that is available for each model in the line.

♦ Standard Documentation Shipped with every I/A Series Pressure Transmitter

♦ A brief “Getting Started” Pocket-Sized Bulletin

♦ This Universal Instruction Manual

♦ A DVD that contains the complete documentation set for I/A Series Pressure 

Transmitters

♦ When Optional Feature K1 is specified in the Model Code when the transmitter is 

ordered:

A brief “Getting Started” Pocket-Sized Bulletin only is supplied

Optional Feature K1 is offered for those users who want to omit the documentation 

shipped with every transmitter. This may be specified when multiple identical 

transmitters are ordered and the user does not want multiple sets of documentation.

Electrical Certification Rating

The electrical safety design code is printed on the data plate as part of the model code. See Item B 

on the example shown in Figure 1. See the “Product Safety Specifications” section of the 

instruction pertaining to your instrument on the enclosed DVD to identify this code. The type of 

protection is also marked on the data plate. See Item D on the example shown in Figure 1.

PED Certification

The PED (Harmonized Pressure Equipment Directive for the European Community) 

certification is offered only with transmitters ordered with ATEX Electrical Safety Design Code 

selections. Transmitters with PED certification have a CE marking on the data plate that also 

carries the PED number 0496. 

Pressure Rating

The maximum working pressure (PS or MWP) for the transmitter is printed on the data plate. 

See Item F on the example shown in Figure 1.

The data plate of flanged level transmitters and transmitters with flanged pressure seals are 

stamped with the MWP if the transmitter pressure range is the limiting factor. It is stamped 

“Flange Rate” if the flange rating is the limiting factor. The MWP of the flanged seal is stamped 

on the seal data plate. See Figure 2.

Figure 2. Sample Seal Data Plate

When using transmitters with threaded, in-line saddle weld, or sanitary pressure seals, compare 

the MWP of the transmitter on the transmitter data plate and the MWP of the seals on the seals 

data plates and use the lesser value as the system MWP. 

The MWP on the seal data plates may not be given at your process temperature. Use the 

following information and industry standards as required to determine the actual pressure limits 

for your application. 

MODEL CODE: PSFPS-A2S0E313B MWP: 275 psig at 100°F 

NOTICE: BREAKING CONNECTIONS VOIDS WARRANTY

BE SURE FILL FLUID CAN MIX SAFELY WITH PROCESS HIGH SIDE SEAL

HIGH SIDE FLUID, DC200, 10 cSt SILICONE TEMP RANGE -40 TO +450°F

PROCESS WETTED MATERIAL 316 SS 

essure Seal PSFLT

Table 1. Pressure Seal PSFLT Pressure Limits

a. Flange temperature/pressure ratings only; seal temperature ratings may be lower; refer to Table 8

b. ASME/ANSI Material Group 1.1; linear interpolation acceptable

c. ASME/ANSI Material Group 2.2; linear interpolation acceptable

d. ANSI flanges per ASME/ANSI B16.5-1988.

e. DIN flanges per BS4504.

Pressure Seals PSFPS and PSFES

Table 2. Pressure Seal PSFPS and PSFES Pressure Limits

Pressure Seals PSSCR and PSSCT

The maximum working pressure of the seal process connection varies with the clamping device 

used. Refer to Tri-Clover Tri-Clamp standards to determine the pressure limits of the clamping 

system that you are using.

PSSSR and PSSST (Sanitary Tank Spud) Seals

The maximum working pressure of mini tank spud seal is 1.55 MPa at 120°C (225 psi at 250°F). 

That of the standard tank spud seal is 1.38 MPa at 120°C (200 psi at 250°F).

Origin Code

The origin code identifies the area of manufacture and the year and week of manufacture. See 

Item E on the example shown in Figure 1. In the example, 2A means the product was 

manufactured in the Measurement and Instrument Division, 01 identifies the year of 

manufacture as 2001, and 25, the week of manufacture in that year.

Operating Temperature Limits

The operating temperature limits of the electronics are -40°C and +85°C (-40°F and +185°F). 

The limits are -40°C and +75°C (-40°F and +167°F) for IAP10, IGP10, IGP25, and IGP50 

Transmitters with ATEX flameproof certification. Ensure that the transmitter is operated within 

this range. 

The sensor body operating temperature limits are determined by the sensor fill fluid. The cover 

material, sensor diaphragm material and fill fluid are specified by two characters in the model 

code on the data plate. See Item A on the example shown in Figure 1. Also see Table 5 and 

Table 6 to interpret this part of the code and Table 7 to determine the sensor body temperature 

limits. In the example IDP10-D12A21E-A3, the number 12 identifies the fill fluid in Table 5 as 

silicone. Table 7 identifies silicone as having temperature limits of -46 and +121°C (-50 and 

+250°F).

The diaphragm material code is found in the pressure seal model number which is located on the 

pressure seal. See following example:

The housing material is 316 ss.

The gasket is provided by the user.

Pressure Seals PSSCT

The housing material is 316 ss.

The diaphragm material is 316L ss.

The gasket is provided by the user.

Pressure Seals PSSSR and PSSST

The housing material is 316 ss.

The diaphragm material is 316L ss.

The gasket material is EPDM.

Warnings

General Warning

! WARNING

1. Transmitters must be installed to meet all applicable local installation regulations, 

such as hazardous location requirements, electrical wiring codes, and mechanical 

piping codes. Persons involved in the installation must be trained in these code 

requirements to ensure that the installation takes maximum advantage of the safety 

features designed into the transmitter.

2. A plug is supplied with each transmitter with 1/2 NPT conduit connection. It is 

intended to provide moisture ingress protection of the unused housing conduit entry. 

The plug must be wrench tight to achieve this level of protection. Thread sealant is 

required. Explosion-proof applications may require a certified plug. 

Housings with M20 / PG 13.5 threaded conduit connections are provided with an 

ATEX certified plug. Thread sealant is required to provide moisture ingress 

protection.

ATEX Warnings

! WARNING

Apparatus marked as Category 1 equipment and used in hazardous areas requiring 

this category must be installed in such a way that, even in the event of rare incidents, 

the versions with an aluminum alloy enclosure can not be an ignition source due to 

impact and friction

Install ATEX certified transmitters in accordance with the requirements of standard 

EN 60079-14.

! WARNING

To install a transmitter labeled with multiple approvals, select and permanently mark 

the certification label in the tick block to distinguish the installed approval type from 

the unused approval types. Once installed, the transmitter cannot be reinstalled using 

any other approval type. Not following these instructions will jeopardize explosion 

safety.

On IGPxx and IAPxx Transmitters with IECEx certification, the maximum constructional gap 

(Ic) is less than that required by IEC 60079-1:2003 as detailed in the table below:

Explosionproof/Flameproof and Enclosure Warning

! WARNING

1. To prevent possible explosion and to maintain explosionproof/flameproof and dustignitionproof protection, plug unused openings with a certified metal pipe plug. For 

1/2 NPT connections, both the plug and conduit must be engaged a minimum of five 

full threads. For M20 and PG 13.5 connections, the certified plug provided and the 

conduit must be engaged a minimum of seven full threads.

2. The threaded housing covers must be installed. Turn covers to seat O-ring into the 

housing and then continue to hand tighten until the cover contacts the housing 

metal-to-metal. 

3. If the electronics housing is removed for any reason, it must be hand tightened 

fully. Then engage the set screw until it bottoms out and back it off 1/8th turn. Fill 

the set screw recess with red lacquer (Foxboro Part Number X0180GS or equivalent). 

The housing then may be rotated up to one full turn in a counterclockwise direction 

for optimum access to adjustments.

Intrinsically Safe and Type n Warning

! WARNING

Since live maintenance is not specified, to prevent ignition of flammable atmospheres, 

disconnect power before servicing unless the area is certified to be nonhazardous.

Type n Warning

! WARNING

On transmitters certified for ATEX protection n, CSA Class I, Division 2, or FM 

nonincendive for Class I, Division 2, the threaded housing covers must be installed.

Pressure Warnings

! WARNING

When installing your transmitter, tighten process connector bolts to a torque of 

61 N•m (45 ft•lb) and drain plugs and optional vent screws to 20 N•m (15 ft•lb). See 

Figure 3.

If a sensor is replaced or process covers are rotated for venting, replace the gaskets and 

torque cover bolts (see Figures 4 and 5) to 100 N•m (75 ft•lb) in several even 

increments. Torque values are 66 N•m (50 ft•lb) when optional 316 ss bolts are 

specified (option B1). A pressure test is required. Perform a hydrostatic test with a 

liquid following proper hydrostatic test procedures. Pressure test the process cover 

assembly by applying a hydrostatic pressure of 150% of the maximum static and 

overrange pressure rating to both sides of the process cover/sensor assembly 

simultaneously through the process connections. Hold pressure for one minute. There 

should be no leakage of the test fluid through the gaskets.

Process Fluid Warning

! WARNING

If process containing parts are to be disassembled:

 1. Make sure that process fluid is not under pressure or at high temperature. 

 2. Take proper precautions concerning leakage or spillage of any toxic or otherwise

 dangerous fluid. Follow any Material Safety Data Sheet (MSDS) 

 recommendations.

Seal or Sensor Fill Fluid Warning

! WARNING

Even though the volume of fill fluid is small, be sure that the fill fluid can mix safely 

with the process fluid.

Parts Replacement Warning

! WARNING

This product contains components that have critical safety characteristics. Do not

substitute components. Replace components only with identical factory supplied 

components. Component substitution may impair the electrical safety of this 

equipment and its suitability for use in hazardous locations.

EU Declaration of Conformity

We, Manufacturer:

Invensys Systems, Inc.

38 Neponset Ave.

Foxboro, Massachusetts 02035

U.S.A.

declare under our sole responsibility that the

I/A Series Pressure Transmitters IGP, IAP, IDP, IPI, IMV

are in conformity with the protection requirements of Council Directives:

♦ 2004/108/EC on the approximation of the laws of the Member States relating to 

Electromagnetic Compatibility

♦ 94/9/EC on the approximation of the laws of the Member States concerning 

equipment and protective systems intended for use in potentially explosive 

atmospheres

♦ 2014/68/EU on the approximation of the laws of the Member States concerning 

pressure equipment

The basis on which Conformity is being declared:

♦ EN 61326-1:2006, Electrical equipment for measurement, control and laboratory use 

EMC requirements, Class A emission limits, and immunity requirements according to 

Table 2 for Industrial locations.

♦ EN50014 1997 A1 1999 A2 1999 Electrical apparatus for potentially explosive 

atmospheres ‘General Requirements’.

♦ EN50018 2000 Electrical apparatus for potentially explosive atmospheres 

‘Flameproof enclosures ‘d”.

♦ EN50020 1995 Electrical apparatus for potentially explosive atmospheres ‘Intrinsic 

safety ‘I”.

♦ EN50021 1999 Electrical apparatus for potentially explosive atmospheres ‘Type of 

protection ‘n”.

♦ EN50284 1999 Special requirements for construction, test and marking of electrical 

apparatus of group II Category 1 G.

♦ EN 50281-1-1 1999 Electrical apparatus for use in the presence of combustible dust.

♦ EN 60079-15 2003 Electrical apparatus for explosive gas atmospheres – Part 15: 

Electrical apparatus with type of protection “n”

For compliance with ATEX, products are in accordance with EC Type Examination Certificates 

KEMA 00ATEX 1060X, KEMA 00ATEX 2019X and KEMA 00ATEX 1009X, issued by KEMA 

Quality B.V., Ultrechtseweg 310, 6812 AR Arnhem, The Netherlands, Notified Body number 

0344, and with EC Type Examination Certificates SIRA 04ATEX1349, SIRA 04ATEX2335X, 

SIRA 06ATEX4056X, SIRA 06ATEX2055X, and SIRA 06ATEX4019X, issued by Sira 

Certification Service, Rake Lane, Eccleston, Chester, CH4 9JN, England, Notified Body number 

0518. The authorized markings for each certificate are shown below. The actual ATEX markings 

on the product vary according to model code. Refer to Product Specification Sheet and marking 

on product for details pertaining to individual model codes.

KEMA 00ATEX1060X II 3 G EEx nL IIC T4 … T6

 II 1 GD EEx nL IIC T4 … T6 T 135°C

KEMA 00ATEX1009X II 1 G EEx ia IIC T4 … T6

 II 1/2 G EEx ib IIC T4 … T6

 II 1 GD EEx ia IIC T4 … T6 T 135°C

 II 1/2 GD EEx ib IIC T4 … T6 T 135°C

KEMA 00ATEX2019X II 2 G EEx d IIC T6

 II 2 GD EEx d IIC T6 T 85°C

SIRA 04ATEX1349 II 2 GD EEx d IIC T6 T 85°C

SIRA 04ATEX2335X II 1G EEx ia IIC T4

SIRA 06ATEX4056X II 3 GD EEx nL IIC T4

SIRA 06ATEX2055X II 1 GD EEx ia IIC T4

SIRA 06ATEX4019X II 3 G EEx nL IIC T4

For the Pressure Equipment Directive, conformity is based on a certificate issued by DNV GL, 

Veritasveien 1, 1322 HOVIK, Norway, Notified Body number 0496, based on Maximum 

Working Pressure (MWP). Conformity Assessment Module “H” is applied for Models IGP, IAP, 

IMV and IDP where the MWP is greater than 200 bar. The applicable design standard is 

IEC/EN 61010-1

. Installation

! CAUTION

To avoid damage to the transmitter sensor, do not use any impact devices, such as an 

impact wrench or stamping device, on the transmitter. 

NOTE

1. The transmitter should be mounted so that any moisture condensing or draining 

into the field wiring compartment can exit through one of the two threaded 

conduit connections.

2. Use a suitable thread sealant on all connections.

3. If the transmitter is not installed in the vertical position, readjust zero output to 

eliminate the position zero effect.

Mechanical Installation

Differential Pressure Transmitter

The IDP10, IDP25, and IDP50 differential pressure transmitters can be supported by the process 

piping (Figure 6), on a bypass manifold (Figures 7 through 10), or mounted to a vertical or 

horizontal pipe or surface using an optional mounting bracket (Figures 11 through 16). For 

dimensional information, refer to DP 020-446.

NOTE

1. The IDP25 and IDP50 transmitters are only available in the Traditional Structure 

at this time.

2. If the transmitter is not installed in the vertical position, readjust zero output to 

eliminate the position zero effect.

3. When pvdf inserts (structure codes 78/79) are used, the process connection must 

be made directly to the pvdf inserts in the Hi and Lo side process covers.

4. The transmitter should be mounted so that any moisture condensing or draining 

into the field wiring compartment can exit through one of the two threaded 

conduit connections.

Process-Mounted Transmitter

Figure 6 shows the transmitter mounted to and supported by the process piping

Figure 8. Typical Mounting of M4A and M4T Manifold with -AM Bracket

Pipe- or Surface-Mounted Transmitter

To mount the transmitter to a pipe or surface, use the Standard Mounting Bracket Set (Model 

Code Option -M1 or -M2) or Universal Bracket Mounting Set (Model Code Option -M3).

Standard Mounting Bracket

The transmitter (with either traditional or LP2 low-profile structures) can be mounted to a 

vertical or horizontal, DN 50 or 2-in pipe using a standard bracket. See Figure 11 for details and 

Figure 12 for examples of different situations. Secure the mounting bracket to the transmitter 

using the four screws provided. Mount the bracket to the pipe. To mount to a horizontal pipe, 

turn the U-bolt 90° from the position shown in Figure 11. The mounting bracket can also be 

used for wall mounting by securing the bracket to a wall using the U-bolt mounting holes.

Universal Mounting Bracket

The transmitter (with either traditional or LP2 low-profile structure) can be mounted in a myriad 

of positions to a vertical or horizontal, DN 50 or 2-in pipe using a universal bracket. See 

Figure 13 for details of a universal bracket and Figure 14 through Figure 16 for examples of 

different mounting situations. Secure the mounting bracket to the transmitter using the two long 

or four short screws provided. Mount the bracket to the pipe. The mounting bracket can also be 

used for wall mounting by securing the bracket to a wall using the U-bolt mounting holes.

