Call us 24/7+86 15396210640
Welcome to the official website of Lingkong Automation Technology Co., Ltd!
Call us 24/7+86 15396210640

ABB Medium Voltage Drives ACS2000

ACS 2000 Drive Manuals

General Manuals ACS2000 User’s Manual 

− Safety 

− Power Electronics and Cabinet Features 

− Control System 

− Transportation, Storage and Disposal 

− Mechanical Installation

− Electrical Installation 

− Commissioning 

− Local Operation 

− CDP Control Panel 

− Troubleshooting and Maintenance ACS2000 Appendices 

− Maintenance Schedule 

− Fieldbus Adapters 

− Technical Data 

− Mechanical Drawings 

− Electrical Drawings 

− Spare Parts Manual 

− MV Switchgear Guide 

− Cable Specification 

− Induction Motor Specification

− Pulse Encoder 

− Motor Temperature Supervision 

− Signal and Parameter Table 

− Troubleshooting Guide 

− DriveMonitorTM Manual

Meaning of safety instructions Safety instructions are used to highlight a potential hazard when working on the equipment. Safety instructions must be strictly followed! Noncompliance can jeopardize the safety of personnel, the equipment and the environment.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury. NOTICE The safety instructions are derived from the following standards: – ISO 3864-2:2004 (E) Graphical symbols 

– Safety colors and safety signs 

– Part 2: Design principles for product safety labels 

– ANSI Z535.6 American National Standard for Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials

The ACS2000 4KV has three sections, the Incoming/Control section, the Input Filter (IFU) section and the Phase Module section. This manual is divided, by frame size, into those sections showing the corresponding spare parts in each section. ABB reserves the right to change part numbers at any time. If you have difficulty identifying the part you need, please feel free to contact Technical Suppor.

Parts can be ordered online at www.abbnow.com or by calling 1-800-752-0696 (US Only) or 1-262-785-3200 (International) Option 1.

Incoming/Control Section

Frame 1 Enclosure Design

Incoming/Control Section

Technical Notes

Note 1 – Frame 2: Replacement of inrestors ABB part number 2UEA003150 has replaced part number 3BHB024327R0001. This has also changed the inrestor configuration from a quantity four (4) inrestors to a quantity of two (2). Please note: If your drive currently utilizes part 3BHB024327R0001 and one of the inrestors fails, all (4) inrestors will need to be removed and replaced with two (2) part number 2UEA003150 inrestors. Note 2 – Frame 3: Clamp inductors 2UEA003213 is the new ABB part number for the clamp inductors used in all Frame 3 units going forward. EXCEPTION: ABB part number 2UEA002974 will be used in units registered with any of the following serial numbers: 2131402054, 2131400989, 2131703324, 2131800104, 2132001102, 2132100102, 2132202416, 2132303473, 2132400343, 2132503681, 2133001095, 2133104388, 2133301488, 2134902217, 2140603274, 2140604672.

ABBACS 6000Medium voltage AC drives for control of 3 – 27 MW motors up to 3.3 kV

ACS 6000 – The world’s most successful MV multidrive

ABB’s ACS 6000 medium voltage drive provides the optimum solution for applications where high power and maximum reliability is required. Since its introduction, the ACS 6000 has gained an excellent reputation for high quality and reliability. As a result ABB has worldwide the largest installed base of medium voltage multidrives incorporating the latest technology

ABB’s ACS 6000 is a modular drive designed for the most demanding single-motor or multi-motor applications. The optimum configuration for each application is reached by combining the modules with minimum engineering effort resulting in lower investment costs and a smaller footprint. It is available with five sizes of inverter modules (3, 5, 7, 9 and 11 MVA). Several motors can be linked to the ACS 6000 via the common DC bus, enabling multi-machine operation with only one multidrive converter. A multidrive, common DC bus converter principle offers a solution with optimum efficiency. The ACS 6000 medium voltage drive can be used in a wide range of industries

Fields of application

Key features

The ACS 6000 medium voltage drive for speed and torque control of 3 – 27 MW induction or synchronous motors is a member of the ABB AC drives product family. It offers a number of unique key features.

