Emerson Modernization of Foxboro I/A Series® Systems to the DeltaV™ System

Introduction

The Foxboro I/A Series® system, as introduced in 1987 was 

claimed to be ahead of its time. Fast forward to the current 

generation of automation technologies and Emerson is the clear 

choice to move your business forward for decades to come. 

Aging I/A Series systems need to be modernized and Emerson 

is committed to making your transition to a DeltaV™ system, 

smooth, low risk and cost effective. From early modernization 

planning to long term lifecycle care, Emerson has provided 

industry leading solutions and service to complete more than 

130 projects replacing Foxboro I/A Series systems. Partner with 

us for your transformation to a digital architecture, resulting in 

improved business performance and competitive edge.

Why Choose Emerson As Your 

Automation Partner?

Modernization projects are different. They require knowledge 

of both old and new technology and have fewer degrees of 

freedom than greenfield projects, i.e. space, time, and budget. 

The transition project will impact operations, often must be 

done during short shutdown windows and has the potential  

to put production at risk.

This puts a premium on risk reduction, flexibility,  

and capital efficiency.

Emerson is the lowest risk option

With over 6000 transitions to DeltaV from all types of  

legacy systems, Emerson has the experience to solve  

any challenge. Utilizing established processes, our subject 

matter experts will assess the state of your automation,  

quantify operational benefits, and justify, plan, and execute 

your project. Emerson has over 5000 project resources 

worldwide along with dedicated Modernization Teams  

to ensure your project is executed flawlessly, on schedule,  

with minimum production impact.

Emerson’s technology can help

DeltaV technology provides unprecedented flexibility  

to work within the constraints of brownfield projects.  

Electronic marshalling can be installed almost anywhere,  

can be highly distributed, and with over 40 I/O wiring options  

it can handle all the signal types existing in your facility. 

The PK controller has the capacity to handle all the basic 

process control functions PLUS advanced control, sequences, 

state-based control, and batch logic. It can also be deployed 

in smaller, standalone applications, and with built-in Ethernet

based connectivity, it can easily integrate data from 3rd party 

devices like PLCs and drives and can easily provide data to 

enterprise applications. 

Brownfield Solutions

On top of this, Emerson has a vast catalog of solutions 

specifically designed to aid in modernizations. The FlexConnect 

Solutions portfolio speeds up cutover and avoids re-termination 

of field wires. Emerson’s Alliance Program includes a  

portfolio of tested gateways that help phase the transition  

to DeltaV. And for the software transition, Emerson has a  

world-class set of tools to enable a modern, maintainable, 

functional implementation of the control strategy while 

retaining important intellectual property from the  

legacy system.

Maximize capital efficiency

With robust processes, tools and with the right technology, 

Emerson can deliver modernization projects that are low risk 

and make best use of your capital. We can help manage scope, 

reduce or eliminate engineering and design work, reduce space 

requirements, and ultimately deliver the value you should 

expect from the world’s leading distributed control system.

Solutions for Legacy Foxboro  

I/A Series Systems

Reduce Downtime by Up To 75%  

with FlexConnect®:

When downtime must be kept to a minimum,  

FlexConnect solutions allow existing field terminations  

to remain. This saves time and reduces the cost of  

rewiring. Solutions are available for both FBM 100 series  

and 200 series I/O.

For FBM 100 series, the nosecones are retained along with the 

existing field I/O terminations. An adapter is connected to the 

nosecone and the signals are routed to DeltaV I/O modules  

via cables which will typically be pre-wired at the factory for  

the shortest possible cutover.

Retain Valuable Intellectual Property 

While Improving Control Performance 

with Tool Based Database and  

Display Analysis

Striking a balance between complete reverse engineering and 

starting design from scratch is achieved by taking a Forward 

Engineering approach which is enabled by using analysis tools, 

purpose built for the legacy platform. For Foxboro I/A Series 

Systems, a tool-set is available for both the control database 

and FoxView displays. Parsers extract the raw data and 

sophisticated algorithms produce reports from detailed I/O lists 

to an assessment of complexity, class-based versus custom code 

and much more. These outputs are designed to allow engineers 

to assess reusable code, such as base level loops, motors,  

valves etc. and complex logic structures which might be 

improved by redesign in a modern system. For example,  

the use of equipment modules can make operation, 

visualization and troubleshooting much easier than “spaghetti” 

function block code. Tools are transforming some traditional 

manual workflows into digital workflows which increases 

project efficiency, ensures the required functionality is  

achieved with a modern design and reduces the risk of errors  

or a flawed implementation. For your business, this translates 

to a faster ramp-up to full production, improved controls, 

confident operators and maintenance staff.