Figure 14. Mounting a Transmitter with Traditional Structure Using a Universal Bracket

Figure 15. Vertical Pipe Mounting a Transmitter with LP2 Structure Using a Universal Bracket

The Field Control Processor 280 is a distributed, optionally fault-tolerant, field-mounted controller that 

performs process control and alarming functions according to a user-defined control strategy.

FEATURES

 Performs regulatory, logic, timing, and sequential 

control together with connected Fieldbus 

Modules (FBMs)

 Performs data acquisition and alarm detection 

and notification

 Supports up to 128 Compact or standard 

200 Series FBMs, or up to 128 of a combination 

of 100 Series FBMs and 200 Series FBMs (with 

no more than 64 100 Series FBMs in this 

configuration)

No Fieldbus Communication Module is required.

 No Fieldbus Expansion Module is required for 

Expanded fieldbus support.

 Supports self-hosting mode, which allows the 

FCP280 to boot itself with a valid control 

database even without its host workstation

 Offers unique, patented, fault-tolerant operation 

using two control modules to greatly improve 

reliability relative to other process controllers

 Offers on-line image upgrade (OLUG) of a faulttolerant FCP280 without shutting down the 

process

 Liquid Crystal Display (LCD) displays letterbug 

and real-time roles and statuses

 Connects to The Mesh control network via 

standard fiber optic or copper 100 Mbps 

Ethernet cables

 Uses a rugged, die cast aluminum housing for 

mounting in a non-vented field enclosure

 Can operate in Class G3 harsh environments

 CE certified for field mounting in enclosures

 Each Fieldbus port on FCP280 baseplates 

supports either a 2 Mbps or 268 Kbps HDLC 

fieldbus exclusively

 Uses versatile control algorithms and a wide 

variety of FBMs to provide control capabilities for 

a broad range of process applications

 Supports time synchronization using optional 

external time from GPS satellites

 Uses soft letterbugs configurable via the keys on 

the FCP280 faceplate.

OVERVIEW

The Field Control Processor 280 (FCP280) is a 

distributed, optionally fault-tolerant, field-mounted 

controller module. The FCP280 performs regulatory, 

logic, timing, and sequential control together with 

connected Fieldbus Modules. It also performs data 

acquisition and alarm detection and notification. 

The FCP280 connects to The Mesh control network 

via standard fiber optic or copper 100 Mbps Ethernet 

cables from network adapters installed on its 

baseplate (shown in Figure 1).

The FCP280 requires Foxboro Evo Control Core 

Services v9.0 or later. A system with the FCP280 and 

this software is called a Foxboro Evo Process 

Automation System

Figure 1. Fault-Tolerant FCP280 Module Pair Mounted on Vertical Mounted 2-Position FCP280 Baseplate

The fault-tolerant version of the FCP280 consists of 

two processor modules. These modules are installed 

in adjacent FCP280 slots in a baseplate for high 

speed communication between the modules.

The FCP280 accepts four PIO channels (that is, four 

separate HDLC fieldbuses) via the four Fieldbus ports 

on its baseplate. These four Fieldbuses are referred 

to collectively as the “Expanded fieldbus.” For a 

description of the FCP280 baseplates, refer to DIN 

Rail Mounted Modular Baseplates

(PSS 21H-2W6 B4).

The number of FBMs which an FCP280 can support 

varies depending on the types of FBMs used:

 200 Series FBMs exclusively used with FCP280 – 

Each Fieldbus port on the FCP280 baseplate can 

connect to a baseplate chain with up to 32 

Compact or standard 200 Series FBMs per chain 

via the 2 Mbps HDLC fieldbus (up to 128 

modules).

 200 Series and 100 Series FBMs (dual baud 

configurations) used with FCP280 – The FCP280 

can support a total of 64 100 Series FBMs (Ymodule) or competitive devices (such as Foxboro 

Evo System migration FBMs) in one or more 

baseplate chains, with the remainder of the 

FCP280’s 128 module limit being 200 Series 

FBMs, depending on the Fieldbus loading of the 

FCP280. For example, an FCP280 could support 

64 100 Series FBMs and 64 200 Series FBMs (as 

128 – 64 = 64). See Figure 2 and Figure 3 below.

NOTE

Certain competitive migration or supported 

third-party modules such as DCS Migration 

fieldbus Modules and Pepperl+Fuchs™ I/O 

modules may increase this 128 module 

maximum per FCP280. For the maximum 

numbers of each of these migration/thirdparty modules supported by the FCP280, 

refer to the supported migration products 

books in Field Control Processor 280 

(FCP280) User’s Guide (B0700FW).

When supporting 200 Series and 100 Series FBMs, 

each Fieldbus port (PIO channel) is dedicated to 

supporting either a 268 Kbps HDLC fieldbus (for 

100 Series FBMs) or a 2 Mbps HDLC fieldbus (for 

200 Series FBMs) – not both.

For connections to 100 Series FBMs over 60 m 

(198 ft), an FBI200 pair is required to extend 

communications up to 1830 m (6000 ft). See 

Figure 2 below.

To connect a Fieldbus port to a 268 Kbps HDLC 

fieldbus directly, the Fieldbus splitter (RH928CV) 

provides a connector for any Fieldbus port on the 

FCP280 baseplate, and two Termination Cable 

Assembly (TCA) termination blocks for the twinaxial 

cabling from the 100 Series FBMs.

The FCP280 can also communicate with serial and 

Ethernet devices, such as PLCs, via Field Device 

System Integrators. This allows you to connect to 

new device interfaces without any changes to the 

controller software.

To estimate the FCP280’s processor load, refer to 

Field Control Processor 280 (FCP280) Sizing 

Guidelines and Excel Workbook (B0700FY)

FIBER AND COPPER NETWORK ADAPTERS

FCP280 modules connect to a pair of fiber or copper 

adapters (see Figure 4) which each connect to one 

Ethernet switch in The Mesh control network. The 

FCP280 baseplate passes inbound traffic from either 

of the two switches to both FCP280s, and pass 

outbound traffic from the primary FCP280 module to 

either switch.

Figure 4. Fiber Optic and Copper Network Adapters

The fiber or copper adapters mount on the FCP280 

baseplate as shown in Figure 1 on page 2. They 

receive their power from the baseplate.

REMOTE MOUNTING

The FCP280 simplifies the Foxboro Evo Process 

Automation System architecture, maintaining control 

while only requiring housing (via field enclosures), 

host workstations with Foxboro Evo Control Core 

Services v9.0 or later, and Ethernet switches for 

communication via The Mesh control network 

architecture, described in PSS 21H-7C2 B3.

The field-mounted FCP280 is an integral part of the 

highly-distributed control network where controllers 

are closely aligned to specific process units mounted 

in close proximity to their I/O and the actual 

equipment being controlled. Coordination between 

process units takes place via a fiber optic 100 Mbps 

Ethernet network.

The FCP280 and its network adapters are packaged 

in a rugged, die cast aluminum housing that does not 

require venting due to its efficient design. The 

FCP280 and its network adapters are CE certified, 

and it can be mounted without expensive special 

cabinets to prevent electronic emissions. The 

FCP280, network adapters, and baseplate can be 

mounted in Class G3 harsh environments.

ENHANCED RELIABILITY (FAULTTOLERANCE)

The unique and patented fault-tolerant operation of 

the FCP280 improves reliability relative to legacy 

process controllers. The fault-tolerant version of the 

FCP280 consists of two modules operating in 

parallel, with two Ethernet connections to The Mesh 

control network. The two FCP280 modules, married 

together as a fault-tolerant pair, provide continuous 

operation of the controller 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 external interfaces. 

Messages only leave the FCP280 when both 

FCP280s agree on the message being sent (bit for 

bit match). Upon detection of a fault, 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.

This fault-tolerant solution has the following major 

advantages over controllers that are merely 

redundant:

 No bad messages are sent to the field or to 

applications using controller data because no 

message is allowed out of the controller unless 

both modules match bit for bit on the message 

being sent.

 The secondary controller is synchronized with the 

primary one, which ensures up to the moment 

data in the event of a primary controller failure.

 The secondary controller will have latent flaws 

detected prior to any switchover because it is 

performing exactly the same operations as the 

primary controller.

UPGRADE OPTIONS

Multiple options are available for replacing existing 

control processors with the FCP280. A fault-tolerant 

FCP280 may replace a fault-tolerant FCP270 or 

ZCP270. It may import the CP database from the 

CP270 it is replacing, for compatibility and minimal 

configuration time.

As well the FCP280 provides an increase in 

performance and block processing capacity over the 

CP270s. When replacing FCP270s, the FCP280 

eliminates the need for FEM100 hardware.

For ease of replacement, the fault-tolerant or nonfault-tolerant FCP280 in its baseplate has the same 

dimensions as the fault-tolerant or non-fault-tolerant 

FCP270 in its baseplate.

Cabling the 100 Series FBMs or Migration products 

to an FCP280 baseplate consists of extending the 

remote 268 Kbps fieldbus between enclosures. This 

is accomplished using termination cable assemblies 

(TCAs) and Fieldbus Isolators (FBIs) to provide 

connections between primary and extended fieldbus 

segments.

The optional FBI200 can extend the 2 Mbps HDLC 

fieldbus between 200 Series FBMs from 60 m (198 ft) 

up to 305 m (1000 ft). As well, it can extend the 

268 Kbps HDLC fieldbus between 100 Series FBMs 

from 60 m (198 ft) up to 1830 m (6000 ft).

As with earlier generations of control processors, up 

to 64 100 Series FBMs (including expansion 

modules) attach to Fieldbus ports through Fieldbus 

Isolators. (Up to 24 100 Series FBMs, excluding 

expansion modules, can connect to each isolator.

However, the expansion modules are considered 

100 Series FBMs in this “64 100 Series FBMs” 

maximum discussed in this PSS.)

Available upgrade scenarios are available in Field 

Control Processor 280 (FCP280) User’s Guide

(B0700FW).

FBI200 FIELDBUS ISOLATOR/FILTER

The FBI200 Fieldbus Isolator/Filter extends the length 

of the 268 Kbps module Fieldbus from the FCP280 

to 100 Series FBMs and similar competitive migration 

modules up to 1830 m (6000 ft) over a twinaxial 

Fieldbus cable. See Figure 2 on page 4.

It can also extend the 2 Mbps HDLC fieldbus to 

200 Series FBMs up to 305 m (1000 ft).

For more information on the FBI200, refer to FBI200 

Fieldbus Isolator/Filter (PSS 21H-2Y18 B4).

FIRMWARE UPGRADES WHILE ON-LINE

For fault-tolerant FCP280 modules, on-line image 

upgrade replaces the executable image (operating 

system) of a running FCP280 with a newer image 

without having to shut down the equipment being 

controlled by the FCP280. 

TIME SYNCHRONIZATION, SOE, TDR/TDA

The Foxboro Evo Process Automation System 

supports time synchronization using either an 

externally maintained optional source of Universal 

Coordinated Time (UTC) from GPS satellites or an 

internal source using proprietary software. FCP280s 

that receive time updates via the external time source 

synchronize their FBMs to 1 ms. For more 

information on time synchronization, refer to Time 

Synchronization Overview (PSS 21S-1C2 B3).

Time stamping is used for alarm messages, values 

sent to the historian, and the Sequence Of Events 

(SOE) and Transient Data Recorder (TDR), and 

Transient Data Analyzer (TDA) features.

SOE data are discrete points that are time stamped at the FBM, optionally to 1 ms, and sent to the workstation on a change basis. TDR/TDA data are analog or digital points that are time stamped at the FBM and sent to the workstation every 10 ms. These features are supported by client software in the workstation. For information on this new software, refer to Field Control Processor 280 (FCP280) Integrated Control Software (PSS 31S-3B3 B3). SOFTWARE CONTROL FEATURES The FCP280 performs regulatory, logic, timing, and sequential control, as well as data acquisition, alarm detection, and alarm notification. Process variables are controlled using time-proven algorithms (mathematical computations performing specific functions). The algorithms are contained in functional control blocks, which on-site process engineers configure to implement the desired control strategies. The versatility of the algorithms, coupled with the variety of FBMs available, provides control capabilities suited to a broad range of process applications. Control strategies ranging from simple feedback and cascade loops to highly sophisticated feedforward, nonlinear, and complex characterization control schemes are readily implemented. The FCP280 also supports the following features:  Setting and reading the FCP280 letterbug via the buttons on the faceplate  Alarm enhancements to 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 allows the FCP280 to start up and run, executing its configured control scheme using the checkpoint file stored in flash memory. This allows the FCP280 to boot itself with a valid control database even if its host workstation is not present.  Support for high speed capabilities such as ladder logic, Motor Driven Actuator Controller (MDACT), and Distributed Proportional Integral Derivative functionality (DPIDA) DEVICES SUPPORTED The FCP280 supports the following devices on the 2 Mbps fieldbus:  All Compact and standard 200 Series FBMs (FBM201, FBM202, and so forth), which can support many types of intelligent field devices, including those on FOUNDATION fieldbus, PROFIBUS, HART, and DeviceNet networks  Field Device Systems Integrator (FDSI) modules  Intrinsically Safe I/O Subsystem (ISCM) – refer to PSS 21H-2Y6 B4).  DCS Migration fieldbus Modules for Siemens APACS+ Systems  DCS Migration fieldbus Modules for Westinghouse WDPF® Systems  DCS Migration fieldbus Modules for Fisher’s PROVOX® Series 20 Migration with HART  DCS Migration fieldbus Modules for Honeywell® TDC 2000 Systems with HART. The FCP280 supports the following devices on the 268 Kbps fieldbus:  100 Series FBMs (FBM01, FBM02, and so forth)  SPECTRUM™ Migration Integrators  SPEC 200™ Control Integrators  SPEC 200 MICRO™ Control Integrators  SPEC 200 CCM Control Integrators

The Field Control Processor 280 is a distributed, optionally fault-tolerant, field-mounted controller that 

performs process control and alarming functions according to a user-defined control strategy.

FEATURES

 Performs regulatory, logic, timing, and sequential 

control together with connected Fieldbus 

Modules (FBMs)

 Performs data acquisition and alarm detection 

and notification

 Supports up to 128 Compact or standard 

200 Series FBMs, or up to 128 of a combination 

of 100 Series FBMs and 200 Series FBMs (with 

no more than 64 100 Series FBMs in this 

configuration)

No Fieldbus Communication Module is required.

 No Fieldbus Expansion Module is required for 

Expanded fieldbus support.

 Supports self-hosting mode, which allows the 

FCP280 to boot itself with a valid control 

database even without its host workstation

 Offers unique, patented, fault-tolerant operation 

using two control modules to greatly improve 

reliability relative to other process controllers

 Offers on-line image upgrade (OLUG) of a faulttolerant FCP280 without shutting down the 

process

 Liquid Crystal Display (LCD) displays letterbug 

and real-time roles and statuses

 Connects to The Mesh control network via 

standard fiber optic or copper 100 Mbps 

Ethernet cables

 Uses a rugged, die cast aluminum housing for 

mounting in a non-vented field enclosure

 Can operate in Class G3 harsh environments

 CE certified for field mounting in enclosures

 Each Fieldbus port on FCP280 baseplates 

supports either a 2 Mbps or 268 Kbps HDLC 

fieldbus exclusively

 Uses versatile control algorithms and a wide 

variety of FBMs to provide control capabilities for 

a broad range of process applications

 Supports time synchronization using optional 

external time from GPS satellites

 Uses soft letterbugs configurable via the keys on 

the FCP280 faceplate.

OVERVIEW

The Field Control Processor 280 (FCP280) is a 

distributed, optionally fault-tolerant, field-mounted 

controller module. The FCP280 performs regulatory, 

logic, timing, and sequential control together with 

connected Fieldbus Modules. It also performs data 

acquisition and alarm detection and notification. 

The FCP280 connects to The Mesh control network 

via standard fiber optic or copper 100 Mbps Ethernet 

cables from network adapters installed on its 

baseplate (shown in Figure 1).

The FCP280 requires Foxboro Evo Control Core 

Services v9.0 or later. A system with the FCP280 and 

this software is called a Foxboro Evo Process 

Automation System

Figure 1. Fault-Tolerant FCP280 Module Pair Mounted on Vertical Mounted 2-Position FCP280 Baseplate

The fault-tolerant version of the FCP280 consists of 

two processor modules. These modules are installed 

in adjacent FCP280 slots in a baseplate for high 

speed communication between the modules.