Powerful performance Fast and accurate process control in combination with low energy consumption results in top performance. The motor control platform of the ACS 6000 is based on ABB’s award-winning Direct Torque Control (DTC) technology. DTC provides the highest torque and speed performance ever achieved in medium voltage drives. As a result, control of the drive is immediate and smooth under all conditions. High efficiency and reliability The ACS 6000 uses a revolutionary power semiconductor switching device known as IGCT (Integrated Gate Commutated Thyristor) researched and designed by ABB. The use of IGCTs results in a less complex, more efficient and reliable high-power medium voltage drive, minimizing operating and maintenance costs

High availability Maximum reliability and short repair time results in a drive with high availability. Optimized energy flow The common DC bus allows several motors to be connected to the same DC bus, providing an optimized energy flow. The braking energy generated in one motor can be transferred to other inverters via the common DC bus without power consumption from the supply network. Due to the near unity power factor throughout the whole speed range the energy efficiency is optimal.

ACS 6000 advantages

• High power and maximum reliability 

• Smooth torque over the entire speed range 

• Applications operate at optimum efficiency 

• Compact and high power density 

• Low noise and vibration levels 

• Minimized energy consumption with common DC bus 

• Regeneration of rotating energy

Flexible Optimum configuration The modular design of the ACS 6000 allows the optimum configuration of any drive system. Each configuration, consisting of well-proven and certified modules, exactly fits the customer’s requirements

Smooth system integration The ACS 6000 integrates easily into the industrial environment because it can be optimally configured for single-motor and multi-motor applications without additional control equipment. The high power density and compact design and the drive’s communication abilities minimize the overall installation and operational costs

The drive can be connected to the network through one or several transformers depending on power and harmonics requirements. Even a transformerless solution is available for certain applications

ACS 6000 water-cooled

Technology highlights Reliability has been the main guiding principle of the research and development activities for ABB’s medium voltage AC drives.

Part count The fewer the parts the higher the reliability. ABB uses high power semiconductor switching devices and a topology that brings down the part count to a minimum. This results in a reliable, compact and service-friendly drive. Fuseless design The ACS 6000 medium voltage drive is designed to operate safely without fuses, resulting in less spare parts and better overall reliability. This allows fast startup after safety interruptions. Encoderless Encoders are known to cause failures due to their exposed position on the motor. ABB’s ACS 6000 medium voltage drive can operate without encoder, thereby reducing maintenance costs and ensuring high levels of availability. IGCT switching devices ABB has developed a high power semiconductor called IGCT (Integrated Gate Commutated Thyristor) to allow the use of modern control algorithms, which can eliminate harmonics, improve dynamic response time and maintain, or even control, the power factor. Low losses The inherently low total losses of the IGCT require low cooling capacity and small cooling equipment.

Control The ACS drive control platform is based on ABB’s award-winning Direct Torque Control (DTC), resulting in the highest torque and speed performance as well as lowest losses ever achieved in medium voltage drives. Control of the drive is immediate and smooth under all conditions and the audible noise in the motor is considerably reduced. What is Direct Torque Control? DTC is a revolutionary motor control method for AC drives that allows accurate control of both motor speed and torque without pulse encoder feedback from the motor shaft. In DTC, stator flux and torque are used as primary control variables. The motor state calculations are updated 40,000 times a second (i.e. every 25 µs) in the advanced motor software model by the high-speed digital signal processor. Due to the continuous updating of the motor state and the comparison of the actual values to the reference values, every single switching in the inverter is determined separately. DTC ensures the absolute lowest losses by switching the power semiconductors only when necessary. Fast response to mains fluctuations and process side changes The exceptionally fast torque step response of the ACS 6000 means that it can respond to process and mains changes extremely fast. This enables easy handling of power-loss situations and sudden load changes.

Common DC bus The ACS 6000 modularity is based on the common DC bus converter principle, where several motors (synchronous and induction) can be connected to the same DC bus. With five sizes of inverter modules available (3, 5, 7, 9 and 11 MVA), the optimum configuration for a specific application can be reached by combining the modules with minimum engineering effort. By linking the modules in parallel, the power can be increased to 27 MVA. Multidrive topologies with a common DC bus offer a solution with optimum efficiency. Energy regenerated from one section in braking mode can be directly used by another section via the DC bus without power consumption from the supply network. ACS 6000 modules Active Rectifier Unit (ARU) , Inverter Unit (INU) The Active Rectifier Unit (ARU) rectifies the AC line voltage and charges the DC link capacitors whereas the Inverter Unit (INU) inverts the DC voltage to the AC motor voltage. The layout and equipment of the INU and the ARU are identical. They are self-commutated, 6-pulse, 3-level voltage source inverters, incorporating IGCT technology for a reliable, fuseless operation with a minimum number of drive components. The ARU allows four-quadrant operation for regenerative braking, which reduces the overall energy consumption. It controls the power factor to unity in the whole operating range even at very low speeds. Optionally the ARU can be dimensioned to compensate reactive power generated by other loads connected to the same network.

