ABB Ability™ Symphony® Plus MR Series

ABB Ability™ Symphony® Plus MR Series

Core positioning and product architecture

1. Product positioning and core values

ABB Ability ™  Symphony ®  The Plus MR Series (Melody Rack) is a modular distributed control system (DCS) launched by ABB for key scenarios in industrial automation. Its core positioning is a full process control solution that is "scalable, highly available, easy to operate, and evolving without elimination". Its core values revolve around the core demands of industrial users:

Adaptability: Modular design supports full-scale deployment from small and medium-sized devices to large and complex factories, compatible with local/remote I/O hybrid configurations, and can be expanded as needed;

Reliability: The inherent redundancy design runs through the entire process of power supply, communication, and hardware, meeting the 24/7 continuous operation requirements of critical task scenarios such as power generation and chemical engineering;

Convenience: Through the unified engineering software S+Engineering, configuration, debugging, and maintenance are integrated, supporting online expansion and hot plugging, reducing operation and maintenance complexity;

Compatibility: Following the concept of "evolution without exclusion", seamlessly compatible with the old Melody series systems, protecting user capital and technological investment;

Security: Compliant with Network Security Standards (DSAC), supports industrial grade protocol encryption and access control, and adapts to modern industrial network security requirements.

2. Overall system architecture

The MR Series adopts a "layered modular" architecture, which is divided from bottom to top into on-site interface layer, control layer, network layer, and engineering operation and maintenance layer. Each level collaborates to achieve data acquisition, control operation, communication transmission, and operation and maintenance management

On site interface layer: including local I/O modules (analog/digital/temperature/frequency, etc.), remote I/O modules (S800/S900 series), responsible for on-site signal acquisition and execution, supporting intrinsic safety (Ex i) design and HART communication;

Control layer: With PM877 controller as the core, it undertakes core tasks such as signal processing, closed-loop/open-loop control, sequence control, and complex operations, and supports hot standby redundancy configuration;

Network layer: divided into control network (redundant high-speed serial network) and operation network. The control network is responsible for real-time signal transmission, while the operation network is responsible for visualizing, configuring, and maintaining data exchange. It supports multiple protocols such as PROFIBUS, Modbus, IEC 61850, etc;

Engineering operation and maintenance layer: With S+Engineering for Melody software as the core, it provides multi-user collaboration, offline engineering, version control, remote debugging and other functions to support full lifecycle operation and maintenance.

Detailed explanation of core components and key specifications

1. Core parameters and characteristics of controller (PM877)

As the "control center" of the MR Series, PM877 is the core guarantee of system performance and reliability. Its key specifications and design highlights are as follows:

(1) Core performance parameters

Specific specifications and design value of the project

Local I/O processing capability: up to 2000 (analog/digital mixed);

Remote I/O (PROFIBUS): Up to 6000 single controllers can cover the full scale control needs of small and medium-sized factories. Remote I/O supports distributed deployment and reduces cable costs

The computing and control capabilities support closed-loop control (PI/PID), sequence control, batch control, and advanced control algorithms;

Built in functional block library that has been verified on-site (supporting S88/NAMUR standards) can adapt to standardized control scenarios in industries such as power generation and chemical engineering without the need for secondary development, reducing programming complexity

Redundant design with hot standby redundancy, real-time synchronization of control strategies and process data between primary and backup controllers, seamless takeover in case of failure (switching time<100ms) without additional configuration/wiring costs, ensuring uninterrupted operation in critical scenarios

Real time multitasking operating system with operational characteristics;

Supports 16 different cycle times (adjustable from 10ms to 10s) that can be flexibly configured according to the priority of control tasks, balancing high-speed control (such as valve adjustment) and low-speed monitoring (such as temperature acquisition)

The time synchronization accuracy between time synchronization controllers is 0.5ms;

SOE timestamp resolution of 1ms (controller and I/O module level) meets the high-precision time requirements for fault tracing and process analysis, and adapts to the compliance needs of the power and chemical industries

Hardware design without battery design;

Wide temperature operation (-20 ° C~+60 ° C);

Complies with IP20 protection level to reduce battery replacement and maintenance costs, adapts to harsh industrial environments, and improves hardware reliability

Network security complies with DSAC network security standards;

Support access control, data encryption, firmware integrity verification to resist industrial network attacks, protect control logic and process data security