The FCP280 accepts four PIO channels (that is, four 

separate HDLC fieldbuses) via the four Fieldbus ports 

on its baseplate. These four Fieldbuses are referred 

to collectively as the “Expanded fieldbus.” For a 

description of the FCP280 baseplates, refer to DIN 

Rail Mounted Modular Baseplates

(PSS 21H-2W6 B4).

The number of FBMs which an FCP280 can support 

varies depending on the types of FBMs used:

 200 Series FBMs exclusively used with FCP280 – 

Each Fieldbus port on the FCP280 baseplate can 

connect to a baseplate chain with up to 32 

Compact or standard 200 Series FBMs per chain 

via the 2 Mbps HDLC fieldbus (up to 128 

modules).

 200 Series and 100 Series FBMs (dual baud 

configurations) used with FCP280 – The FCP280 

can support a total of 64 100 Series FBMs (Ymodule) or competitive devices (such as Foxboro 

Evo System migration FBMs) in one or more 

baseplate chains, with the remainder of the 

FCP280’s 128 module limit being 200 Series 

FBMs, depending on the Fieldbus loading of the 

FCP280. For example, an FCP280 could support 

64 100 Series FBMs and 64 200 Series FBMs (as 

128 – 64 = 64). See Figure 2 and Figure 3 below.

NOTE

Certain competitive migration or supported 

third-party modules such as DCS Migration 

fieldbus Modules and Pepperl+Fuchs™ I/O 

modules may increase this 128 module 

maximum per FCP280. For the maximum 

numbers of each of these migration/thirdparty modules supported by the FCP280, 

refer to the supported migration products 

books in Field Control Processor 280 

(FCP280) User’s Guide (B0700FW).

When supporting 200 Series and 100 Series FBMs, 

each Fieldbus port (PIO channel) is dedicated to 

supporting either a 268 Kbps HDLC fieldbus (for 

100 Series FBMs) or a 2 Mbps HDLC fieldbus (for 

200 Series FBMs) – not both.

For connections to 100 Series FBMs over 60 m 

(198 ft), an FBI200 pair is required to extend 

communications up to 1830 m (6000 ft). See 

Figure 2 below.

To connect a Fieldbus port to a 268 Kbps HDLC 

fieldbus directly, the Fieldbus splitter (RH928CV) 

provides a connector for any Fieldbus port on the 

FCP280 baseplate, and two Termination Cable 

Assembly (TCA) termination blocks for the twinaxial 

cabling from the 100 Series FBMs.

The FCP280 can also communicate with serial and 

Ethernet devices, such as PLCs, via Field Device 

System Integrators. This allows you to connect to 

new device interfaces without any changes to the 

controller software.

To estimate the FCP280’s processor load, refer to 

Field Control Processor 280 (FCP280) Sizing 

Guidelines and Excel Workbook (B0700FY)

FIBER AND COPPER NETWORK ADAPTERS

FCP280 modules connect to a pair of fiber or copper 

adapters (see Figure 4) which each connect to one 

Ethernet switch in The Mesh control network. The 

FCP280 baseplate passes inbound traffic from either 

of the two switches to both FCP280s, and pass 

outbound traffic from the primary FCP280 module to 

either switch.

Figure 4. Fiber Optic and Copper Network Adapters

The fiber or copper adapters mount on the FCP280 

baseplate as shown in Figure 1 on page 2. They 

receive their power from the baseplate.

REMOTE MOUNTING

The FCP280 simplifies the Foxboro Evo Process 

Automation System architecture, maintaining control 

while only requiring housing (via field enclosures), 

host workstations with Foxboro Evo Control Core 

Services v9.0 or later, and Ethernet switches for 

communication via The Mesh control network 

architecture, described in PSS 21H-7C2 B3.

The field-mounted FCP280 is an integral part of the 

highly-distributed control network where controllers 

are closely aligned to specific process units mounted 

in close proximity to their I/O and the actual 

equipment being controlled. Coordination between 

process units takes place via a fiber optic 100 Mbps 

Ethernet network.

The FCP280 and its network adapters are packaged 

in a rugged, die cast aluminum housing that does not 

require venting due to its efficient design. The 

FCP280 and its network adapters are CE certified, 

and it can be mounted without expensive special 

cabinets to prevent electronic emissions. The 

FCP280, network adapters, and baseplate can be 

mounted in Class G3 harsh environments.

ENHANCED RELIABILITY (FAULTTOLERANCE)

The unique and patented fault-tolerant operation of 

the FCP280 improves reliability relative to legacy 

process controllers. The fault-tolerant version of the 

FCP280 consists of two modules operating in 

parallel, with two Ethernet connections to The Mesh 

control network. The two FCP280 modules, married 

together as a fault-tolerant pair, provide continuous 

operation of the controller 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 external interfaces. 

Messages only leave the FCP280 when both 

FCP280s agree on the message being sent (bit for 

bit match). Upon detection of a fault, 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.

This fault-tolerant solution has the following major 

advantages over controllers that are merely 

redundant:

 No bad messages are sent to the field or to 

applications using controller data because no 

message is allowed out of the controller unless 

both modules match bit for bit on the message 

being sent.

 The secondary controller is synchronized with the 

primary one, which ensures up to the moment 

data in the event of a primary controller failure.

 The secondary controller will have latent flaws 

detected prior to any switchover because it is 

performing exactly the same operations as the 

primary controller.

UPGRADE OPTIONS

Multiple options are available for replacing existing 

control processors with the FCP280. A fault-tolerant 

FCP280 may replace a fault-tolerant FCP270 or 

ZCP270. It may import the CP database from the 

CP270 it is replacing, for compatibility and minimal 

configuration time.

As well the FCP280 provides an increase in 

performance and block processing capacity over the 

CP270s. When replacing FCP270s, the FCP280 

eliminates the need for FEM100 hardware.

For ease of replacement, the fault-tolerant or nonfault-tolerant FCP280 in its baseplate has the same 

dimensions as the fault-tolerant or non-fault-tolerant 

FCP270 in its baseplate.

Cabling the 100 Series FBMs or Migration products 

to an FCP280 baseplate consists of extending the 

remote 268 Kbps fieldbus between enclosures. This 

is accomplished using termination cable assemblies 

(TCAs) and Fieldbus Isolators (FBIs) to provide 

connections between primary and extended fieldbus 

segments.

The optional FBI200 can extend the 2 Mbps HDLC 

fieldbus between 200 Series FBMs from 60 m (198 ft) 

up to 305 m (1000 ft). As well, it can extend the 

268 Kbps HDLC fieldbus between 100 Series FBMs 

from 60 m (198 ft) up to 1830 m (6000 ft).

As with earlier generations of control processors, up 

to 64 100 Series FBMs (including expansion 

modules) attach to Fieldbus ports through Fieldbus 

Isolators. (Up to 24 100 Series FBMs, excluding 

expansion modules, can connect to each isolator.

However, the expansion modules are considered 

100 Series FBMs in this “64 100 Series FBMs” 

maximum discussed in this PSS.)

Available upgrade scenarios are available in Field 

Control Processor 280 (FCP280) User’s Guide

(B0700FW).

FBI200 FIELDBUS ISOLATOR/FILTER

The FBI200 Fieldbus Isolator/Filter extends the length 

of the 268 Kbps module Fieldbus from the FCP280 

to 100 Series FBMs and similar competitive migration 

modules up to 1830 m (6000 ft) over a twinaxial 

Fieldbus cable. See Figure 2 on page 4.

It can also extend the 2 Mbps HDLC fieldbus to 

200 Series FBMs up to 305 m (1000 ft).

For more information on the FBI200, refer to FBI200 

Fieldbus Isolator/Filter (PSS 21H-2Y18 B4).

FIRMWARE UPGRADES WHILE ON-LINE

For fault-tolerant FCP280 modules, on-line image 

upgrade replaces the executable image (operating 

system) of a running FCP280 with a newer image 

without having to shut down the equipment being 

controlled by the FCP280. 

TIME SYNCHRONIZATION, SOE, TDR/TDA

The Foxboro Evo Process Automation System 

supports time synchronization using either an 

externally maintained optional source of Universal 

Coordinated Time (UTC) from GPS satellites or an 

internal source using proprietary software. FCP280s 

that receive time updates via the external time source 

synchronize their FBMs to 1 ms. For more 

information on time synchronization, refer to Time 

Synchronization Overview (PSS 21S-1C2 B3).

Time stamping is used for alarm messages, values 

sent to the historian, and the Sequence Of Events 

(SOE) and Transient Data Recorder (TDR), and 

Transient Data Analyzer (TDA) features.

SOE data are discrete points that are time stamped at the FBM, optionally to 1 ms, and sent to the workstation on a change basis. TDR/TDA data are analog or digital points that are time stamped at the FBM and sent to the workstation every 10 ms. These features are supported by client software in the workstation. For information on this new software, refer to Field Control Processor 280 (FCP280) Integrated Control Software (PSS 31S-3B3 B3). SOFTWARE CONTROL FEATURES The FCP280 performs regulatory, logic, timing, and sequential control, as well as data acquisition, alarm detection, and alarm notification. Process variables are controlled using time-proven algorithms (mathematical computations performing specific functions). The algorithms are contained in functional control blocks, which on-site process engineers configure to implement the desired control strategies. The versatility of the algorithms, coupled with the variety of FBMs available, provides control capabilities suited to a broad range of process applications. Control strategies ranging from simple feedback and cascade loops to highly sophisticated feedforward, nonlinear, and complex characterization control schemes are readily implemented. The FCP280 also supports the following features:  Setting and reading the FCP280 letterbug via the buttons on the faceplate  Alarm enhancements to 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 allows the FCP280 to start up and run, executing its configured control scheme using the checkpoint file stored in flash memory. This allows the FCP280 to boot itself with a valid control database even if its host workstation is not present.  Support for high speed capabilities such as ladder logic, Motor Driven Actuator Controller (MDACT), and Distributed Proportional Integral Derivative functionality (DPIDA) DEVICES SUPPORTED The FCP280 supports the following devices on the 2 Mbps fieldbus:  All Compact and standard 200 Series FBMs (FBM201, FBM202, and so forth), which can support many types of intelligent field devices, including those on FOUNDATION fieldbus, PROFIBUS, HART, and DeviceNet networks  Field Device Systems Integrator (FDSI) modules  Intrinsically Safe I/O Subsystem (ISCM) – refer to PSS 21H-2Y6 B4).  DCS Migration fieldbus Modules for Siemens APACS+ Systems  DCS Migration fieldbus Modules for Westinghouse WDPF® Systems  DCS Migration fieldbus Modules for Fisher’s PROVOX® Series 20 Migration with HART  DCS Migration fieldbus Modules for Honeywell® TDC 2000 Systems with HART. The FCP280 supports the following devices on the 268 Kbps fieldbus:  100 Series FBMs (FBM01, FBM02, and so forth)  SPECTRUM™ Migration Integrators  SPEC 200™ Control Integrators  SPEC 200 MICRO™ Control Integrators  SPEC 200 CCM Control Integrators

The Field Control Processor 280 is a distributed, optionally fault-tolerant, field-mounted controller that 

performs process control and alarming functions according to a user-defined control strategy.

FEATURES

 Performs regulatory, logic, timing, and sequential 

control together with connected Fieldbus 

Modules (FBMs)

 Performs data acquisition and alarm detection 

and notification

 Supports up to 128 Compact or standard 

200 Series FBMs, or up to 128 of a combination 

of 100 Series FBMs and 200 Series FBMs (with 

no more than 64 100 Series FBMs in this 

configuration)

No Fieldbus Communication Module is required.

 No Fieldbus Expansion Module is required for 

Expanded fieldbus support.

 Supports self-hosting mode, which allows the 

FCP280 to boot itself with a valid control 

database even without its host workstation

 Offers unique, patented, fault-tolerant operation 

using two control modules to greatly improve 

reliability relative to other process controllers

 Offers on-line image upgrade (OLUG) of a faulttolerant FCP280 without shutting down the 

process

 Liquid Crystal Display (LCD) displays letterbug 

and real-time roles and statuses

 Connects to The Mesh control network via 

standard fiber optic or copper 100 Mbps 

Ethernet cables

 Uses a rugged, die cast aluminum housing for 

mounting in a non-vented field enclosure

 Can operate in Class G3 harsh environments

 CE certified for field mounting in enclosures

 Each Fieldbus port on FCP280 baseplates 

supports either a 2 Mbps or 268 Kbps HDLC 

fieldbus exclusively

 Uses versatile control algorithms and a wide 

variety of FBMs to provide control capabilities for 

a broad range of process applications

 Supports time synchronization using optional 

external time from GPS satellites

 Uses soft letterbugs configurable via the keys on 

the FCP280 faceplate.

OVERVIEW

The Field Control Processor 280 (FCP280) is a 

distributed, optionally fault-tolerant, field-mounted 

controller module. The FCP280 performs regulatory, 

logic, timing, and sequential control together with 

connected Fieldbus Modules. It also performs data 

acquisition and alarm detection and notification. 

The FCP280 connects to The Mesh control network 

via standard fiber optic or copper 100 Mbps Ethernet 

cables from network adapters installed on its 

baseplate (shown in Figure 1).

The FCP280 requires Foxboro Evo Control Core 

Services v9.0 or later. A system with the FCP280 and 

this software is called a Foxboro Evo Process 

Automation System

Figure 1. Fault-Tolerant FCP280 Module Pair Mounted on Vertical Mounted 2-Position FCP280 Baseplate

The fault-tolerant version of the FCP280 consists of 

two processor modules. These modules are installed 

in adjacent FCP280 slots in a baseplate for high 

speed communication between the modules.

The FCP280 accepts four PIO channels (that is, four 

separate HDLC fieldbuses) via the four Fieldbus ports 

on its baseplate. These four Fieldbuses are referred 

to collectively as the “Expanded fieldbus.” For a 

description of the FCP280 baseplates, refer to DIN 

Rail Mounted Modular Baseplates

(PSS 21H-2W6 B4).

The number of FBMs which an FCP280 can support 

varies depending on the types of FBMs used:

 200 Series FBMs exclusively used with FCP280 – 

Each Fieldbus port on the FCP280 baseplate can 

connect to a baseplate chain with up to 32 

Compact or standard 200 Series FBMs per chain 

via the 2 Mbps HDLC fieldbus (up to 128 

modules).

 200 Series and 100 Series FBMs (dual baud 

configurations) used with FCP280 – The FCP280 

can support a total of 64 100 Series FBMs (Ymodule) or competitive devices (such as Foxboro 

Evo System migration FBMs) in one or more 

baseplate chains, with the remainder of the 

FCP280’s 128 module limit being 200 Series 

FBMs, depending on the Fieldbus loading of the 

FCP280. For example, an FCP280 could support 

64 100 Series FBMs and 64 200 Series FBMs (as 

128 – 64 = 64). See Figure 2 and Figure 3 below.

NOTE

Certain competitive migration or supported 

third-party modules such as DCS Migration 

fieldbus Modules and Pepperl+Fuchs™ I/O 

modules may increase this 128 module 

maximum per FCP280. For the maximum 

numbers of each of these migration/thirdparty modules supported by the FCP280, 

refer to the supported migration products 

books in Field Control Processor 280 

(FCP280) User’s Guide (B0700FW).

When supporting 200 Series and 100 Series FBMs, 

each Fieldbus port (PIO channel) is dedicated to 

supporting either a 268 Kbps HDLC fieldbus (for 

100 Series FBMs) or a 2 Mbps HDLC fieldbus (for 

200 Series FBMs) – not both.

For connections to 100 Series FBMs over 60 m 

(198 ft), an FBI200 pair is required to extend 

communications up to 1830 m (6000 ft). See 

Figure 2 below.

To connect a Fieldbus port to a 268 Kbps HDLC 

fieldbus directly, the Fieldbus splitter (RH928CV) 

provides a connector for any Fieldbus port on the 

FCP280 baseplate, and two Termination Cable 

Assembly (TCA) termination blocks for the twinaxial 

cabling from the 100 Series FBMs.

The FCP280 can also communicate with serial and 

Ethernet devices, such as PLCs, via Field Device 

System Integrators. This allows you to connect to 

new device interfaces without any changes to the 

controller software.