ACS 6000 for induction or synchronous motors ACS 6000 for induction motors Squirrel cage induction motors are the workhorses of the industry due to their versatility, reliability and simplicity. ABB’s broad range of medium voltage AC induction motors includes ribbed cast iron fan cooled motors and modular type welded frame motors. The ACS 6000 is typically used with induction motors for applications such as pumps, fans, compressors, conveyors, hoists, mills, crushers and propulsion systems.

ACS 6000 for synchronous motors Synchronous motors are typically considered for higher power ratings (e.g. above 8 MW to more than 100 MW). In addition to their high power capabilities, synchronous motors offer a wide field weakening range as well as the benefits of high efficiency and high performance. The ACS 6000 synchronous drive is ideal for applications which require dynamic response and high torque, such as rolling mills and mine hoists and for high power applications, such as marine propulsion drives. For special applications (e.g. low speed pumps) the ACS 6000 can be used with permanent magnet motors.

System integration The ACS 6000 can either be installed to control just one motor, or to control several motors with comprehensive control features, minimizing overall installation and operational costs. The drive can be supplied by one or several transformers depending on power and harmonics requirements. Even a transformerless solution is available for certain applications. The ACS 6000 medium voltage drive with its modular concept allows optimum integration into the customer’s industrial environment.

• Low network harmonics • High power factor in the whole operating range • Optional reactive power (VAr) compensation • Small footprint • Fast commissioning • EMC compliant

Smooth integration into existing systems Commissioning The ACS 6000 is easy to commission. In its multidrive configuration, the ACS 6000 is much faster to commission than the equivalent number of single drives.

Control system ABB offers an open communication strategy enabling connection to a PLC (Programmable Logic Controller) or a DCS (Distributed Control System). Fieldbus connectivity with a wide variety of protocols is available. The ACS 6000 product family platform offers the possibility to monitor the transformers as well as the motors with the drive’s control system.

Applicable standards The ACS 6000 meets the IEEE 519-1992 and IEC 61000-2-4 specifications for voltage and current harmonic distortion for virtually all installations. This eliminates the need for expensive harmonic filters and protects other electrical equipment from harmonic disturbances. The ACS 6000 meets EN (IEC), CE, UL* , cUL* and other standards to ensure smooth system integration worldwide. * on request

The ACS 6000 allows smooth and simple system integration into the customer’s industrial environment.

Open control system ABB offers an open communication strategy, enabling connection to higher-level process controllers. The ACS 6000 can be installed with all major fieldbus adapters for smooth integration, monitoring and controlling of different processes, according to customer requirements. IndustrialIT ABB’s IndustrialIT means increased standardization and seamless interaction of different ABB products. The ACS 6000 bears the IndustrialIT Enabled symbol, a special mark indicating that the drive can be easily integrated into the IndustrialIT architecture in a ‘plug & produce’ manner.

ABB wind turbine converters

Creating the perfect wind economy with every turn The wind power market continues to expand Wind turbine manufacturers and wind farm owners are experiencing steady growth which is predicted to continue. With many governments resuming their push for increased renewable power capacity, the cost of energy is gaining more focus. Diverse grid codes provide special challenges Wind farm owners and turbine manufactures need to efficiently produce power and achieve the desired return on investment while meeting grid code requirements. They must avoid making costly retrofits to newly installed turbines in response to grid code changes. Power utilities and governments have developed grid code specifications that outline expected wind farm behavior in response to defined fault conditions. These codes help wind farms avoid black-outs and other service disruptions resulting from transmission grid faults. Such faults can significantly impact the stability of the entire grid. ABB wind turbine converters for a better wind economy The wind turbine converter plays an important role in helping customers create the perfect wind economy. The selection of the right wind turbine converter is critical in the turbine design and for a higher wind farm return on investment. As part of the electrical drivetrain, ABB converters help turbines produce more megawatts more economically while providing the technology to meet the grid code needs of today and tomorrow. They are designed for high efficiency and are backed by a comprehensive set of global life-cycle services that ensure trouble-free operation and maximum availability. ABB technology helps to make wind power economically viable.

