Category: ABB

Scalable, highly available, easy to configure and efficient control system

Continuous productivity improvements and increased profitability are the driving

force behind today’s automation system. Furthermore, systems must support users

with the power to react quickly to ever rising demands from the markets they serve.

Traditionally, production facilities maintained

many controller subsystems, each of which

had to meet specific plant needs. However,

as business goals have changed, using a scalable

controller platform that possesses multi

functional capabilities, adapts to changing

requirements, and maximizes openness and

availability, is paramount to success.

ABB Ability Symphony Plus MR Series (Melody

Rack) controllers, communication interfaces

and I/O modules meet the most challenging

requirements in each of these areas.

Thanks to their modular design, MR Series

controllers can be adapted to a wide variety

of plant types and sizes. Supported by an

efficient engineering workbench, MR Series

control based solutions contribute to a higher

return on assets by improving overall production

control, maximizing process availability, and minimizing maintenance.

Real-time bi-directional server-client communication Symphony® Plus Gateway Software

(SGS) is a configurable component of Symphony® Plus that provides real-time bi-directional

communication between ModbusTCP devices and Symphony® Plus Controllers.

The Symphony® Plus Gateway Software (SGS) con

sists of two main components: Engineering Utilities

and Runtime software. The Engineering Utilities of

SGS provide a full function menu driven interface

that simplifies configuration for startup engineer

ing, commissioning and ongoing maintenance of the

ModbusTCP interface. With first time configura

tions, as only minimum parameters are required, en

gineering hours can be reduced by using the Quick

Config feature to generate the Mapping and Client

Definition tables. Individual interface points can

then be configured using the SGS menus.

The Runtime portion of SGS performs ModbusTCP

communications to other ABB equipment (e.g.

AC500. AC 800M) or 3rd party PLC’s over a 100Mbps

Ethernet network and remote wireless gateways.

The Symphony Plus Gateway Software is licensed

based on the number of function block outputs and

inputs the interface exchanges. 

All in all, the HPC800 provides users with the benefits of fast,

accurate and uninterrupted control of their process.

S+ Operations, S+ Engineering and other applications

communicate with HPC800 controllers over the system’s

high-speed, high-throughput and high-security 100 Mbps

Fast Ethernet-based redundant communication Plant

Network (PN800). The network-centric architecture allows

for integration of field devices, process and electrical system

areas, and business enterprise systems in a simple, scalable,

seamless and secure manner.

Protecting the integrity and confi dentiality of system data

The process and power industries face intensifying cyber

security risks. In order to increase stability, security

and robustness in its solutions, ABB has established an

independent Device Security Assurance Center (DSAC)

where cyber security robustness is tested as part of the

product development process. The DSAC test facility uses

state-of-the-art open source, commercial and proprietary

robustness and vulnerability analysis tools in its certification

testing. All Symphony Plus Ethernet-based devices –

including SD Series products such as the HPC800. and

CI850 – are continually tested at the DSAC center in different

configurations and with an explicit focus on operational

performance. This ensures that all Symphony Plus products

are robust, secure and of the highest quality.

Overview

The SD Series HPC800 controller is a high-performance,

high-capacity process controller that is used to support

the plant’s total control requirements, from discrete and

continuous, to batch and advanced control applications.

The HPC800’s controller environment executes demanding

process control applications that are both data and program

intensive. Redundancy options are available at all levels

of control, I/O and communication, resulting in maximum

flexibility and availability.

Along with a range of I/O options, the HPC800 delivers

powerful, versatile and scalable automation solutions for

plant applications of all sizes.

Simultaneously, the HPC800 connects to DIN style I/O

modules and traditional Rack I/O modules. Intelligent I/O

devices such as smart transmitters, actuators, intelligent

electronic devices (IEDs), and third-party PLCs are easily

integrated through industry-standard fieldbuses and

networks. Each device’s resident information can be used

in control strategies and higher-level applications in order to

produce tighter and more reliable process control solutions.

The HPC800 controller uses ABB’s extensive set of

field-proven standard function code algorithms and

S+ Engineering’s graphical design tools to develop its control

strategies. By using the same function code algorithms as

previous generation Harmony and INFI 90 rack controllers,

the HPC800 supports the easy and risk-free re-use of time

tested, field proven control application solutions.

Included in Symphony Plus is a comprehensive suite of

standards-based control hardware and software that meets

the requirements of total plant automation. SD Series

HPC800 represents the newest addition to the S+ Control

family. HPC800 control-based system solutions feature

modular DIN-rail packaging; a flexible, high-performance Fast

Ethernet-based plant network; intelligent electrical and field

device integration; PROFIBUS and HART communication

protocols; integrated turbine control; an efficient, easy-to-use

engineering tool, and a state-of-the-art HMI workplace.