To estimate the FCP280’s processor load, refer to 

Field Control Processor 280 (FCP280) Sizing 

Guidelines and Excel Workbook (B0700FY)

FIBER AND COPPER NETWORK ADAPTERS

FCP280 modules connect to a pair of fiber or copper 

adapters (see Figure 4) which each connect to one 

Ethernet switch in The Mesh control network. The 

FCP280 baseplate passes inbound traffic from either 

of the two switches to both FCP280s, and pass 

outbound traffic from the primary FCP280 module to 

either switch.

Figure 4. Fiber Optic and Copper Network Adapters

The fiber or copper adapters mount on the FCP280 

baseplate as shown in Figure 1 on page 2. They 

receive their power from the baseplate.

REMOTE MOUNTING

The FCP280 simplifies the Foxboro Evo Process 

Automation System architecture, maintaining control 

while only requiring housing (via field enclosures), 

host workstations with Foxboro Evo Control Core 

Services v9.0 or later, and Ethernet switches for 

communication via The Mesh control network 

architecture, described in PSS 21H-7C2 B3.

The field-mounted FCP280 is an integral part of the 

highly-distributed control network where controllers 

are closely aligned to specific process units mounted 

in close proximity to their I/O and the actual 

equipment being controlled. Coordination between 

process units takes place via a fiber optic 100 Mbps 

Ethernet network.

The FCP280 and its network adapters are packaged 

in a rugged, die cast aluminum housing that does not 

require venting due to its efficient design. The 

FCP280 and its network adapters are CE certified, 

and it can be mounted without expensive special 

cabinets to prevent electronic emissions. The 

FCP280, network adapters, and baseplate can be 

mounted in Class G3 harsh environments.

ENHANCED RELIABILITY (FAULTTOLERANCE)

The unique and patented fault-tolerant operation of 

the FCP280 improves reliability relative to legacy 

process controllers. The fault-tolerant version of the 

FCP280 consists of two modules operating in 

parallel, with two Ethernet connections to The Mesh 

control network. The two FCP280 modules, married 

together as a fault-tolerant pair, provide continuous 

operation of the controller 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 external interfaces. 

Messages only leave the FCP280 when both 

FCP280s agree on the message being sent (bit for 

bit match). Upon detection of a fault, 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.

This fault-tolerant solution has the following major 

advantages over controllers that are merely 

redundant:

 No bad messages are sent to the field or to 

applications using controller data because no 

message is allowed out of the controller unless 

both modules match bit for bit on the message 

being sent.

 The secondary controller is synchronized with the 

primary one, which ensures up to the moment 

data in the event of a primary controller failure.

 The secondary controller will have latent flaws 

detected prior to any switchover because it is 

performing exactly the same operations as the 

primary controller.

UPGRADE OPTIONS

Multiple options are available for replacing existing 

control processors with the FCP280. A fault-tolerant 

FCP280 may replace a fault-tolerant FCP270 or 

ZCP270. It may import the CP database from the 

CP270 it is replacing, for compatibility and minimal 

configuration time.

As well the FCP280 provides an increase in 

performance and block processing capacity over the 

CP270s. When replacing FCP270s, the FCP280 

eliminates the need for FEM100 hardware.

For ease of replacement, the fault-tolerant or nonfault-tolerant FCP280 in its baseplate has the same 

dimensions as the fault-tolerant or non-fault-tolerant 

FCP270 in its baseplate.

Cabling the 100 Series FBMs or Migration products 

to an FCP280 baseplate consists of extending the 

remote 268 Kbps fieldbus between enclosures. This 

is accomplished using termination cable assemblies 

(TCAs) and Fieldbus Isolators (FBIs) to provide 

connections between primary and extended fieldbus 

segments.

The optional FBI200 can extend the 2 Mbps HDLC 

fieldbus between 200 Series FBMs from 60 m (198 ft) 

up to 305 m (1000 ft). As well, it can extend the 

268 Kbps HDLC fieldbus between 100 Series FBMs 

from 60 m (198 ft) up to 1830 m (6000 ft).

As with earlier generations of control processors, up 

to 64 100 Series FBMs (including expansion 

modules) attach to Fieldbus ports through Fieldbus 

Isolators. (Up to 24 100 Series FBMs, excluding 

expansion modules, can connect to each isolator.

However, the expansion modules are considered 

100 Series FBMs in this “64 100 Series FBMs” 

maximum discussed in this PSS.)

Available upgrade scenarios are available in Field 

Control Processor 280 (FCP280) User’s Guide

(B0700FW).

FBI200 FIELDBUS ISOLATOR/FILTER

The FBI200 Fieldbus Isolator/Filter extends the length 

of the 268 Kbps module Fieldbus from the FCP280 

to 100 Series FBMs and similar competitive migration 

modules up to 1830 m (6000 ft) over a twinaxial 

Fieldbus cable. See Figure 2 on page 4.

It can also extend the 2 Mbps HDLC fieldbus to 

200 Series FBMs up to 305 m (1000 ft).

For more information on the FBI200, refer to FBI200 

Fieldbus Isolator/Filter (PSS 21H-2Y18 B4).

FIRMWARE UPGRADES WHILE ON-LINE

For fault-tolerant FCP280 modules, on-line image 

upgrade replaces the executable image (operating 

system) of a running FCP280 with a newer image 

without having to shut down the equipment being 

controlled by the FCP280. 

TIME SYNCHRONIZATION, SOE, TDR/TDA

The Foxboro Evo Process Automation System 

supports time synchronization using either an 

externally maintained optional source of Universal 

Coordinated Time (UTC) from GPS satellites or an 

internal source using proprietary software. FCP280s 

that receive time updates via the external time source 

synchronize their FBMs to 1 ms. For more 

information on time synchronization, refer to Time 

Synchronization Overview (PSS 21S-1C2 B3).

Time stamping is used for alarm messages, values 

sent to the historian, and the Sequence Of Events 

(SOE) and Transient Data Recorder (TDR), and 

Transient Data Analyzer (TDA) features.

SOE data are discrete points that are time stamped at the FBM, optionally to 1 ms, and sent to the workstation on a change basis. TDR/TDA data are analog or digital points that are time stamped at the FBM and sent to the workstation every 10 ms. These features are supported by client software in the workstation. For information on this new software, refer to Field Control Processor 280 (FCP280) Integrated Control Software (PSS 31S-3B3 B3). SOFTWARE CONTROL FEATURES The FCP280 performs regulatory, logic, timing, and sequential control, as well as data acquisition, alarm detection, and alarm notification. Process variables are controlled using time-proven algorithms (mathematical computations performing specific functions). The algorithms are contained in functional control blocks, which on-site process engineers configure to implement the desired control strategies. The versatility of the algorithms, coupled with the variety of FBMs available, provides control capabilities suited to a broad range of process applications. Control strategies ranging from simple feedback and cascade loops to highly sophisticated feedforward, nonlinear, and complex characterization control schemes are readily implemented. The FCP280 also supports the following features:  Setting and reading the FCP280 letterbug via the buttons on the faceplate  Alarm enhancements to 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 allows the FCP280 to start up and run, executing its configured control scheme using the checkpoint file stored in flash memory. This allows the FCP280 to boot itself with a valid control database even if its host workstation is not present.  Support for high speed capabilities such as ladder logic, Motor Driven Actuator Controller (MDACT), and Distributed Proportional Integral Derivative functionality (DPIDA) DEVICES SUPPORTED The FCP280 supports the following devices on the 2 Mbps fieldbus:  All Compact and standard 200 Series FBMs (FBM201, FBM202, and so forth), which can support many types of intelligent field devices, including those on FOUNDATION fieldbus, PROFIBUS, HART, and DeviceNet networks  Field Device Systems Integrator (FDSI) modules  Intrinsically Safe I/O Subsystem (ISCM) – refer to PSS 21H-2Y6 B4).  DCS Migration fieldbus Modules for Siemens APACS+ Systems  DCS Migration fieldbus Modules for Westinghouse WDPF® Systems  DCS Migration fieldbus Modules for Fisher’s PROVOX® Series 20 Migration with HART  DCS Migration fieldbus Modules for Honeywell® TDC 2000 Systems with HART. The FCP280 supports the following devices on the 268 Kbps fieldbus:  100 Series FBMs (FBM01, FBM02, and so forth)  SPECTRUM™ Migration Integrators  SPEC 200™ Control Integrators  SPEC 200 MICRO™ Control Integrators  SPEC 200 CCM Control Integrators

This Universal Instruction Manual is designed to provide the user with a single, concise, easy-touse manual that covers the key points needed for configuration, calibration, installation, and 

operation of I/A Series Pressure Transmitters.

It covers all models of single variable pressure transmitters in the I/A Series family, including 

absolute, gauge, and differential pressure transmitters, with FoxCom, HART, FOUNDATION

Fieldbus, or analog output electronics.

This universal manual, along with a DVD containing detailed information, is provided free of 

charge with every I/A Series Pressure Transmitter, unless the purchaser requests that these two 

items be omitted. 

For additional detailed information about each model, including dimensional prints, parts lists, 

and more detailed instructions, please refer to the standard DVD supplied or the optional paper 

instruction book that is available for each model in the line.

♦ Standard Documentation Shipped with every I/A Series Pressure Transmitter

♦ A brief “Getting Started” Pocket-Sized Bulletin

♦ This Universal Instruction Manual

♦ A DVD that contains the complete documentation set for I/A Series Pressure 

Transmitters

♦ When Optional Feature K1 is specified in the Model Code when the transmitter is 

ordered:

A brief “Getting Started” Pocket-Sized Bulletin only is supplied

Optional Feature K1 is offered for those users who want to omit the documentation 

shipped with every transmitter. This may be specified when multiple identical 

transmitters are ordered and the user does not want multiple sets of documentation.

Electrical Certification Rating

The electrical safety design code is printed on the data plate as part of the model code. See Item B 

on the example shown in Figure 1. See the “Product Safety Specifications” section of the 

instruction pertaining to your instrument on the enclosed DVD to identify this code. The type of 

protection is also marked on the data plate. See Item D on the example shown in Figure 1.

PED Certification

The PED (Harmonized Pressure Equipment Directive for the European Community) 

certification is offered only with transmitters ordered with ATEX Electrical Safety Design Code 

selections. Transmitters with PED certification have a CE marking on the data plate that also 

carries the PED number 0496. 

Pressure Rating

The maximum working pressure (PS or MWP) for the transmitter is printed on the data plate. 

See Item F on the example shown in Figure 1.

The data plate of flanged level transmitters and transmitters with flanged pressure seals are 

stamped with the MWP if the transmitter pressure range is the limiting factor. It is stamped 

“Flange Rate” if the flange rating is the limiting factor. The MWP of the flanged seal is stamped 

on the seal data plate. See Figure 2.

Figure 2. Sample Seal Data Plate

When using transmitters with threaded, in-line saddle weld, or sanitary pressure seals, compare 

the MWP of the transmitter on the transmitter data plate and the MWP of the seals on the seals 

data plates and use the lesser value as the system MWP. 

The MWP on the seal data plates may not be given at your process temperature. Use the 

following information and industry standards as required to determine the actual pressure limits 

for your application. 

MODEL CODE: PSFPS-A2S0E313B MWP: 275 psig at 100°F 

NOTICE: BREAKING CONNECTIONS VOIDS WARRANTY

BE SURE FILL FLUID CAN MIX SAFELY WITH PROCESS HIGH SIDE SEAL

HIGH SIDE FLUID, DC200, 10 cSt SILICONE TEMP RANGE -40 TO +450°F

PROCESS WETTED MATERIAL 316 SS 

essure Seal PSFLT

Table 1. Pressure Seal PSFLT Pressure Limits

a. Flange temperature/pressure ratings only; seal temperature ratings may be lower; refer to Table 8

b. ASME/ANSI Material Group 1.1; linear interpolation acceptable

c. ASME/ANSI Material Group 2.2; linear interpolation acceptable

d. ANSI flanges per ASME/ANSI B16.5-1988.

e. DIN flanges per BS4504.

Pressure Seals PSFPS and PSFES

Table 2. Pressure Seal PSFPS and PSFES Pressure Limits

Pressure Seals PSSCR and PSSCT

The maximum working pressure of the seal process connection varies with the clamping device 

used. Refer to Tri-Clover Tri-Clamp standards to determine the pressure limits of the clamping 

system that you are using.

PSSSR and PSSST (Sanitary Tank Spud) Seals

The maximum working pressure of mini tank spud seal is 1.55 MPa at 120°C (225 psi at 250°F). 

That of the standard tank spud seal is 1.38 MPa at 120°C (200 psi at 250°F).

Origin Code

The origin code identifies the area of manufacture and the year and week of manufacture. See 

Item E on the example shown in Figure 1. In the example, 2A means the product was 

manufactured in the Measurement and Instrument Division, 01 identifies the year of 

manufacture as 2001, and 25, the week of manufacture in that year.

Operating Temperature Limits

The operating temperature limits of the electronics are -40°C and +85°C (-40°F and +185°F). 

The limits are -40°C and +75°C (-40°F and +167°F) for IAP10, IGP10, IGP25, and IGP50 

Transmitters with ATEX flameproof certification. Ensure that the transmitter is operated within 

this range. 

The sensor body operating temperature limits are determined by the sensor fill fluid. The cover 

material, sensor diaphragm material and fill fluid are specified by two characters in the model 

code on the data plate. See Item A on the example shown in Figure 1. Also see Table 5 and 

Table 6 to interpret this part of the code and Table 7 to determine the sensor body temperature 

limits. In the example IDP10-D12A21E-A3, the number 12 identifies the fill fluid in Table 5 as 

silicone. Table 7 identifies silicone as having temperature limits of -46 and +121°C (-50 and 

+250°F).

The diaphragm material code is found in the pressure seal model number which is located on the 

pressure seal. See following example:

The housing material is 316 ss.

The gasket is provided by the user.

Pressure Seals PSSCT

The housing material is 316 ss.

The diaphragm material is 316L ss.

The gasket is provided by the user.

Pressure Seals PSSSR and PSSST

The housing material is 316 ss.

The diaphragm material is 316L ss.

The gasket material is EPDM.

Warnings

General Warning

! WARNING

1. Transmitters must be installed to meet all applicable local installation regulations, 

such as hazardous location requirements, electrical wiring codes, and mechanical 

piping codes. Persons involved in the installation must be trained in these code 

requirements to ensure that the installation takes maximum advantage of the safety 

features designed into the transmitter.

2. A plug is supplied with each transmitter with 1/2 NPT conduit connection. It is 

intended to provide moisture ingress protection of the unused housing conduit entry. 

The plug must be wrench tight to achieve this level of protection. Thread sealant is 

required. Explosion-proof applications may require a certified plug. 

Housings with M20 / PG 13.5 threaded conduit connections are provided with an 

ATEX certified plug. Thread sealant is required to provide moisture ingress 

protection.

ATEX Warnings

! WARNING

Apparatus marked as Category 1 equipment and used in hazardous areas requiring 

this category must be installed in such a way that, even in the event of rare incidents, 

the versions with an aluminum alloy enclosure can not be an ignition source due to 

impact and friction

Install ATEX certified transmitters in accordance with the requirements of standard 

EN 60079-14.

! WARNING

To install a transmitter labeled with multiple approvals, select and permanently mark 

the certification label in the tick block to distinguish the installed approval type from 

the unused approval types. Once installed, the transmitter cannot be reinstalled using 

any other approval type. Not following these instructions will jeopardize explosion 

safety.

On IGPxx and IAPxx Transmitters with IECEx certification, the maximum constructional gap 

(Ic) is less than that required by IEC 60079-1:2003 as detailed in the table below:

Explosionproof/Flameproof and Enclosure Warning

! WARNING

1. To prevent possible explosion and to maintain explosionproof/flameproof and dustignitionproof protection, plug unused openings with a certified metal pipe plug. For 

1/2 NPT connections, both the plug and conduit must be engaged a minimum of five 

full threads. For M20 and PG 13.5 connections, the certified plug provided and the 

conduit must be engaged a minimum of seven full threads.

2. The threaded housing covers must be installed. Turn covers to seat O-ring into the 

housing and then continue to hand tighten until the cover contacts the housing 

metal-to-metal. 