More than delivering a product From the early evaluation phase of a new wind turbine to final operation, ABB provides consulting, support, training and services. ABB converter specialists are experts in every aspect of the drivetrain system. They will support turbine manufacturers in selecting the most suitable drivetrain concept, design and dimension the drivetrain components to function in perfect sync and provide support in the grid code certification process. ABB helps its customers to create the perfect wind economy by: − Providing wind turbine converters designed to deliver maximum efficiency and productivity at low operational expenditure − Optimally designing and dimensioning the drivetrain − Ensuring grid code compliance − Offering global service and support throughout the entire lifetime of the equipment ensuring trouble-free operation and maximum availability

Grid code compliance ABB has the expertise and technology to ensure its customers’ wind turbines meet the grid code needs of today and tomorrow.

Grid code reassurance As the installed capacity of wind farms increases, the share of power they provide to the transmission network rises. As such, the way a wind farm deals with a grid fault has a significant impact on the stability of that grid. Utility companies regulate these conditions by ensuring wind farms meet demanding regional grid code specifications. Grid codes are becoming more demanding and vary between countries. The wind turbine converter plays an important role in helping the wind turbine meet these grid code requirements and to obtain the necessary operational certification. Globally active in grid code working groups and research ABB’s customer commitment is that its wind turbine converters support the needs of the wind turbine in meeting the diverse grid code requirements. ABB invests significantly into research and development and is active in grid code and power quality working groups supporting power system reliability. ABB engineers provide technical feedback on the feasibility of proposed grid code changes, ensuring the current technology and production costs are compatible with the proposed changes. Low voltage ride-through and grid support A common requirement for all grid codes is a fault ride-through capability where the wind farm and the turbines must be capable of operating continuously at reduced voltage and must not trip off-line because of transient voltages. Wind farms have to remain connected during voltage dips and to provide active and/or reactive power to the network during the fault. ABB has designed its wind turbine converters to provide full reactive current immediately when the grid fault starts. Low voltage ride-through laboratory ABB has taken the testing and certification process one step further. Its multi-megawatt grid code laboratory is designed to replicate a complete wind turbine with generator, wind turbine converter, transformer, medium voltage switchgear, and is connected to a 20 kV transmission line. This configuration allows ABB engineers to test the low voltage ride-through behavior of wind turbines in a controlled environment. Various wind conditions can be simulated with a speed-controlled motor driving the generator. This allows testing of multiple power levels more efficiently, reducing on-site testing costs.

Complete drivetrain tests Besides comprehensive real-time simulations of grid code disturbances, fault ride-through and power quality tests of the wind turbine converter, ABB is able to perform tests of the complete drivetrain – including generator and converter – to verify the performance and to ensure a smooth integration of the drivetrain into the customer’s wind turbine. Capitalize on ABB engineering Wind turbine design demands a significant amount of technical engineering. ABB supports turbine manufacturers during their converter engineering phase, working with the customer to integrate the converter into the turbine design and control system. Additionally, ABB engineers help the turbine manufacturer understand how to obtain the best performance out of the converter to increase the overall turbine performance.

Turbine certification support Turbine certifications are based on the grid codes used in the region where the turbine will be installed. When turbine manufacturers are applying for certification, ABB engineers can help the manufacturer use and maximize the converter’s technology to meet the requirements of the grid code.

ABB wind turbine converters ABB low voltage wind turbine converter ABB medium voltage wind turbine converter ABB offers the complete range of wind turbine converters for onshore and offshore installations.

ABB offers the complete range of converters for wind turbines – from small wind turbines for residential or small business use to utility-scale wind turbines installed in onshore or offshore wind farms. ABB wind turbine converters help increase turbines’ energy production through high availability, grid code compliance and long life cycles. Converters for doubly-fed and full power concepts ABB offers doubly-fed and full power converter designs. Doubly-fed power converters feature reactive power control, high efficiency at the nominal point and very low total harmonic distortion (THD). Full power converters isolate the wind turbine generator from line transients and enable fast response to line faults. They provide better ride-through capabilities and support during grid faults. Converters for small wind turbines (2 – 110 kW) ABB offers a wide range of small wind turbine converters for residential or small business use. ABB’s portfolio includes single-phase and three-phase wind turbine converters as well as grid-tie transformerless solutions. The compact converters are characterized by high efficiency and are easy to install and maintain. Converters for utility-scale wind turbines Low voltage wind turbine converters (600 kW – 8 MW) Low voltage wind turbine converters are available in full power or doubly-fed designs, with air or liquid cooling. They feature ABB’s direct torque control (DTC) which monitors the generator torque up to 80,000 times per second, enabling the most efficient generator control. This provides the foundation for grid code and fault ride-through compliance. Parallel connected sub-converters are available as design option for a higher overall efficiency and redundancy. Medium voltage wind turbine converters (4 – 12 MW) Designed for larger turbines, ABB’s medium voltage full power converters provide fault ride-through and grid code compliance. They are characterized by low parts count, long life expectancy even under load cycling, high availability and low losses. The modular design allows easy customization to meet customer requirements. The liquid-cooled converters enable low cost and efficient cable installation. ABB’s low and medium voltage wind turbine converters are available in in-line, back-to-back or face-to-face configurations and are suitable for nacelle or tower installation..