Together, HPC800’s technology enhancements meet the

present and future needs of the power generation and water

industries. HPC800 control-based solutions lower system

installation and maintenance costs through their smaller

footprint, reduced field wiring, simplified and repeatable

engineering, shorter project schedules, tighter and more

reliable process control, and greater visibility of plant

operations to all users of plant data.

Symphony® Plus is the new generation of ABB’s widely acclaimed

Symphony family of distributed control systems – the world’s most

widely used DCS in the power generation and water industries.

In all, there are more than 6.500 Symphony DCS installations

in operation all over the world, more than 4.500 of which are in

power and water applications.

No other automation platform has such a long field record

and large installed base in power and water applications

as Symphony. For more than 30 years, ABB has evolved

this family, ensuring that each new generation enhances its

predecessors and is backwardly compatible with them – all in

accordance with ABB’s long-held policy of ‘Evolution without

obsolescence.’

SPC800 supports up to 30.000 Function Blocks, 1000

hardwired IO, and up to 8 remote IO links. SPC800 is capable

of executing closed-loop control logic for up to 5000 process IO in

less than 250 msec.

SPC800K02 is a horizontal row mount, redundant controller kit

that includes: 2x SPC800 modules + 1x MB710 base + 2x TER810 bus

terminators.

Features and benefits

• SIMPLE: SPC800 controllers provide time proven solutions optimized for processed control

• SCALABLE: SPC800 is optimized for medium-sized control applications of up to 5000 process I/O

• SEAMLESS: SPC800 controllers connect directly to SD Series IO over the redundant HN800 IO bus

• SECURE: S+ systems using SPC800 controllers have been certified to Security Level 1 as defined by

IEC 62443

• SPC800 controllers are configured by the S+ Engineering Tool Suite

• SPC800 hardware is designed for optimum communication connectivity (Ethernet, PROFIBUS DP,

IEC 104. etc.)

The SD Series SPC800 are the newest additions to the Symphony

Plus controller family. SPC800 controller features include; a

modular high-density design, low energy consumption, flexible

DIN-Rail column or row mounting, and extreme operating

temperature range (-40 to +70 °C).

The SPC800 controllers also are high-performance process

controllers that support all types of control requirements including

discrete, continuous, sequential, and advanced control

applications. SPC800 controllers are capable of executing control

applications that demanding in terms of both data and

computations.

The mounting bases of the SPC800 controllers have (4) RJ45

Ethernet ports PN800A and PN800B for connection to the PN800

Plant Network, EN 2A for connection to an optional SNTP network

that provides precise time synchronization, and EN 2B for

connection to MODBUS TCP networks.

Flexibility – reliability – safety

The Cyberex® RPP with ABB ProLine panelboard provides a flexible, reliable, and safe

solution for electrical distribution on the data center floor. The RPP’s integral

panelboard features touch safe, plug-in branch circuit breakers, designed for the

most mission critical applications.

The ABB circuit breakers are current limiting

branch breakers and provide the highest level of

protection for sensitive downstream IT loads and

the mitigation of arc flash hazard for workers.

Along with providing superior short circuit current

protection, these current limiting breakers are

easily coordinated with upstream ABB circuit

breakers, helping to eliminate the risk of cascading

faults and unnecessary outages to critical loads.

Flexibility and future proofing are also inherent

benefits of the RPP. The panel’s touch safe plug in

breakers allow for quick changes or replacement

with minimal impact to the rest of the system. The

RPP allows system owners to design in provisions

to replace branch breakers and increase protection

as their power demands increase on the rack.

Proper foresight may allow system designers and

data center owners to build in electrical

infrastructure to support IT refreshes without the

need for extended downtime.

Product features

•   Panelboard options: Up to 240V, up to 400A, up

to 168 circuits – panelboards by ABB or GE

•   Input connections: main lug only or main circuit breaker

•   Top or bottom entry – 24″ cabinets are bottom

exit only and 38″ cabinets are top/bottom exit

•   Multiple input capability and traditional

configurations – up to 4 sources, 4 panelboards

and 4 main circuit breakers

•   Multiple footprint options – sizing as small as a 2′

x 2′ square raised floor tile

•   Circuit management system provides enhanced

power data collection

•   Remote monitoring interface to building

management system

•   Welded frame door, door-in-door hinged dead front

•   Optional seismic rated floor stands available

•   Optional integrated IR port solutions to identify potential system issues