3. If the electronics housing is removed for any reason, it must be hand tightened 

fully. Then engage the set screw until it bottoms out and back it off 1/8th turn. Fill 

the set screw recess with red lacquer (Foxboro Part Number X0180GS or equivalent). 

The housing then may be rotated up to one full turn in a counterclockwise direction 

for optimum access to adjustments.

Intrinsically Safe and Type n Warning

! WARNING

Since live maintenance is not specified, to prevent ignition of flammable atmospheres, 

disconnect power before servicing unless the area is certified to be nonhazardous.

Type n Warning

! WARNING

On transmitters certified for ATEX protection n, CSA Class I, Division 2, or FM 

nonincendive for Class I, Division 2, the threaded housing covers must be installed.

Pressure Warnings

! WARNING

When installing your transmitter, tighten process connector bolts to a torque of 

61 N•m (45 ft•lb) and drain plugs and optional vent screws to 20 N•m (15 ft•lb). See 

Figure 3.

If a sensor is replaced or process covers are rotated for venting, replace the gaskets and 

torque cover bolts (see Figures 4 and 5) to 100 N•m (75 ft•lb) in several even 

increments. Torque values are 66 N•m (50 ft•lb) when optional 316 ss bolts are 

specified (option B1). A pressure test is required. Perform a hydrostatic test with a 

liquid following proper hydrostatic test procedures. Pressure test the process cover 

assembly by applying a hydrostatic pressure of 150% of the maximum static and 

overrange pressure rating to both sides of the process cover/sensor assembly 

simultaneously through the process connections. Hold pressure for one minute. There 

should be no leakage of the test fluid through the gaskets.

Process Fluid Warning

! WARNING

If process containing parts are to be disassembled:

 1. Make sure that process fluid is not under pressure or at high temperature. 

 2. Take proper precautions concerning leakage or spillage of any toxic or otherwise

 dangerous fluid. Follow any Material Safety Data Sheet (MSDS) 

 recommendations.

Seal or Sensor Fill Fluid Warning

! WARNING

Even though the volume of fill fluid is small, be sure that the fill fluid can mix safely 

with the process fluid.

Parts Replacement Warning

! WARNING

This product contains components that have critical safety characteristics. Do not

substitute components. Replace components only with identical factory supplied 

components. Component substitution may impair the electrical safety of this 

equipment and its suitability for use in hazardous locations.

EU Declaration of Conformity

We, Manufacturer:

Invensys Systems, Inc.

38 Neponset Ave.

Foxboro, Massachusetts 02035

U.S.A.

declare under our sole responsibility that the

I/A Series Pressure Transmitters IGP, IAP, IDP, IPI, IMV

are in conformity with the protection requirements of Council Directives:

♦ 2004/108/EC on the approximation of the laws of the Member States relating to 

Electromagnetic Compatibility

♦ 94/9/EC on the approximation of the laws of the Member States concerning 

equipment and protective systems intended for use in potentially explosive 

atmospheres

♦ 2014/68/EU on the approximation of the laws of the Member States concerning 

pressure equipment

The basis on which Conformity is being declared:

♦ EN 61326-1:2006, Electrical equipment for measurement, control and laboratory use 

EMC requirements, Class A emission limits, and immunity requirements according to 

Table 2 for Industrial locations.

♦ EN50014 1997 A1 1999 A2 1999 Electrical apparatus for potentially explosive 

atmospheres ‘General Requirements’.

♦ EN50018 2000 Electrical apparatus for potentially explosive atmospheres 

‘Flameproof enclosures ‘d”.

♦ EN50020 1995 Electrical apparatus for potentially explosive atmospheres ‘Intrinsic 

safety ‘I”.

♦ EN50021 1999 Electrical apparatus for potentially explosive atmospheres ‘Type of 

protection ‘n”.

♦ EN50284 1999 Special requirements for construction, test and marking of electrical 

apparatus of group II Category 1 G.

♦ EN 50281-1-1 1999 Electrical apparatus for use in the presence of combustible dust.

♦ EN 60079-15 2003 Electrical apparatus for explosive gas atmospheres – Part 15: 

Electrical apparatus with type of protection “n”

For compliance with ATEX, products are in accordance with EC Type Examination Certificates 

KEMA 00ATEX 1060X, KEMA 00ATEX 2019X and KEMA 00ATEX 1009X, issued by KEMA 

Quality B.V., Ultrechtseweg 310, 6812 AR Arnhem, The Netherlands, Notified Body number 

0344, and with EC Type Examination Certificates SIRA 04ATEX1349, SIRA 04ATEX2335X, 

SIRA 06ATEX4056X, SIRA 06ATEX2055X, and SIRA 06ATEX4019X, issued by Sira 

Certification Service, Rake Lane, Eccleston, Chester, CH4 9JN, England, Notified Body number 

0518. The authorized markings for each certificate are shown below. The actual ATEX markings 

on the product vary according to model code. Refer to Product Specification Sheet and marking 

on product for details pertaining to individual model codes.

KEMA 00ATEX1060X II 3 G EEx nL IIC T4 … T6

 II 1 GD EEx nL IIC T4 … T6 T 135°C

KEMA 00ATEX1009X II 1 G EEx ia IIC T4 … T6

 II 1/2 G EEx ib IIC T4 … T6

 II 1 GD EEx ia IIC T4 … T6 T 135°C

 II 1/2 GD EEx ib IIC T4 … T6 T 135°C

KEMA 00ATEX2019X II 2 G EEx d IIC T6

 II 2 GD EEx d IIC T6 T 85°C

SIRA 04ATEX1349 II 2 GD EEx d IIC T6 T 85°C

SIRA 04ATEX2335X II 1G EEx ia IIC T4

SIRA 06ATEX4056X II 3 GD EEx nL IIC T4

SIRA 06ATEX2055X II 1 GD EEx ia IIC T4

SIRA 06ATEX4019X II 3 G EEx nL IIC T4

For the Pressure Equipment Directive, conformity is based on a certificate issued by DNV GL, 

Veritasveien 1, 1322 HOVIK, Norway, Notified Body number 0496, based on Maximum 

Working Pressure (MWP). Conformity Assessment Module “H” is applied for Models IGP, IAP, 

IMV and IDP where the MWP is greater than 200 bar. The applicable design standard is 

IEC/EN 61010-1

. Installation

! CAUTION

To avoid damage to the transmitter sensor, do not use any impact devices, such as an 

impact wrench or stamping device, on the transmitter. 

NOTE

1. The transmitter should be mounted so that any moisture condensing or draining 

into the field wiring compartment can exit through one of the two threaded 

conduit connections.

2. Use a suitable thread sealant on all connections.

3. If the transmitter is not installed in the vertical position, readjust zero output to 

eliminate the position zero effect.

Mechanical Installation

Differential Pressure Transmitter

The IDP10, IDP25, and IDP50 differential pressure transmitters can be supported by the process 

piping (Figure 6), on a bypass manifold (Figures 7 through 10), or mounted to a vertical or 

horizontal pipe or surface using an optional mounting bracket (Figures 11 through 16). For 

dimensional information, refer to DP 020-446.

NOTE

1. The IDP25 and IDP50 transmitters are only available in the Traditional Structure 

at this time.

2. If the transmitter is not installed in the vertical position, readjust zero output to 

eliminate the position zero effect.

3. When pvdf inserts (structure codes 78/79) are used, the process connection must 

be made directly to the pvdf inserts in the Hi and Lo side process covers.

4. The transmitter should be mounted so that any moisture condensing or draining 

into the field wiring compartment can exit through one of the two threaded 

conduit connections.

Process-Mounted Transmitter

Figure 6 shows the transmitter mounted to and supported by the process piping

Figure 8. Typical Mounting of M4A and M4T Manifold with -AM Bracket

Pipe- or Surface-Mounted Transmitter

To mount the transmitter to a pipe or surface, use the Standard Mounting Bracket Set (Model 

Code Option -M1 or -M2) or Universal Bracket Mounting Set (Model Code Option -M3).

Standard Mounting Bracket

The transmitter (with either traditional or LP2 low-profile structures) can be mounted to a 

vertical or horizontal, DN 50 or 2-in pipe using a standard bracket. See Figure 11 for details and 

Figure 12 for examples of different situations. Secure the mounting bracket to the transmitter 

using the four screws provided. Mount the bracket to the pipe. To mount to a horizontal pipe, 

turn the U-bolt 90° from the position shown in Figure 11. The mounting bracket can also be 

used for wall mounting by securing the bracket to a wall using the U-bolt mounting holes.

Universal Mounting Bracket

The transmitter (with either traditional or LP2 low-profile structure) can be mounted in a myriad 

of positions to a vertical or horizontal, DN 50 or 2-in pipe using a universal bracket. See 

Figure 13 for details of a universal bracket and Figure 14 through Figure 16 for examples of 

different mounting situations. Secure the mounting bracket to the transmitter using the two long 

or four short screws provided. Mount the bracket to the pipe. The mounting bracket can also be 

used for wall mounting by securing the bracket to a wall using the U-bolt mounting holes.

Figure 14. Mounting a Transmitter with Traditional Structure Using a Universal Bracket

Figure 15. Vertical Pipe Mounting a Transmitter with LP2 Structure Using a Universal Bracket

 1 General Information

1.1 About this manual

The manual is part of the product and contains important information about installation,

startup, operation and service. The manual is written for everyone installing, starting up

or servicing this product.

The manual must be accessible and legible. Make sure that persons responsible for the

system and its operation, as well as persons who work independently on the unit, have

read through the manual carefully and understood it. If you are unclear about any of the

information in this documentation, or if you require further information, contact SEWEURODRIVE.

1.2 Structure of the safety notes

The safety notes in this manual are designed as follows:

1.3 Rights to claim under limited warranty

A requirement of fault-free operation and fulfillment of any rights to claim under limited

warranty is that you adhere to the information in the MOVITRAC® B documentation.

Therefore, read the operating instructions before you start working with the unit.

Make sure that the documentation is available to persons responsible for the system and

its operation as well as to persons who work independently on the unit. You must also

ensure that the documentation is legible.

1.4 Exclusion of liability

You must comply with the information contained in the MOVITRAC® B documentation

to ensure safe operation of MOVITRAC® B and to achieve the specified product characteristics and performance requirements. SEW-EURODRIVE assumes no liability for

injury to persons or damage to equipment or property resulting from non-observance of

the documentation. In such cases, any liability for defects is excluded.

1.5 Copyright notice

© 2009 – SEW-EURODRIVE. All rights reserved.

Unauthorized duplication, modification, distribution or any other use of the whole or any

part of this documentation is strictly prohibited.

1.6 Content of this publication

This publication contains conditions and amendments related to MOVITRAC® B in

safety-oriented applications.

The system comprises a frequency inverter with asynchronous motor and safety-tested

external disconnecting device.

1.7 Other applicable publications

This document supplements the MOVITRAC® B operating instructions and limits the

application notes according to the following information.

It can only be used in conjunction with the following publications: 

• The MOVITRAC® B operating instructions must always be observed.

For permitted connection variants, refer to chapter “Connection variants” (see page 17).

Safety Concept

• In case of danger, any potential risk related to a machine must be eliminated as

quickly as possible. Standstill with restart prevention is generally the safe condition

for preventing dangerous movements. 

• MOVITRAC® B is characterized by the optional connection of X17 to an external failsafe, prototype tested safety relay. The safety relay disconnects all active elements

(disconnection of the safety oriented 24 V power supply of the output stage control)

that generate the pulse trains to the power output stage (IGBT) when a connected

control device (E-STOP button with latching function) is activated. 

• Disconnecting the 24 V voltage supply at connector X17 ensures that the supply

voltages required for operating the frequency inverter and consequently for

generating a rotating field of pulse patterns (which allow the generation of a rotating

field) are safely interrupted, preventing automatic restart.

• Instead of separating the drive galvanically from the power supply using contactors

or switches, the disconnection procedure described here prevents the power

semiconductors in the frequency inverter from being activated, thus ensuring safe

disconnection. This process disconnects the rotating field generation for the

respective motor. The individual motor cannot develop any torque in this state even

though the mains voltage is still present.

• The requirements for the safety control are clearly defined in the following sections

and must be observed.

Using a suitable external circuit via a safety control

– with approval to at least EN 954-1 category 3

enables operation of the MOVITRAC® B frequency inverter with safe disconnection to stop category 0 or 1 according to EN 60204-1, fail-safe protection against

restart according to EN 1037 and fulfillment of safety category 3 to EN 954-1.

Using a suitable external circuit via a safety control

– with approval for EN ISO 13849-1, performance level “d”

enables operation of the MOVITRAC® B frequency inverter with safe disconnection according to stop category 0 or 1 to EN 60204-1, fail-safe protection against

restart according to EN 1037 and fulfillment of performance level “d” to EN ISO

13849-1.

Limitations

• Important: The safety concept is only suitable for performing mechanical work

on system/machine components.

• Important: A system/machine-specific risk analysis must always be carried out

by the system/machine manufacturer and taken into account for the use of the

MOVITRAC® B frequency inverter.

• Danger of fatal injury: When the safety-oriented 24 V voltage supply is

disconnected, the mains supply voltage is still present at the frequency

inverter DC link.

• Danger of fatal injury: When the 24 V voltage supply is disconnected, the DC

link voltage is still present at the MOVITRAC® B frequency inverter.

• Important: If work is carried out on the electrical section of the drive system,

the DC link voltage must be disconnected.

Representation of the “Safety concept for MOVITRAC® B / control unit”

[1] Safety relay (external)

[2] Low-voltage switch-mode power supply

[3] Safety switched-mode power supply (SNT)

[4] Voltage supply for controlling the power transistors

[5] Feedback to the central processing unit: Voltage supply for output stage control OK (not in safety circuit)

[6] Pulse width modulated signals for output stage

[7] Power section

[8] Motor

[9] High-voltage switch-mode power supply

Representation of the “Safety concept for MOVITRAC® B / size 0”

Safety-Relevant Conditions

The following conditions are mandatory for the installation and operation of

MOVITRAC® B in applications with safe disconnection of the drive in accordance with

category 0 or 1 of EN 60204-1 and fail-safe protection against restart according to

EN 1037, and conformance with safety category 3 of EN 954-1 or performance level “d”

of EN ISO 13849-1. The conditions are divided into the following sections:

• Approved devices

• Installation requirements

• Requirements for external safety relays

• Startup requirements

• Operation requirements

3.1 Information on the stop categories

• Stop category 0 means that the safety 24 V voltage supply can be disconnected

independent of the setpoints.

• Observe the following procedure for stop category 1:

– Decelerate the drive using an appropriate brake ramp specified by the setpoint.

– Disconnect the safety-oriented 24 V voltage supply

3.2 Approved devices

The following frequency inverters are permitted for applications with safe disconnection

according to stop category 0 or 1 of EN 60204-1, fail-safe protection against restart

according to EN 1037 and compliance with safety category 3 according to EN 954-1 or

performance level “d” according to EN ISO 13489-1.

3.2.1 MOVITRAC® B for AC 3 × 380 – 500 V / 200 – 240 V supply voltage

3.2.2 Hazard caused by coasting drive

Note that if the drive does not have a mechanical brake, or if the brake is defective, the

drive may coast to a halt.

Note: If coasting to a halt results in application-dependent hazards, take

additional protective measures (e.g. movable covers with closure), which cover

the hazardeous area until persons are no longer in danger.

The additional protective covers must be designed and integrated in such a way that

they meet the safety category required for the machine. 

After activating the stop command, access to the machine must remain blocked until the

drive has reached standstill, or the access time has to be determined to ensure that an

adequate safety distance is maintained.

3.3 Installation requirements

Note the following instructions for applications of MOVITRAC® B with safe disconnection of the drive according to stop category 0 or 1 according to EN 60204-1 and fail-safe

protection against restart according to EN 954-1 safety category 3 or performance level

“d” according to EN ISO 13849-1. 

• The line between the safety control system (or the safety-oriented tripping device)

and MOVITRAC® B terminal X17 is designated as the safety-oriented 24 V voltage

supply.

• Power lines and the safety-oriented 24 V supply voltage must be installed in separate

cable ducts. 

• The safety-oriented 24 V supply voltage must be routed according to EMC guidelines

and as follows:

– Outside an electrical installation space: Shielded cables must be routed

permanently (fixed) and protected against external damage, or other equivalent

measures.