Reliability ABB wind turbine converters are based on the same world leading ABB variable-speed drive technology installed in thousands of applications worldwide. They are designed for operation in harsh environmental conditions, such as dust, sand and salt and are available with up to IP54 levels of protection. Remote monitoring Wind turbines typically have a built-in condition monitoring capability that is used to assess the overall status of the turbine. However, sometimes wind farm engineers and turbine manufacturers need more information to help assess fault conditions or to analyze the turbine’s performance. ABB provides remote monitoring capabilities that allow wind farm operators to directly access the converter to obtain data such as voltage, power, reactive power, temperature and speed.

Service and support ABB offers comprehensive global life-cycle services to help customers’ wind turbine converters operate like new

ABB engineers not only work with turbine manufacturers during the design and converter specification phase, but provide their services throughout the entire life cycle of the converters. Installation and commissioning ABB’s certified onshore and offshore commissioning engineers have extensive know-how and experience in wind turbine converters and mechanical start-ups, which makes commissioning fast and smooth and lays the foundation for high reliability and efficiency. Technical support ABB provides remote services for fast failure analysis as part of its maintenance program for wind turbine converters. On customer request, a 24/7 support line for getting instant advice by ABB’s certified engineers, and on-site field support can be provided. Spares and consumables Having the correct spare parts available at the correct locations, either at the turbine manufacturer’s warehouse, regional stocking centers or at wind farms, needs to be wellplanned to ensure the highest wind turbine energy production. ABB can help plan spare part stocking throughout the life cycle of the wind turbine. Preventive maintenance The turbine converter performs critical duties in power generation and its failure may result in loss of production and revenue. Adopting and implementing ABB’s converter-specific preventive maintenance schedules reduces the risk of failure and increases the lifetime of the converter, lowering overall operational costs. ABB developed preventive maintenance kits containing all the genuine ABB spare parts needed to perform a specific maintenance task, helping to simplify the preventive maintenance process.

Training ABB provides a wide selection of wind turbine converter training to turbine manufacturers and wind farm operators. The training can take place at ABB training centers or at the customers’ locations. Service agreements Depending on the needs of the turbine manufacturer or wind farm operator, ABB can bundle individual services in one contract. A contract can be made at any stage of the wind turbine converter’s service life. Global network, local presence ABB’s global presence and worldwide organization with its network of selected partners provide local support, training and services as and when required. Services for ABB wind turbine converters – Installation and commissioning – Grid integration support – On-site support – Training – Remote diagnostics – 24/7 support line – Maintenance – Customized maintenance contracts – Spare parts and logistics network Benefits – Reduced down- and recovery time – Lifetime extension of converter – Enhanced operational efficiency – Lowered captial expenditure – Improved cost control

ABBDevice Management PROFIBUS DP/FMS Redundancy Link Module, RLM01

Section 1 Features/ Application

RLM 01 converts one simple, non-redundant Profibus line into two reciprocally redundant lines A/B. The module works bidirectionally, which means that all three interfaces can receive and transmit data

• Conversion: Line M <=> Lines A/B 

• Use on PROFIBUS DP/FMS lines 

• Automatic line selection 

• Transmission rate 9.6 kBit/s …. 12 MBit/s 

• Monitoring of communication 

• Repeater functionality 

• Redundant power supply 

• Status and error display 

• Monitoring of the power supply 

• Potential-free alarm contact 

• Simple assembly on DIN mounting rail

You can position the module directly after a master, before a bus segment with several slaves or before an individual slave. PROFIBUS stations with redundant couplers [K] can be directly connected to the PROFIBUS set redundant by RLM 01. Stations with only one interface can be optionally assigned to the A or B line. Each RLM 01 PROFIBUS interface can serve up to 31 PROFIBUS stations. Using repeaters [R] and media converters [O/E] makes it possible to increase the length of the PROFIBUS lines and the number of stations.