(2) Core design highlights

Battery free design: Compared to older controllers such as CMC 50/60, PM877 eliminates battery configuration to avoid maintenance costs and failure risks caused by battery aging, while simplifying hardware structure;

Hot standby redundancy seamless switching: The primary and backup controllers synchronize data in real time through redundant communication interfaces, and can complete fault switching without manual intervention. The switching process does not disturb the on-site equipment;

Multi protocol integration: onboard Modbus TCP interface, supporting PROFIBUS DP (DPV0/1/2) and IEC 61850 protocol extensions, adapted to the interconnection requirements of modern industrial equipment;

Firmware online upgrade: Supports uninterrupted firmware download, allowing system upgrades to be completed without downtime, ensuring production continuity.

2. I/O module system and characteristics

MR Series provides comprehensive I/O module solutions, covering various signal types in industrial sites, supporting local and remote deployment, with the following core features:

(1) I/O module classification and specifications

Module type, specific model/function, applicable scenarios

Analog Input (AI) CAI Series (Ex/Non Ex Type): Supports 4-20mA, 0-10V signals; Integrated HART communication, 1ms timestamp pressure, temperature, flow and other analog data acquisition

Analog output (AO) CAO series (Ex/non Ex type): supports 4-20mA, 0-10V signals; Support the execution of analog signals such as fault-tolerant output valve adjustment and pump speed control

Digital Input (DI) CBI Series (Ex/Non Ex Type): Supports dry contact and wet contact inputs; Support edge detection, filtering function, limit switch, button and other digital quantity acquisition

Digital Output (DO) CBO series: supports relay and transistor outputs; Support the execution of digital quantities such as fault-tolerant output motor start stop and solenoid valve control

Special Function Module Temperature Input (CTI): Supports RTD and thermocouple signals;

Frequency Input (CFI): Supports pulse signal acquisition;

Control module (CAC/CBC): used for temperature monitoring, speed acquisition, and valve positioning control of closed-loop/open-loop control equipment

CCF series communication interface module: supports PROFIBUS and Modbus RTU expansion;

IEC 61850 interface card: compatible with third-party device integration and electrical subsystem interconnection of intelligent electrical equipment

(2) Core characteristics of I/O module

Intelligent design: Each I/O module is equipped with an independent processor that supports event detection, alarm generation, 1ms timestamp, signal filtering, and other functions, reducing the computational load on the controller;

Intrinsic safety support: Ex type modules comply with intrinsic safety (Ex i) design and can be directly connected to on-site equipment in hazardous areas (Zone 1/2) without the need for additional safety barriers;

HART Integration: The analog I/O module natively supports the HART protocol, and HART variables (such as device diagnostic information and range settings) can be directly used for control logic without the need for additional communication modules;

Hot swappable and online expansion: The module supports hot swappable replacement, and local I/O can expand new modules online without downtime, ensuring production continuity;

Fault safety design: supports outputting preset values in case of faults (such as analog output holding, digital output power-off) to avoid on-site equipment misoperation;

Convenient wiring: Connect on-site cables through terminal units, and module replacement does not require disconnecting cables, reducing maintenance complexity.

3. Communication network system

The MR Series adopts a "layered redundancy" communication architecture, divided into control network and operation network, ensuring a balance between real-time performance and reliability:

(1) Control the core characteristics of the network

Type: Redundant High Speed Serial Network (Fnet), supporting coaxial cable or fiber optic transmission, with a fiber optic transmission distance of up to 2km (without relays);

Real time performance: adjustable transmission rate (up to 2Mbit/s), control signal cyclic transmission delay<10ms;

Redundancy design: Dual link redundancy, automatic switching in case of link failure, switching time<50ms;

Scalability: Supports expanding network range through repeaters, up to 32 control stations can be connected;

Protocol support: Native support for PROFIBUS DP (DPV0/1/2), single controller can expand 2 PROFIBUS lines, each line supports redundancy.