– Individual conductors can be routed inside an electrical installation space.

Observe the respective regulations governing the application.

• It must be ensured that parasitic voltages cannot be generated in the safety-oriented

24 V supply voltage.

• The total cable length between the safety control system (e.g. safety relay) and

MOVITRAC® B is limited to a maximum length of 100 m for EMC reasons.

• The switching capacity of the safety relay and the maximum permissible voltage drop

on the 24 V supply cable must be observed during disconnection of group drives.

• Only use terminal connections (terminal blocks) that meet EN 60204-1 and prevent

short-circuits.

• Observe the notes in the “MOVITRAC® B” operating instructions on EMC compliant

cabling. It is essential that you apply the shielding at both ends on the housing.

• Only use power supplies with safe isolation (SELV/PELV) according to VDE010.

According to EN 60950-1, the voltage between the outputs or between any output

and a ground part must not exceed DC 60 V voltage for longer than 0.2 s after only

one fault. The maximum DC voltage must be 120 V.

• You must remove the jumpers at X17:1 to X17:4 (see following figure) for use in

applications with safe disconnection of the drive according to stop category 0 or 1 in

accordance with EN 60204-1 and fail-safe protection against restart according to

EN 954-1 safety category 3 or performance level “d” according to EN ISO 13849-1.

• The shielded lines of the safety-oriented 24 V voltage supply (terminal X17) must be

clamped under the signaling electronics shield clamp.

• You must observe the technical data of MOVITRAC® B (see MOVITRAC® B

operating instructions).

Removing jumpers

Requirements on external safety relays

• If the requirements of the standard EN 954-1 are to be met, at least one approval for

safety category 3 according to EN 954-1 must be available.

• If the requirements of the standard EN ISO 13849-1 are to be met, at least one

approval for performance level “d” according to EN ISO 13849-1 must be available.

• If the DC 24 V voltage supply is safely disconnected at the positive pole only, no test

pulses must be applied to this pole in disconnected condition.

• Bipolar disconnection of the DC 24 V supply is permitted.

• The values specified for the safety relays must be adhered to when designing the

circuit.

• The switching capacity of the safety relays must correspond at least to the maximum

permitted limited output current of the DC 24 V voltage supply. Observe the

manufacturer’s instructions for the safety relays concerning the permitted

contact loads and fusing that may be required for the safety contacts. Unless

specified otherwise, the contacts must be protected with 0.6 times the nominal

value of the maximum contact rating specified by the manufacturer.

• The controller must be designed and connected in such a way that resetting the

control device itself will not lead to a restart. A restart may only be carried out after

an additional reset of the controller.

3.4.1 “Safety relay” sample circuit

The following figure shows the basic connection of an external safety relay (according

to the before mentioned requirements) to MOVITRAC® B.

The information in the respective manufacturer’s data sheets must be observed for

connection. 

1-pole disconnection of the 24 V supply voltage:

3.5 Startup requirements

• Startup must be documented and the functionality of the safety functions must be

demonstrated.

• Startup checks of the disconnecting device and the correct wiring must be performed

and documented for MOVITRAC® B with safe disconnection of the drive according

to stop category 0 or 1 of EN 60204-1, fail-safe protection against restart according

to EN 1037 and compliance with safety category 3 according to EN 954-1 or

performance level “d” according to EN ISO 13849-1. 

• At startup, the safety-related 24 V control voltage must be included in the functional

test. 

3.6 Operation requirements

• Operation is only allowed within the limits specified in the data sheets. This applies

both to the external safety relay as well as MOVITRAC® B.

• The safety functions must be checked at regular intervals to ensure proper

functioning. The period of time between the tests should be specified in accordance

with the risk analysis.

Connection Variants

Refer to the publication “Safe Disconnection for MOVITRAC® B – Applications” for

examples of approved connection variants of units listed in the section “Approved Units”

for safe disconnection of the drive according to stop category 0 or 1 of EN 60204-1 and

fail-safe protection against restart according to EN 1037 and fulfillment of the safety

category according to EN 954-1 or performance level “d” of EN ISO 13849-1. The

publication “Safe Disconnection for MOVITRAC® B – Applications” is constantly being

supplemented by possible applications. The publication includes checklists, which offer

additional assistance in project planning and installation as well as operating

MOVITRAC® B drives in safety-oriented applications. It is essential that you comply with

the publications listed in the section “Safety and warning instructions” for all the

connection variants listed in the publication “Safe Disconnection for MOVITRAC® B –

Applications”.

4.1 Disconnection of single drives

4.1.1 Requirements

The requirements of the manufacturers of safety relays (such as protecting the output

contacts against welding) or other safety components must be strictly observed. In

addition, the basic requirements described in the manual “Safe Disconnection for

MOVITRAC® B – Conditions” apply for cable routing.

For reasons of EMC, the length of the cable between connection X17 on

MOVITRAC® B and the safety components (e.g. safety relay) is limited to a maximum

of 100 m. Other instructions by the manufacturer on the use of safety relays for specific

applications must also be observed.

4.1.2 Internal 24 V supply, stop category 0

4.2 Disconnection of group drives

4.2.1 Requirements

For group drives, the 24 V supply of several MOVITRAC® B units can be made available

by a single safety relay. The maximum possible number of units (n units) results from

the maximum permitted contact load of the safety relay and the maximum permitted

voltage drop of the DC supply for MOVITRAC® B units.

Other requirements of the safety relay manufacturer (such as protecting the output

contacts against welding) must be strictly observed. In addition, the basic requirements

described in the manual “Safe Disconnection for MOVITRAC® B – Conditions” apply for

cable routing.

For reasons of EMC, the length of the cable between connection X17 (MOVITRAC® B)

and the safety components (e.g. safety relay) is limited to a maximum of 100 m.

Other instructions by the manufacturer on the safety relay used in the specific

application must also be observed.

Determining the maximum number of MOVITRAC® B drives for disconnection of group drives

The number (n units) of MOVITRAC® B units that can be connected to a group drive with

safe disconnection is limited by the following points:

1. Switching capacity of the safety relay.

A fuse must be connected in front of the safety contacts according to the

specifications of the safety relay manufacturer to prevent the contacts from sticking

or welding.

The project planner is responsible for ensuring that the specifications on the

switching capacity according to EN 60947-4-1, 02/1 and EN 60947-5-1, 11/97 as well

as on contact fuse protection given in the operating instructions of the safety relay

manufacturer are strictly observed.

2. Maximum permitted voltage drop in the 24 V power supply cable.

Values concerning cable lengths and permitted voltage drops must be observed

during project planning for group drives.

3. Maximum cable cross section of 1×1.5 mm2 or 2×0.75 mm2.

A calculation based on the technical data of MOVITRAC® B must be performed

separately for each group drive application

 1 General Information

1.1 About this manual

The manual is part of the product and contains important information about installation,

startup, operation and service. The manual is written for everyone installing, starting up

or servicing this product.

The manual must be accessible and legible. Make sure that persons responsible for the

system and its operation, as well as persons who work independently on the unit, have

read through the manual carefully and understood it. If you are unclear about any of the

information in this documentation, or if you require further information, contact SEWEURODRIVE.

1.2 Structure of the safety notes

The safety notes in this manual are designed as follows:

1.3 Rights to claim under limited warranty

A requirement of fault-free operation and fulfillment of any rights to claim under limited

warranty is that you adhere to the information in the MOVITRAC® B documentation.

Therefore, read the operating instructions before you start working with the unit.

Make sure that the documentation is available to persons responsible for the system and

its operation as well as to persons who work independently on the unit. You must also

ensure that the documentation is legible.

1.4 Exclusion of liability

You must comply with the information contained in the MOVITRAC® B documentation

to ensure safe operation of MOVITRAC® B and to achieve the specified product characteristics and performance requirements. SEW-EURODRIVE assumes no liability for

injury to persons or damage to equipment or property resulting from non-observance of

the documentation. In such cases, any liability for defects is excluded.

1.5 Copyright notice

© 2009 – SEW-EURODRIVE. All rights reserved.

Unauthorized duplication, modification, distribution or any other use of the whole or any

part of this documentation is strictly prohibited.

1.6 Content of this publication

This publication contains conditions and amendments related to MOVITRAC® B in

safety-oriented applications.

The system comprises a frequency inverter with asynchronous motor and safety-tested

external disconnecting device.

1.7 Other applicable publications

This document supplements the MOVITRAC® B operating instructions and limits the

application notes according to the following information.

It can only be used in conjunction with the following publications: 

• The MOVITRAC® B operating instructions must always be observed.

For permitted connection variants, refer to chapter “Connection variants” (see page 17).

Safety Concept

• In case of danger, any potential risk related to a machine must be eliminated as

quickly as possible. Standstill with restart prevention is generally the safe condition

for preventing dangerous movements. 

• MOVITRAC® B is characterized by the optional connection of X17 to an external failsafe, prototype tested safety relay. The safety relay disconnects all active elements

(disconnection of the safety oriented 24 V power supply of the output stage control)

that generate the pulse trains to the power output stage (IGBT) when a connected

control device (E-STOP button with latching function) is activated. 

• Disconnecting the 24 V voltage supply at connector X17 ensures that the supply

voltages required for operating the frequency inverter and consequently for

generating a rotating field of pulse patterns (which allow the generation of a rotating

field) are safely interrupted, preventing automatic restart.

• Instead of separating the drive galvanically from the power supply using contactors

or switches, the disconnection procedure described here prevents the power

semiconductors in the frequency inverter from being activated, thus ensuring safe

disconnection. This process disconnects the rotating field generation for the

respective motor. The individual motor cannot develop any torque in this state even

though the mains voltage is still present.

• The requirements for the safety control are clearly defined in the following sections

and must be observed.

Using a suitable external circuit via a safety control

– with approval to at least EN 954-1 category 3

enables operation of the MOVITRAC® B frequency inverter with safe disconnection to stop category 0 or 1 according to EN 60204-1, fail-safe protection against

restart according to EN 1037 and fulfillment of safety category 3 to EN 954-1.

Using a suitable external circuit via a safety control

– with approval for EN ISO 13849-1, performance level “d”

enables operation of the MOVITRAC® B frequency inverter with safe disconnection according to stop category 0 or 1 to EN 60204-1, fail-safe protection against

restart according to EN 1037 and fulfillment of performance level “d” to EN ISO

13849-1.

Limitations

• Important: The safety concept is only suitable for performing mechanical work

on system/machine components.

• Important: A system/machine-specific risk analysis must always be carried out

by the system/machine manufacturer and taken into account for the use of the

MOVITRAC® B frequency inverter.

• Danger of fatal injury: When the safety-oriented 24 V voltage supply is

disconnected, the mains supply voltage is still present at the frequency

inverter DC link.

• Danger of fatal injury: When the 24 V voltage supply is disconnected, the DC

link voltage is still present at the MOVITRAC® B frequency inverter.

• Important: If work is carried out on the electrical section of the drive system,

the DC link voltage must be disconnected.

Representation of the “Safety concept for MOVITRAC® B / control unit”

[1] Safety relay (external)

[2] Low-voltage switch-mode power supply

[3] Safety switched-mode power supply (SNT)

[4] Voltage supply for controlling the power transistors

[5] Feedback to the central processing unit: Voltage supply for output stage control OK (not in safety circuit)

[6] Pulse width modulated signals for output stage

[7] Power section

[8] Motor

[9] High-voltage switch-mode power supply

Representation of the “Safety concept for MOVITRAC® B / size 0”

Safety-Relevant Conditions

The following conditions are mandatory for the installation and operation of

MOVITRAC® B in applications with safe disconnection of the drive in accordance with

category 0 or 1 of EN 60204-1 and fail-safe protection against restart according to

EN 1037, and conformance with safety category 3 of EN 954-1 or performance level “d”

of EN ISO 13849-1. The conditions are divided into the following sections:

• Approved devices

• Installation requirements

• Requirements for external safety relays

• Startup requirements

• Operation requirements

3.1 Information on the stop categories

• Stop category 0 means that the safety 24 V voltage supply can be disconnected

independent of the setpoints.

• Observe the following procedure for stop category 1:

– Decelerate the drive using an appropriate brake ramp specified by the setpoint.

– Disconnect the safety-oriented 24 V voltage supply

3.2 Approved devices

The following frequency inverters are permitted for applications with safe disconnection

according to stop category 0 or 1 of EN 60204-1, fail-safe protection against restart

according to EN 1037 and compliance with safety category 3 according to EN 954-1 or

performance level “d” according to EN ISO 13489-1.

3.2.1 MOVITRAC® B for AC 3 × 380 – 500 V / 200 – 240 V supply voltage

3.2.2 Hazard caused by coasting drive

Note that if the drive does not have a mechanical brake, or if the brake is defective, the

drive may coast to a halt.

Note: If coasting to a halt results in application-dependent hazards, take

additional protective measures (e.g. movable covers with closure), which cover

the hazardeous area until persons are no longer in danger.

The additional protective covers must be designed and integrated in such a way that

they meet the safety category required for the machine. 

After activating the stop command, access to the machine must remain blocked until the

drive has reached standstill, or the access time has to be determined to ensure that an

adequate safety distance is maintained.

3.3 Installation requirements

Note the following instructions for applications of MOVITRAC® B with safe disconnection of the drive according to stop category 0 or 1 according to EN 60204-1 and fail-safe

protection against restart according to EN 954-1 safety category 3 or performance level

“d” according to EN ISO 13849-1. 

• The line between the safety control system (or the safety-oriented tripping device)

and MOVITRAC® B terminal X17 is designated as the safety-oriented 24 V voltage

supply.

• Power lines and the safety-oriented 24 V supply voltage must be installed in separate

cable ducts. 

• The safety-oriented 24 V supply voltage must be routed according to EMC guidelines

and as follows:

– Outside an electrical installation space: Shielded cables must be routed

permanently (fixed) and protected against external damage, or other equivalent

measures.

– Individual conductors can be routed inside an electrical installation space.

Observe the respective regulations governing the application.

• It must be ensured that parasitic voltages cannot be generated in the safety-oriented

24 V supply voltage.

• The total cable length between the safety control system (e.g. safety relay) and

MOVITRAC® B is limited to a maximum length of 100 m for EMC reasons.

• The switching capacity of the safety relay and the maximum permissible voltage drop

on the 24 V supply cable must be observed during disconnection of group drives.

• Only use terminal connections (terminal blocks) that meet EN 60204-1 and prevent

short-circuits.

• Observe the notes in the “MOVITRAC® B” operating instructions on EMC compliant

cabling. It is essential that you apply the shielding at both ends on the housing.

• Only use power supplies with safe isolation (SELV/PELV) according to VDE010.

According to EN 60950-1, the voltage between the outputs or between any output

and a ground part must not exceed DC 60 V voltage for longer than 0.2 s after only

one fault. The maximum DC voltage must be 120 V.

• You must remove the jumpers at X17:1 to X17:4 (see following figure) for use in

applications with safe disconnection of the drive according to stop category 0 or 1 in

accordance with EN 60204-1 and fail-safe protection against restart according to

EN 954-1 safety category 3 or performance level “d” according to EN ISO 13849-1.

• The shielded lines of the safety-oriented 24 V voltage supply (terminal X17) must be

clamped under the signaling electronics shield clamp.

• You must observe the technical data of MOVITRAC® B (see MOVITRAC® B

operating instructions).

Removing jumpers

Requirements on external safety relays

• If the requirements of the standard EN 954-1 are to be met, at least one approval for

safety category 3 according to EN 954-1 must be available.

• If the requirements of the standard EN ISO 13849-1 are to be met, at least one

approval for performance level “d” according to EN ISO 13849-1 must be available.

• If the DC 24 V voltage supply is safely disconnected at the positive pole only, no test

pulses must be applied to this pole in disconnected condition.

• Bipolar disconnection of the DC 24 V supply is permitted.

• The values specified for the safety relays must be adhered to when designing the

circuit.

• The switching capacity of the safety relays must correspond at least to the maximum

permitted limited output current of the DC 24 V voltage supply. Observe the

manufacturer’s instructions for the safety relays concerning the permitted

contact loads and fusing that may be required for the safety contacts. Unless

specified otherwise, the contacts must be protected with 0.6 times the nominal

value of the maximum contact rating specified by the manufacturer.