Figure 1. Application example

RLM01 does not support master redundancy where one master only runs line A and the other one only line B. The bus communication is asynchronous, even if both masters balance their program modules against each other on the applicational level. A Melody central unit CMC 60/70 offers clock sy

Network devices like repeater, FOC coupler, DP/PA converter as well as RLM01 cause a N x bit time delay of data telegrams. The delay time (see technical data) is device specific and depends upon the selected baud rate. It must be taken into consideration for the master bus configuration.

Section 2 Description of functions

The three RS 485 interfaces of the module support all transmission rates specified in DIN 19245 for the PROFIBUS from 9.6 kBit/s to 12 MBit/s. The module has repeater functionality, i.e., it regenerates the signal shape and the amplitude of received data. RLM 01 monitors all three lines A, B and M for activity and error states. Detected errors are signalled by lit diodes on the front panel. The potentialfree alarm contact activated in parallel to this can be polled for diagnostic purposes by the process control system PCS or by a programmable logic control PLC. The three serial RS 485 interfaces are potential-free relative to each other and to the power supply. This is a functional electrical isolation. The first data coming in over line A or line B with a correct telegram start are routed to terminal M. With simultaneity, either line A or line B is selected at random. Testing and selection is always based on the first character. In the case of a telegram start with error on A, the control logic switches to the redundant line B. The same procedure applies vice-versa for line B. Data coming in over line M with a correct telegram start are routed in parallel to the two terminals A and B. The test for data is always based on the first character. In the case of a telegram start with error, the control logic does not output any data to A and B. Either a single or a redundant power supply with 24 VDC is possible. The distribution of load across L1+ and L2+ is based on the level of the voltages applied. If a voltage source fails, the switch to the redundant supply source is made without interruption. A monitoring logic circuit tests whether both voltages are present.

Section 3 Commissioning

Safety information

To supply RLM 01, use only a safety-low voltage. This requirement also applies to the alarm contact supply. In accordance with the UL/CSA requirements an external protection (e.g. fuse) is prescribed. The fuse rating can amounted to 1.6A to 10A (characteristic: medium slow-acting or slow-acting). Protection of groups of several devices with a common fuse is admissible (several RLM 01 or RLM 01 together with other devices). When selecting a mounting location, make certain that the limit values for ambient conditions specified in the technical data are observed and the module can discharge heat without any obstruction. Do not connect any bus lines that are laid partially or entirely outside buildings. Voltage overload, for example resulting from lightning strikes, may destroy the module. For protection against cases such as these, use optical fibre cable and appropriate medium converters (electrical <==> optical) as high-quality electrical isolation. In accordance with the PROFIBUS installation guideline the shielding of the bus cables are preferably connected at the start and at the end with earth potential. Place the module on a low-resistance and low-inductance earthed DIN mounting rail. Grounding measures by way of the E terminal (1) on the terminal strip are then not required.

Front panel elements

Three Sub-D connectors A, B and M are located on the front panel of the RLM 01 for connection of the PROFIBUS cable. The 8-pin male multi-pin connector with the associated terminal strip is used to connect the alarm and power supply wires. There are also LEDs for activity/error display, a rotary switch for setting the transmission rate and a reset button (activate transmission rate)

Mounting

The module should preferably be attached vertically on a DIN mounting rail. To do this, place the two rear-side clamps on the top edge of the mounting rail. Then press lightly on the underside of the module until the clamps spread apart and the bottom edge of the rail locks audibly into place. The mounting location should be selected so that the RLM 01 can discharge heat arising from power loss without hindrance. A

distance of > 30 mm should be maintained between the top/bottom of the module and cable ducts, other devices, etc.