(2) Industrial protocol compatibility

Protocol type, core specifications, application scenarios

PROFIBUS DP supports DPV0 (Basic I/O Switching), DPV1 (Alarm/Diagnostic), and DPV2 (Clock Synchronization/Events);

Transmission rate of 9.6kbit/s~12Mbit/s for connecting S800/S900 remote I/O and PROFIBUS devices

Modbus Modbus RTU (extended through CCF module);

Modbus TCP (onboard, 128 servers/16 slaves) third-party device integration (such as instruments, frequency converters)

IEC 61850 is supported through extended interface cards;

Support GOOSE message and MMS service for intelligent electrical device (IED) interconnection, adapting to the needs of the power industry

HART integrated into analog I/O module;

Supports HART 7.0 protocol, bidirectional communication for intelligent instrument configuration and diagnosis

Installation and deployment features

1. Installation method and physical specifications

MR Series supports flexible and diverse installation methods, adapting to different factory layouts and space requirements:

Installation types: DIN rail installation, cabinet installation, 19 inch rack installation. The three methods can be mixed and used in the same project;

Physical specifications:

The module height is uniformly 7 units (approximately 126mm), and the front panel width is divided into 8 rack units (approximately 144mm) or 16 rack units (approximately 288mm);

Both the controller and I/O module adopt a compact design, and the local I/O module has high integration, which can significantly reduce the space occupied by the cabinet;

Protection and environmental adaptability:

Module protection level IP20, suitable for installation inside control cabinets;

Working temperature range -20 ° C~+60 ° C, humidity 5%~95% (non condensing), suitable for high temperature and high humidity industrial environments;

Wiring design:

The on-site cables are connected through standardized terminal units, which support redundant configurations;

The module and terminal unit are connected by plug-in connection, and module replacement does not require disconnecting the on-site cables, achieving "disturbance free maintenance".

2. Deployment Mode and Scalability

The MR Series supports multiple deployment modes, allowing for flexible selection based on factory size and layout

Centralized deployment: The controller and local I/O modules are centrally installed in the central control cabinet, suitable for small and medium-sized devices with simple wiring;

Distributed deployment: The controller is installed in the central control cabinet, and the remote I/O module is deployed in the on-site control cabinet, connected through Fnet or PROFIBUS, reducing the length and cost of on-site cables;

Hybrid deployment: Combining centralized and distributed advantages, key I/O is centrally deployed, decentralized I/O is remotely deployed, and it is suitable for large and complex factories;

Scalability:

A single control station can expand up to 8 local I/O interfaces;

The control network can connect up to 32 control stations and support cross regional collaborative control;

Online scalability: Supports adding I/O modules or control stations during system operation without the need for downtime.

Engineering and Operations Tools

1. Core engineering software: S+Engineering for Melody

S+Engineering for Melody is the unified engineering workbench of MR Series, which adopts a client/server architecture and supports full lifecycle engineering and operation management. Its core functions are as follows:

(1) Configuration and programming functions

Graphic programming: Supports IEC 61131-3 standard programming languages (functional block diagram FBD, ladder diagram LD, sequential functional diagram SFC, etc.), with built-in industry-specific functional block libraries that have been verified on site (such as boiler control in the power generation industry and batch control in the chemical industry);

System configuration: Visualize configuration controller, I/O module, communication network, automatically generate configuration files, support configuration template reuse;

Equipment integration: Implement on-site device "plug and play" integration through FDT/DTM interface, supporting batch configuration and diagnosis of HART and PROFIBUS devices;

Version control: Built in version management function, supporting version comparison, rollback, audit tracking of configuration files, facilitating multi-user collaboration and change management.

(2) Debugging and operation functions

Offline engineering: supports offline configuration and simulation debugging, and can verify control logic without connecting on-site devices;

Remote Access: Supports remote access to controllers and I/O modules through network operations, enabling remote debugging, fault diagnosis, and firmware upgrades;

Fault diagnosis: Real time collection of diagnostic information from controllers, I/O modules, and communication networks, automatic reporting of fault alarms, and providing fault location guidance;

Data Management: Supports importing/exporting configuration data (compatible with CSV, XML, and other formats) for easy data backup and migration;

Online operation: supports online modification of control logic, online expansion of I/O modules, and uninterrupted firmware download to ensure production continuity.

(3) Multi user collaboration capability

Configure the server to support up to 10 clients connecting simultaneously, enabling collaborative work among multiple engineers;

Strict permission management: supports assigning operational permissions based on roles (such as configuration, debugging, read-only) to ensure configuration security;

Real time data sharing: The client can obtain real-time on-site process data and equipment status, supporting online monitoring and debugging.