• The controller must be designed and connected in such a way that resetting the

control device itself will not lead to a restart. A restart may only be carried out after

an additional reset of the controller.

3.4.1 “Safety relay” sample circuit

The following figure shows the basic connection of an external safety relay (according

to the before mentioned requirements) to MOVITRAC® B.

The information in the respective manufacturer’s data sheets must be observed for

connection. 

1-pole disconnection of the 24 V supply voltage:

3.5 Startup requirements

• Startup must be documented and the functionality of the safety functions must be

demonstrated.

• Startup checks of the disconnecting device and the correct wiring must be performed

and documented for MOVITRAC® B with safe disconnection of the drive according

to stop category 0 or 1 of EN 60204-1, fail-safe protection against restart according

to EN 1037 and compliance with safety category 3 according to EN 954-1 or

performance level “d” according to EN ISO 13849-1. 

• At startup, the safety-related 24 V control voltage must be included in the functional

test. 

3.6 Operation requirements

• Operation is only allowed within the limits specified in the data sheets. This applies

both to the external safety relay as well as MOVITRAC® B.

• The safety functions must be checked at regular intervals to ensure proper

functioning. The period of time between the tests should be specified in accordance

with the risk analysis.

Connection Variants

Refer to the publication “Safe Disconnection for MOVITRAC® B – Applications” for

examples of approved connection variants of units listed in the section “Approved Units”

for safe disconnection of the drive according to stop category 0 or 1 of EN 60204-1 and

fail-safe protection against restart according to EN 1037 and fulfillment of the safety

category according to EN 954-1 or performance level “d” of EN ISO 13849-1. The

publication “Safe Disconnection for MOVITRAC® B – Applications” is constantly being

supplemented by possible applications. The publication includes checklists, which offer

additional assistance in project planning and installation as well as operating

MOVITRAC® B drives in safety-oriented applications. It is essential that you comply with

the publications listed in the section “Safety and warning instructions” for all the

connection variants listed in the publication “Safe Disconnection for MOVITRAC® B –

Applications”.

4.1 Disconnection of single drives

4.1.1 Requirements

The requirements of the manufacturers of safety relays (such as protecting the output

contacts against welding) or other safety components must be strictly observed. In

addition, the basic requirements described in the manual “Safe Disconnection for

MOVITRAC® B – Conditions” apply for cable routing.

For reasons of EMC, the length of the cable between connection X17 on

MOVITRAC® B and the safety components (e.g. safety relay) is limited to a maximum

of 100 m. Other instructions by the manufacturer on the use of safety relays for specific

applications must also be observed.

4.1.2 Internal 24 V supply, stop category 0

4.2 Disconnection of group drives

4.2.1 Requirements

For group drives, the 24 V supply of several MOVITRAC® B units can be made available

by a single safety relay. The maximum possible number of units (n units) results from

the maximum permitted contact load of the safety relay and the maximum permitted

voltage drop of the DC supply for MOVITRAC® B units.

Other requirements of the safety relay manufacturer (such as protecting the output

contacts against welding) must be strictly observed. In addition, the basic requirements

described in the manual “Safe Disconnection for MOVITRAC® B – Conditions” apply for

cable routing.

For reasons of EMC, the length of the cable between connection X17 (MOVITRAC® B)

and the safety components (e.g. safety relay) is limited to a maximum of 100 m.

Other instructions by the manufacturer on the safety relay used in the specific

application must also be observed.

Determining the maximum number of MOVITRAC® B drives for disconnection of group drives

The number (n units) of MOVITRAC® B units that can be connected to a group drive with

safe disconnection is limited by the following points:

1. Switching capacity of the safety relay.

A fuse must be connected in front of the safety contacts according to the

specifications of the safety relay manufacturer to prevent the contacts from sticking

or welding.

The project planner is responsible for ensuring that the specifications on the

switching capacity according to EN 60947-4-1, 02/1 and EN 60947-5-1, 11/97 as well

as on contact fuse protection given in the operating instructions of the safety relay

manufacturer are strictly observed.

2. Maximum permitted voltage drop in the 24 V power supply cable.

Values concerning cable lengths and permitted voltage drops must be observed

during project planning for group drives.

3. Maximum cable cross section of 1×1.5 mm2 or 2×0.75 mm2.

A calculation based on the technical data of MOVITRAC® B must be performed

separately for each group drive application.

The UniOP eTOP Series 500 HMI products combine state-of-the-art features and top performance 

with an oustanding design. They are the ideal choice for all demanding HMI applications including 

factory and building automation. 

The eTOP507 features a bright 7” TFT widescreen (16:9) display with a fully dimmable LED backlight. 

The JMobile software offers full vector graphic capabilities and plenty of connectivity options. 

• 7” TFT color display, LED backlight

• 800×480 pixel (WVGA) resolution, 64K colors

• Resistive touchscreen

• 2 Ethernet ports with switch function

• 2 USB Host ports

• SD Card Slot

• Connection to fieldbus systems and I/O using 

optional plug-in modules

• Slim design. Mounting depth less than 50mm

The eTOP Series 500 HMI panels have been designed to run the JMobile software. 

• JMobile runtime included. Full 

compatibility with JMobile Studio. 

• Full vector graphic support. Native support 

of SVG graphic objects. Trasparency and 

alpha blending. 

• Full object dynamics: control visibility and 

transparency, move, resize, rotate any 

object on screen. Change properties of 

basic and complex objects. 

• TrueType fonts 

• Multilanguage applications. Easily create 

and manage your applications in multiple 

languages to meet global requirements. 

Far East languages are supported. Tools 

available in JMobile Studio support easy 

third-party translations and help reducing 

development and maintenance costs of 

the application 

• Data display in numerical, text, bargraph, 

analog gauges and graphic image 

formats. 

• Rich set of state-of-the-art HMI features: 

data acquisition, alarm handling, 

scheduler and timed actions (daily and 

weekly schedulers, exception dates), 

recipes, users and passwords, e-mail and 

RSS feeds, rotating menus 

• Includes support for a wide range of 

communication drivers for Factory and 

Building Automation systems. 

• Multiple drivers communication capability. 

• Remote monitoring and control. ClientServer functionality. Mobile clients 

supported. 

• Remote maintenance and support with 

VNC-based functionality. 

• Off-line simulation of the HMI application 

with JMobile Studio. 

• Powerful scripting language for 

automating HMI applications. Script 

debugging improves efficiency in 

application development. 

• Rich gallery of symbols and objects 

• Project templates 

• Optional plug-in modules for fieldbus 

systems, I/O and controllers. 

• Display backlight dimmable to 0%

The UniOP eTOP Series 500 HMI products combine state-of-the-art features and top performance 

with an oustanding design. They are the ideal choice for all demanding HMI applications including 

factory and building automation. 

The eTOP507 features a bright 7” TFT widescreen (16:9) display with a fully dimmable LED backlight. 

The JMobile software offers full vector graphic capabilities and plenty of connectivity options. 

• 7” TFT color display, LED backlight

• 800×480 pixel (WVGA) resolution, 64K colors

• Resistive touchscreen

• 2 Ethernet ports with switch function

• 2 USB Host ports

• SD Card Slot

• Connection to fieldbus systems and I/O using 

optional plug-in modules

• Slim design. Mounting depth less than 50mm

The eTOP Series 500 HMI panels have been designed to run the JMobile software. 

• JMobile runtime included. Full 

compatibility with JMobile Studio. 

• Full vector graphic support. Native support 

of SVG graphic objects. Trasparency and 

alpha blending. 

• Full object dynamics: control visibility and 

transparency, move, resize, rotate any 

object on screen. Change properties of 

basic and complex objects. 

• TrueType fonts 

• Multilanguage applications. Easily create 

and manage your applications in multiple 

languages to meet global requirements. 

Far East languages are supported. Tools 

available in JMobile Studio support easy 

third-party translations and help reducing 

development and maintenance costs of 

the application 

• Data display in numerical, text, bargraph, 

analog gauges and graphic image 

formats. 

• Rich set of state-of-the-art HMI features: 

data acquisition, alarm handling, 

scheduler and timed actions (daily and 

weekly schedulers, exception dates), 

recipes, users and passwords, e-mail and 

RSS feeds, rotating menus 

• Includes support for a wide range of 

communication drivers for Factory and 

Building Automation systems. 

• Multiple drivers communication capability. 

• Remote monitoring and control. ClientServer functionality. Mobile clients 

supported. 

• Remote maintenance and support with 

VNC-based functionality. 

• Off-line simulation of the HMI application 

with JMobile Studio. 

• Powerful scripting language for 

automating HMI applications. Script 

debugging improves efficiency in 

application development. 

• Rich gallery of symbols and objects 

• Project templates 

• Optional plug-in modules for fieldbus 

systems, I/O and controllers. 

• Display backlight dimmable to 0%

Safety Summary (continued)

• Process technicians are to be present when testing and operating process 

objects.

• Never activate any System Initialization push-button if any uncertainty 

exists regarding exactly what occurs within the system during initialization. 

ALWAYS CHECK FIRST.

• Remember at all times, that the control system can be controlled from a 

remote engineering station, connected at another node via Control 

Network.

• Remember, the AC 800M Controller will start automatically when voltage 

is applied.

Taking steps to bring the process to a safe state, provides an improved level of 

safety when power supplies, communication links or parts of the control system 

fail. Such steps may require, for example, the installation of valves or relays that 

automatically return to a fail-safe position.

Product Safety

The following safety rules must be observed at all times:

• To avoid discharging static electricity, ground both yourself and any tools 

before handling printed circuit boards, batteries, memory cards, and other 

sensitive pieces of the equipment

• All electronic devices are sensitive to ESD (electrostatic discharge). To 

avoid accidental damage while handling printed circuit boards, it is 

recommended to wear a wrist strap, grounded to the chassis. The strap must 

have a built-in protective resistor

• Anti-static, conductive plastic bags must be used for storage and transport 

of PC boards in transit.

Safety Summary

Before replacing Units

Maintenance

All procedures for replacing units can be located by referring to the relevant 

documentation.

Removing or replacing units with system power connected can cause injury to 

personnel and damage to equipment. It is, therefore, of the utmost importance 

that the power supply be fully disconnected, on the process side, before removal 

or insertion of units takes place. 

See Online Replacement of Unit on page 198 and I/O documentation.

It is recommended that a stock of suitable spare components be maintained to 

avoid system downtime.

Ensure that back-up copies of the current application program are made at 

regular, predetermined intervals to avoid system downtime.

Safety Summary (continued)

Operating Environment

Before the AC 800M Controller system is brought online, investigate which 

environmental conditions are applicable. Take note in particular of the 

following:

• The controller must not be exposed to conditions that exceed the values given 

in the relevant technical specifications.

• The controller must not be used in an environment exposed to strong electrical 

interference. Electrical machines can produce interference that exceeds levels 

permitted for the equipment, for example during repair work.

• All products must be handled with appropriate precautions with regard to 

electrostatic damage.

• The controller must not be exposed to direct sunlight.

Important Software Check

• Use the system’s fault-monitoring facilities to prevent accidents or mishaps.

• When in doubt, ALWAYS CHECK before executing changes.

Important Hardware Notice

• DO NOT, under any circumstances, disconnect the power supply to a 

normally functioning system. Always use the correct system shut-down 

procedure prior to disconnecting the power supply.

Signal Noise Due to Cables

Cables which may cause electrical interference (for example, power supply cables) 

must not be installed adjacent to bus cables carrying fast digital signals. Ensure that 

a minimum distance of 10 cm (4 in.) is provided between cables installed inside 

cabinets.

Hazardous Electrical Supplies

Operational and maintenance procedures, during which personnel may come into 

contact with high voltage, should only be carried out by personnel fully trained in 

the maintenance of electrical equipment within those environments, and who are 

fully aware of all risks involved.

Safety Summary

Electrostatic Sensitive Device

Devices labeled with this symbol require special handling precautions as 

described in the installation section.

GENERAL

 WARNINGS

Equipment Environment

All components, whether in transportation, operation or storage, must be 

in a noncorrosive environment.

Electrical Shock Hazard During Maintenance

Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing.

SPECIFIC

WARNINGS

Page 67: The AC 800M Controller and associated units must be unpowered and disconnected when being mounted onto a DIN-rail!

Page 68: It is not allowed to manipulate CEX bus baseplates in a powered 

and running system. Before changing or removing a baseplate, all CEX 

modules on that segment must be removed.

Page 72: AC 800M units must be disconnected from the power source 

before removing them from a DIN-rail!

Page 72: It is not allowed to manipulate CEX bus baseplates in a powered 

and running system. Before changing or removing a baseplate, all CEX 

modules on that segment must be removed.

Page 78: For PM861/PM864/PM865/PM866 insert the RCU Link Termination plug TB852, at the RCU Link connector. The termination plug must 

always be used for PM861/PM864/PM865/PM866 when running in single 

configuration. When a redundant processor is running in a single configuration use the RCU Link Cable TK851, if the RCU Link Termination plug 

TB852 is not available.

SPECIFIC

WARNINGS 

(continued)

Page 124: The CI862 baseplate has no locking device. Insert only the 

CI862 unit into this baseplate. Insertion of other unit types may cause 

damage to the equipment.

Page 191: Before attempting maintenance or troubleshooting, read the 

Safety Summary on page 13. Failure to do so could lead to personal 

injury or damage to equipment.

Page 198: It is not allowed to manipulate CEX bus baseplates in a powered and running system. Before changing or removing a baseplate, all 

CEX modules on that segment must be removed.

Page 429: Explosion hazard – Substitution of components may impair 

suitability for Class I, Zone 2.

Page 429: Explosion hazard – Do not replace batteries unless the power 

has been switched off or the area is known to be non-hazardous.

Page 430: Explosion hazard – Do not disconnect equipment unless the 

power has been switched off or the area is known to be non-hazardous.

SPECIFIC

 CAUTIONS

Page 68: To prevent damage to the pins, be sure the baseplate plugs and 

sockets are fully aligned as the units interconnect. Under no circumstances use excessive force!

Page 68: It is essential that the locking device be placed in the LOCKED 

position to avoid possible problems caused by vibration and/or intermittent 

grounding.

Page 73: In order to provide adequate access and removal space, note 

that the SLIDE sequence must be carried out on the unit baseplates adjacent to the unit that is to be removed.

Page 73: The unit baseplates are easily disconnected from each other by 

gently prying them apart with a blade screwdriver (see Figure 23 on page 

74).

SPECIFIC

 CAUTIONS 

(continued)

Page 76: Do not manipulate the locking device. ABB will take no responsibility for errors caused by manipulating locking devices.

-79 and Page 92: Do not place the internal back-up battery in the battery 

holder until the AC 800M Controller has been powered-up normally and 

the memory back-up function has been activated, that is, the B(attery) 

LED flashes. If no normal power supply is connected to the processor unit 

with the battery in place, then the CPU memory will immediately start to 

consume battery power.

Page 90: Note that in redundant CPU configuration, COM3 and the electrical ModuleBus on the baseplate can not be used.

Page 91: Note that the RCU Link Cable TK851 must be used and can not 

be replaced by a similar cable. Using another cable will disable the identification of the CPUs in the CB and Operator Station. When running in single configuration the RCU Link Cable TK851 might temporarily be used to 

perform the function of a termination plug.

Page 98: Do not connect the two CEX-Bus segments, separated with 

BC810, to each other with CEX-Bus extension cable TK850.

Page 98: In AC 800M High Integrity Controllers it is required that the external supply input of BC810 is connected and that the power supply is 

strictly configured either according to Figure 33 or according to Figure 34 

and nor is it allowed to change the configuration by way of for instance 

individual circuit breakers between modules.

Page 99: Hot swap of the BC810 located next to a primary or single controller CPU, otherwise called “direct BC810”, might jeopardize the whole 

controller and should not be performed unless every module on the 

CEX-Bus are in a non-operating state. Note: In an AC 800M HI controller 

this is unconditionally and intentionally leading to a shutdown of the controller.

Page 112: It is not possible to change the CI851 unit via hot swap and it is 

not allowed to perform an online upgrade of firmware in a system containing CI851.