Installation

The redundant PROFIBUS lines are connected to the two terminals A and B. Terminal M is provided for the non-redundant PROFIBUS line. All three PROFIBUS connections A, B and M are designed uniformly with 9-pin Sub-D connectors (sockets). The pin assignment conforms to the PROFIBUS standard. RLM 01 uses only pins 3+8 for data transfer and 6+5 for power supply to an external resistor combination for bus termination. The following table shows the maximum assignment for PROFIBUS usage

If terminals A/B of RLM 01 are positioned at the beginning or end of a bus segment, two terminals must be provided with one bus termination each (resistor combination). The same also applies for terminal M if it is located at the beginning or the end of a PROFIBUS segment. It is preferable to use PROFIBUS terminals with an integrated resistor combination that can be turned on and off. A shortcircuit-proof power supply to supply the resistors located in the connector is available on pins 5 (VP+) and 6 (DGND). The designation A/B in the following figure refers to the cables in the PROFIBUS cable and not to the redundant PROFIBUS cables, which are also named A/B.

Use only shielded PROFIBUS connectors of suitable design. The connectors should preferably have a cable connection that is angled down at 35° and is no wider than 18 mm.

The power supply and alarm lines are connected directly to the terminals labelled 1 to 8. If it is necessary to replace the module, you need only remove the terminal strips. The maximum of 8 cables remain connected. The functions of terminals 1… 8 are given in the following table.

You can press down the orange-coloured pin using a narrow screwdriver to open the cage tension spring. Only press the pin in far enough to feel a noticiable resistance ( about 1 mm below the upper surface of the terminal strip ). Now insert the stripped wire as far as it will go into the large hole on the left. Reliable contact is only ensured if the cage tension spring grasps the wire and not the insulation around it. The cage tension spring can receive solid wires or rough wire strands with cross sections from 0.14 to 1.5 mm2. Please use flexible or rough wire strands with the lowest possible cross section for better handling and reduced mechanical stress to the terminal strip.

Setting the baud rate

Configuration of the RLM 01 merely involves setting the baud rate. It should be set with the rotary switch on the front panel before turning on the power supply. You can select baud rates of from 9.6 kbd to 12 Mbd. If the baud rate is changed during ongoing operation, you should push the reset button once briefly to reset the control logic and the counters etc. to a defined initial state.

Application on ships and maritime systems

RLM01 is certified for applications on ships and maritime systems by the Germanic Lloyd (GL). To meet the increased requirements regarding EMC and overvoltage, RLM01 must have one or two “24 VDC power supply filters (surge)” depending on the supply (single / redundant). The supply of several RLM01 behind one filter is not admissible. The max. length of the lines between filter and RLM01 must not exceed 1 m. Possibly needed fuse elements have to be arranged before the filter. The electrical connection to ground potential is effected via the module attachment as with RLM01. The following example shows the interconnection in case of a redundant supply of RLM01. For a single supply of RLM01, the L2+ terminal has to be bridged with the second L1+ terminal.

Section 4 Monitoring

The LEDs assigned to lines A, B and M on the front panel are used to indicate bus activity (Act) and possible errors (Err) on the PROFIBUS lines. The monitoring logic in RLM 01 assumes that lines A & B are used for communication during operation. If it is subsequently possible to receive data over only one of the two lines, the non-available line is reported as faulty. If the redundant (second) line also fails, the same state results for the monitoring logic as for a redundant PROFIBUS link A AND B that is not in operation at all. Since the logic has no criterion for making a distinction, no error message is generated by RLM 01. The alarm contact remains closed and the two Act and Err LEDs are unlit. But the condition just described does not go undetected. In this case the PROFIBUS master generates the error message, since it cannot access the slaves either via line A or line B. An Err LED flashing at an undefined pulse/pause ratio indicates that the line in question has failed AND that there is only sporadic data traffic on the redundant line. The monitoring logic can only indicate operating and error states correctly if the baud rate is set correctly. RLM 01 also tests whether the supply voltage is present at inputs L1+ and L2+. A single power supply with L1+ alone always requires a cable jumper from L1+ to L2+ (see Chapter 3). This prevents an unwanted error message

Section 5 Signalling

The monitoring logic in RLM 01 indicates operating and possible error states via LEDs on the front panel. In normal operation, all yellow Act LEDs (flashing or continuous) and the green Pwr LED are lit. The two red Err LEDs are unlit. Any signalling configuration other than this indicates a communication or power supply error

以下两个表中的文字(黄色、红色、绿色)表示相应的 LED 亮起,从而显示运行或错误状态

ABB 能力™交响乐 ® Plus

HR Series Control and I/O Achieving total plant automation with a single control and I/O platform

ABB Ability™ Symphony® Plus is the new generation of ABB’s highly acclaimed Symphony family of distributed control systems – the world’s most widely used DCS in power generation and water management applications. In all, there are more than 7,000 Symphony DCS installations in operation all over the world, more than 5,000 of which are in power and water applications.