2. Old system upgrade support

One of the core advantages of the MR Series is "no elimination evolution", providing seamless upgrade support for old Melody series systems (such as CMC 50/60/70, PM875/876):

Hardware compatibility: The PM877 controller can directly replace old controllers, and the installation size and wiring interface are fully compatible;

I/O reuse: The old I/O module (375kBaud/2Mbit card) can be directly connected to the new system without the need for replacement;

Configuration migration: S+Engineering software provides the function of importing old configuration files, automatically migrating old control logic to the new system without the need for reprogramming;

Function extension: After the upgrade, support for protocols such as Modbus TCP and IEC 61850 can be added to expand network security functions and improve system performance.

Safety compliance and reliability

1. Security features

Network Security: Compliant with DSAC network security standards, supports access control, data encryption, firmware integrity verification, security audit logs, and resists industrial network attacks;

Functional safety: Some modules support SIL3 certification (2oo3 architecture) and are compatible with safety critical scenarios such as boiler protection;

Electrical safety: The module complies with the IEC 61010-1 standard and has overvoltage and overcurrent protection. The Ex type module is ATEX/IECEx certified;

Operational Security: Supports hierarchical management of control permissions to prevent accidental operations; Output preset safety values in case of faults to avoid misoperation of on-site equipment.

2. Reliability indicators

Mean Time Between Failures (MTBF): Controller MTBF>100000 hours, I/O module MTBF>80000 hours;

Redundant switching time: Controller redundant switching time<100ms, communication link switching time<50ms;

Availability: Under redundant configuration, the system availability is ≥ 99.99%, meeting the continuous operation requirements of critical industrial scenarios;

Diagnostic coverage: The diagnostic coverage of controllers and I/O modules is ≥ 95%, supporting automatic detection and reporting of multiple types of faults such as hardware failures, communication failures, and signal abnormalities.

3. Global Compliance Certification

Electrical safety: IEC 61010-1, UL 61010-1, CSA C22.2 No. 61010-1;

Electromagnetic compatibility (EMC): IEC 61326-1, EN 55011;

Hazardous area: ATEX/IECEx (Ex i, Ex nA);

Functional safety: SIL3 certification (some modules);

Network security: DSAC authentication.

Applicable scenarios and boundary limitations

1. Core applicable scenarios

The MR Series, with its high reliability, scalability, and compatibility, is widely adaptable to key scenarios in multiple industrial fields

(1) Power generation industry

Application scenarios: boiler control, turbine control, auxiliary control, electrical system integration for thermal power, nuclear power, new energy (photovoltaic/wind power), hydropower;

Core advantages: high availability redundancy design, support for IEC 61850 protocol, SOE high-precision timestamp, compatibility with old system upgrades;

(2) Petrochemical industry

Application scenarios: Process control, batch control, and Safety Instrumented System (SIS) linkage in refining and chemical plants;

Core advantages: Intrinsic safety I/O support, HART device integration, distributed deployment capability, and anti harsh environment design;

(3) Water treatment industry

Application scenarios: Control of flocculation, sedimentation, filtration, and disinfection processes in water plants and sewage treatment plants;

Core advantages: modular expansion, low maintenance costs, integration of third-party devices (such as water pumps and valves);

(4) Public utilities and industrial auxiliary equipment

Application scenarios: Auxiliary equipment control in the steel, metallurgy, and cement industries (such as fans, water pumps, dust removal systems);

Core advantages: strong compatibility, flexible deployment, and convenient operation and maintenance.

2. Scene boundaries and limitations

Prohibited scenarios:

Explosion hazard Zone 0/1 area (only supports Zone 2 area, requires cooperation with Ex type module);

Extreme environments (temperature<-20 ° C or>+60 ° C, humidity>95% condensation, strong corrosive environment);

Ultra high speed control scenario (control cycle<10ms, such as precision motion control);

Performance limitations:

The maximum I/O processing capacity of a single controller is 8000, which exceeds the requirement for expanding multiple control stations;

The maximum transmission distance of PROFIBUS line is 1200m (without relay), exceeding which a relay needs to be configured;

Configuration restrictions:

The control network can connect up to 32 control stations, exceeding the required partition deployment;

Redundant configuration requires the use of controllers and I/O modules of the same model, and mixed model redundancy is prohibited.