SPECIFIC

 CAUTIONS 

(continued)

Page 114: It is not possible to change the CI852 unit via hot swap and it is 

not allowed to perform an online upgrade of firmware in a system containing CI852.

Page 118: Hot swap is supported for CI854A (not CI854).

Page 133: – 115 V for 110–120 V AC – 230 V for 220–240 V AC 

(default position on delivery).

Page 141: To avoid error indications from SA/SB when single power supply is used, it is recommended to connect the input terminals SA/SB on 

the CPU to +24 V, see Figure 47.

Page 143: Do not connect the TK821V020 cable until the AC 800M Controller has been powered-up normally and the memory back-up function 

has been activated, that is, the B(attery) LED flashes. If no normal power 

supply is connected to the PM8xx processor unit, the CPU memory will 

immediately start to consume battery power when the cable is connected.

Page 157: When setting the IP address of the primary CPU in Control 

Builder, the backup CPU must be turned off (powered down). Otherwise 

the backup CPU will take over and you get disconnected.

Page 159: Note that the electrical ModuleBus can only be used for connection of S800 I/O when AC 800M is running in single CPU configuration.

Page 184: Note that a Backup CPU with severe communication errors on 

the ModuleBus will be rejected (if ModuleBus is part of the HW configuration) and synchronized state will never be reached as long as error 

remains.

Page 189: The RCU Link Cable must NEVER be removed from the primary Processor Unit during redundant operation. Removal of the cable 

may cause the unit to stop.

Page 192: Due to the batteries being connected in parallel, it is necessary, 

when using the SB821 external battery, to remove the internal battery 

from the PM8xx in order to avoid reducing available memory back-up time

Safety Summary

SPECIFIC

 CAUTIONS 

(continued

Page 195: Due to the batteries being connected in parallel, it is necessary, 

when using the SB821 external battery, to remove the internal battery 

from the processor unit in order to avoid reducing available memory 

back-up time.

-200 and Page 201: Reuse of CPU modules replaced from redundant configurations within the same control network, might cause control network 

problems due to the MAC and IP address handling. See MAC and IP 

Address Handling in Redundant Configuration on page 49. Such reuse 

should not be fulfilled unless both the replaced module and the module 

previously acting together with it in redundant configuration are known to 

be restored from the previous mutual address swap. It is recommended to 

set up an IP-config session and use the “Restore factory settings” option 

subsequently followed by reassignment of the IP address or assignment 

of a new IP address.

Page 200: Do not, under any circumstances, remove the RCU Link Cable 

from the primary CPU now running in a single state. Removing the cable 

might cause the CPU to stop.

Page 201: The unit baseplates are easily disconnected from each other by 

gently prying them apart with a blade screwdriver (see Figure 23 on page 

74).

Page 202: Do not replace the RCU link cable online in a previous version 

than 5.0. The support for online replacement also depends on hardware 

Product Revision levels. Please consult Release Notes (3BSE021377*) 

for detailed information.

Page 428: If you use other power supplies, except SD82X and SD83X, to 

provide the 24V d.c. for AC 800M it is required that they also are CE 

marked, Underwriters Laboratories (UL ) listed and fulfill the LVD (SELVandPELV) criteria.

Page 428: The AC 800M modules are IP20 semi-protected equipment and 

must be mounted in non-public localities.

About This User Manual

General

This book describes the hardware platform AC 800M. It also describes in detail how 

to install, configure, operate and perform the necessary maintenance on all 

equipment making up the AC 800M or AC 800M HI controllers.

Control Builder is used to configure and program the AC 800M controller, and is 

referred to in this manual as Control Builder. For information on the controller 

software, see controller software documentation. 

For important information about late changes and work-arounds for known 

problems, refer to the Release Notes (see Released User Manuals and Release Notes

on page 28). 

User Manual Conventions

Microsoft Windows conventions are normally used for the standard presentation of 

material when entering text, key sequences, prompts, messages, menu items, screen 

elements, etc.

Any security measures described in this User Manual, for example, for user 

access, password security, network security, firewalls, virus protection, etc., 

represent possible steps that a user of an 800xA System may want to consider 

based on a risk assessment for a particular application and installation. This risk 

assessment, as well as the proper implementation, configuration, installation, 

operation, administration, and maintenance of all relevant security related 

equipment, software, and procedures, are the responsibility of the user of the 

800xA System

Warning, Caution, Information, and Tip Icons

This publication includes Warning, Caution, and Information where appropriate 

to point out safety related or other important information. It also includes Tip to 

point out useful hints to the reader. The corresponding symbols should be 

interpreted as follows:

Although Warning hazards are related to personal injury, and Caution hazards are 

associated with equipment or property damage, it should be understood that 

operation of damaged equipment could, under certain operational conditions, result 

in degraded process performance leading to personal injury or death. Therefore, 

fully comply with all Warning and Caution notices.

Terminology

A complete and comprehensive list of terms is included in System 800xA System 

Guide Functional Description (3BSE038018*). The listing includes terms and 

definitions that apply to the 800xA System where the usage is different from 

commonly accepted industry standard definitions and definitions given in standard 

dictionaries such as Webster’s Dictionary of Computer Terms. 

Electrical warning icon indicates the presence of a hazard which could result in 

electrical shock.

Warning icon indicates the presence of a hazard which could result in personal 

injury.

Caution icon indicates important information or warning related to the concept 

discussed in the text. It might indicate the presence of a hazard which could 

result in corruption of software or damage to equipment/property.

Information icon alerts the reader to pertinent facts and conditions.

Tip icon indicates advice on, for example, how to design your project or how to 

use a certain function

Terms that uniquely apply to this User Manual are listed in the following table.

Table 1. Terminology

UL requirements for hazardous locations, the instructions in Appendix E, Standards

must be followed.

TÜV Approval

Units mentioned in this document are TÜV qualified for IEC 61508 SIL2 or SIL3 if 

the

product is marked with the TÜV logo.

Released User Manuals and Release Notes

A complete list of all User Manuals and Release Notes applicable to System 800xA 

is provided in System 800xA Released User Manuals and Release Notes 

(3BUA000263*).

System 800xA Released User Manuals and Release Notes (3BUA000263*) is 

updated each time a document is updated or a new document is released. It is in pdf 

format and is provided in the following ways:

• Included on the documentation media provided with the system and published 

to ABB SolutionsBank when released as part of a major or minor release, 

Service Pack, Feature Pack, or System Revision.

• Published to ABB SolutionsBank when a User Manual or Release Note is 

updated in between any of the release cycles listed in the first bullet.

A product bulletin is published each time System 800xA Released User Manuals 

and Release Notes (3BUA000263*) is updated and published to ABB 

SolutionsBank.

Product Overview

AC 800M – General

AC 800M is a hardware platform comprising individual hardware units, which can 

be configured and programmed to perform multiple functions.

Once configured and programmed, the AC 800M effectively becomes the AC 800M 

or AC 800M HI controller.

The hardware units that form the AC 800M and AC 800M HI Controllers are:

• Processor units (including baseplate)

(PM851/PM851A/PM856/PM856A/PM860/PM860A/PM861/PM861A/

PM864/PM864A/PM865/PM866/PM891)

• High Integrity Processor Unit

(consists of PM865 and SM810/SM811 with corresponding baseplates)

• Communication interfaces for different protocols (including baseplates)

(CI851/CI852/CI853/CI854/CI854A/CI855/CI856/CI857/CI858/CI860/ 

CI862/CI865/CI867/CI868/CI869/CI871/CI872/CI873)

• CEX-Bus Interconnection Unit

(BC810)

• Power supply units, providing various power output levels

SD831/SD832/SD833/SD834/SS823/SS832)

• Battery back-up unit

(SB821/SB822)

The SB821 is not supported with PM891.

PM851 is equivalent with PM856 unless stated otherwise.

PM851A is equivalent with PM851 unless stated otherwise.

PM856A is equivalent with PM856 unless stated otherwise.

PM860A is equivalent with PM860 unless stated otherwise

PM861A is equivalent to PM861 unless stated otherwise.

PM864A is equivalent to PM864 unless stated otherwise

When equipped with the specified Control Software, the AC 800M Controller acts 

either as a stand-alone process controller, or as a controller performing local control 

tasks in a control network consisting of many interconnected controllers, operator 

stations and servers.

Various I/O systems can be connected to the AC 800M Controller, either directly 

(S800 I/O) or via PROFIBUS DP or FOUNDATION Fieldbus.

The AC 800M is delivered without Control Software. To provide the controller 

with Control Software, first load the firmware and then create the application 

separately using the Control Builder M engineering tool.

The AC 800M Controller consists of a selection of units mounted on horizontal 

DIN-rails, which can be housed within an enclosure. The majority of units consist of 

a base mounting plate and removable cover attached with screws. 

The baseplate, which is always mounted onto the DIN-rail, carries the majority of 

the connections to processor, power supplies and communication interfaces, as well 

as the connections to the external buses and systems.

The AC 800M Controller provides a cost-effective, low-maintenance solution for 

applications ranging from small Programmable Logic Controller (PLC) to advanced 

Distributed Control Systems (DCS) control applications and combined DCS, and 

High Integrity systems control applications. 

In the AC 800M High Integrity Controller, it is possible to run both non-SIL and 

SIL classified applications. The AC 800M HI consist of PM865, SM810/SM811 

and a High Integrity version of Control Software, and is also available in redundant 

configuration. AC 800M HI requires the use of SIL certified S800 I/O units in SIL

classified applications. If the application is not SIL classified, standard S800 I/O 

units can be used with AC 800M HI controller.

Figure 1 shows the physical appearance of an AC 800M Controller with an 

S800 I/O Unit. This physical appearance does not apply to PM891.

Figure 1. Example of an AC 800M Controller (except PM891) with an S800 I/O 

Unit

shows the PM861 processor unit that is part of the AC 800M controller. 

This processor unit is different from PM891.

PM8xx/TP830 Processor Unit – General

Physically the PM8xx/TP830 Processor Unit consists of two basic parts:

• Processor Unit 

(PM851/PM851A/PM856/PM856A/PM860/PM860A/PM861/PM861A/

PM864/PM864A/PM865/PM866) with processor and Power Supply boards.

• Baseplate (TP830), housing the unit termination board.

For the Functional Block Diagram, see Figure 4 on page 35 and

Figure 5 on page 36. The CPU board contains the microprocessor and the RAMmemory, controllers for all built-in communication interfaces, real-time clock, LED 

indicators, INIT push button and a Compact Flash interface.

The main function of the power supply board is to generate isolated, circuit-proof 

+5 V and +3.3 V supplies to the CPU and I/O units. The board also contains optoisolated RS-232C drivers/receivers for the service port, together with a back-up 

battery holder for memory/real time clock, (RTC).

The termination board, housed in the TP830 Baseplate, is where the majority of 

the external connections terminates. The board is grounded to the DIN-rail through 

of the metallic components of the housing. The termination board is provided with 

screw terminals for power supply and redundant power supply monitoring, with 

RJ45 connectors for the control network and serial port, a connector for the service 

port, the electrical ModuleBus and the CEX-Bus.

The 24 V DC supply, connected to the TP830 Baseplate, powers all the units on the 

CEX-Bus and the electrical ModuleBus.

In single CPU configuration, it is possible to connect an S800 I/O cluster directly to 

the built-in electrical ModuleBus plug located on the right hand side of the TP830 

Baseplate.

The processor unit has a communication expansion bus connector located on 

the left-hand side of the TP830 Baseplate. This CEX-Bus provides for extending 

the on-board communication ports with additional communication interfaces

PROFIBUS DP, FOUNDATION Fieldbus H1, FOUNDATION Fieldbus High Speed 

Ethernet and dual RS-232C ports are some examples of unit types available for 

connection to the CEX-Bus. It is possible to use redundant communication 

interfaces, for example PROFIBUS DP. 

Figure 6 on page 38 provides examples of various ways to connect the S800 I/O 

units. It can be seen, at the top right-hand area of Figure 6 on page 38, that one 

cluster (or group) of units (maximum number of units per cluster is 12) is connected 

to the electrical ModuleBus of an AC 800M Controller. However, a further seven 

clusters (each comprising up to 12 units) can be added to the optical ModuleBus, 

thus achieving a total count of 96 units per AC 800M Controller when using only 

the ModuleBus.

To the left on Figure 6 on page 38, there is a PROFIBUS DP segment. This allows 

for a large increase in the numbers of units connected to each AC 800M Controller. 

Here the segment is shown as having an FCI unit (type CI801), connected to the 

PROFIBUS DP network. The use of FCI units allows the selection of units from 

several I/O families.

Figure 7 on page 39 shows another example for I/O units based on a 

FOUNDATION Fieldbus High Speed Ethernet (FF HSE).

For further examples refer to the relevant documentation for the I/O system in 

question.

Connecting S800 I/O units (using the ModuleBus) to an AC 800M Controller 

mounted with a PM851/PM851A processor unit is restricted to, one electrical 

ModuleBus cluster and one optical ModuleBus cluster

PM891 Processor Unit – General

PM891 is a high performance controller, which is capable of handling applications 

with high requirements.

PM891 connects to the S800 I/O system through the optical Modulebus. It can act 

as a stand-alone Process Controller, or as a controller performing local control tasks 

in a control network. 

Two PM891 controllers can function together as a redundant pair, with one PM891 

acting as the primary controller and the other acting as the backup. The backup 

controller takes over the process controller tasks if any hardware error occurs in the 

primary controller.

The control network connectivity is obtained by two built in IEEE802.3 Ethernet 

channels on PM891.

PM891 also provides a communication expansion bus (CEX-Bus) to which a 

number of expansion modules can be connected. These modules offers connectivity 

to a wide range of field bus and I/O systems. In case of a redundant pair, both 

PM891s are connected to the same CEX-Bus and one of them can control the 

modules.

Physically, the PM891 Processor Unit consists of:

• Connector for power supply and status signals (L+, L-, SA, SB).

• DB25 connector for Electrical CEX-Bus.

• External battery connector.

• RJ45 connectors for the two Ethernet channels.

• One Com port.

• Optical Modulebus connector for connection to a maximum of seven clusters, 

with 12 non-redundant or six redundant modules (that is, 7×12 = 84 modules).

• Connectors for Redundancy Link.

• SD (Secure Digital) memory connector.

• LEDs.

• Pushbutton reset switch.

shows the front view, Figure 9 shows the top view, and Figure 10 shows the 

bottom view of PM891.

Screw terminals are provided for connections to the power supply and the external 

battery. 

The 24 V DC power supply powers all the units on the CEX-Bus. The optical 

module clusters are powered independently.

PM891/PM86x/TP830 Processor Unit – Redundancy

Processor unit redundancy is available for PM861, PM864, PM865, PM866, and 

PM891. In this case, the controller contains two processor units, each including 

memory for system and application software. One unit is acting as primary, the 

other is backup (hot stand-by). The primary processor unit controls the process. The 

backup stands by, ready to take over in case of a fault in the primary. The 

changeover is done bumplessly and in less than 10 ms. During the changeover, the 

process outputs are frozen.

Following a changeover, the system operates as a system without redundancy with 

only one processor unit in operation. You can replace the malfunctioning processor 

unit while the system is running. After the replacement is carried out, the system 

once again has a redundant processor unit.

If an error arises in the backup unit, you can also replace the backup unit while the 

system is running.

Errors which occur in the backup unit can never affect the primary unit’s operation. 

The primary unit and the backup unit are logically separated from one another. 

Hardware errors in the primary processor unit cause the system to perform a correct 

changeover. These hardware errors are single errors.

The application programming and the communication are totally unaffected by the 

redundancy.

PM86x/TP830 Redundancy

The PM861/PM864/PM865/PM866 has an RCU Link Connector for connecting the 

RCU Link Cable (see Figure 2 on page 32). In a redundant system the two processor 

units are linked together with the RCU Link Cable (max 1 m). Both processor units 

are also connected to the same CEX-Bus and either of the two can control the 

expansion units (see Figure 29 on page 93).

S800 I/O units are connected to the two CPUs via the optical ModuleBus and two 

TB840 cluster modems on each S800 I/O cluster (see Figure 55 on page 161). The 

built-in electrical ModuleBus on the TP830 baseplate cannot be used for connecting 

S800 I/O in a redundant system.

The serial port, COM3 on the baseplate TP830, cannot be used in redundant CPU 

configuration.