  • No other automation platform has such a long field record and large global installed base as ABB’s Symphony Plus family. For more than 35 years, the system has progressed through several evolutionary steps. From Network 90 in 1980, through INFI 90TM, INFI 90TM Open, and Symphony, to Symphony Plus, the system progression has followed ABB’s long-held policy of ‘Evolution without obsolescence,’ ensuring that each new generation enhances its predecessor all the while maintaining full compatibility with them.
  • Symphony Plus includes a comprehensive suite of standards-based control and I/O hardware and software that meets your requirements for total plant control. The suite’s HR Series (Harmony Rack) meets the past, present and future needs of its users by protecting their previous control investments while delivering higher performance, reliability, and capacity. HR Series control-based systems feature scalable,
  • high-performance controllers, a comprehensive set of I/O options, fast, secure and redundant communications, an efficient easy-to-use engineering tool, and a state-of-the-art HMI workplace. Newest additions to the HR Series portfolio include an environmentally hardened DIN-rail mounted native remote I/O option and integration of intelligent electrical and field devices via PROFIBUS, HART and Modbus TCP communication protocols.
  • high-performance controllers, a comprehensive set of I/O options, fast, secure and redundant communications, an efficient easy-to-use engineering tool, and a state-of-the-art HMI workplace. Newest additions to the HR Series portfolio include an environmentally hardened DIN-rail mounted native remote I/O option and integration of intelligent electrical and field devices via PROFIBUS, HART and Modbus TCP communication protoco
  • Overview Symphony Plus HR Series provides a scalable solution that spans and integrates loop, unit, area, plant and interplant controls. Its system communication architecture is based on a high-speed, high-throughput and highsecurity redundant INFI-Net control network. The scalable network supports any combination and quantity of control, engineering, operation and application interface nodes. Each node on the control network operates independently of other nodes. Acting as its own communication manager, the system requires no traffic directors. INFI-Net to INFI-Net communication modules support multinetwork system topologies that provide a system capacity of more than 62,000 nodes.
  • High system reliability and availability are key characteristics of this mission-critical control network. Reliability is bolstered by redundant hardware and communication paths. Extensive use of error checking and message acknowledgment assures accurate communication of critical process data. Patented exception reporting technology optimizes the use of control network bandwidth. The store and forward ring topology of INFI-Net, along with multi-master and multi-cast messaging features result in INFI-Net having an effective bandwidth that exceeds 300 Mbaud. INFI-Net communications are also highly deterministic.
  • HR Series process control unit (PCUs) communication products including the NIS21/ NPM22 modules provide significant increases to performance and capacity compared to previous generations. Additionally, new HR Series INFI-Net to Computer Interface (ICI), INFINet to INFI-Net Local and Remote Bridge modules, and INFINet to PN800 (INFI-Net over Ethernet) Bridge modules are available.
  • The Harmony OPC server provides OPC connectivity between devices on the INFI-Net control network and OPC client applications. In non-redundant and redundant configurations, it can be used in conjunction with ABB products such as DataLink and popular non-ABB products such as OSIsoft PI System and Aspen InfoPlus.21.
  • HR Series ICI800 Ethernet CIU provides Ethernetbased communication between INFI-Net and the system’s engineering tools, HMI and the Harmony OPC server for connection to thirdparty applications. As per NERC CIP-007-2 R5, SSL certifications authenticate its connections with interface applications, further safeguarding the integrity and privacy of the ICI800 communication path.

HR Series Achieving greater levels of performance

  • Powerful, scalable control platform HR Series controllers are the latest in a long line of field-proven multi-function rack process controllers, and include the BRC300, BRC400, and the BRC410 bridge controllers (figure 3). This scalable family of controllers, based on a 160 MHz, 32-bit Freescale Coldfire processor, can be adapted to a broad spectrum of applications and process requirements. HR Series controllers feature an extensive library of more than 150 predefined control algorithms or function codes. These functions provide the power to easily design complex control strategies to fit any control application, including continuous, sequential, batch and advanced control. In addition to standard function blocks, HR Series controllers support C programming and batch functions.
  • HR Series controller features include:• Enhanced controller reliability• More than 10x performance of previous generation controllers• Simultaneous support for all HR Series I/O, SD Series I/O and S800 I/O subsystems• Intelligent device integration via HART I/O and PROFIBUS DP V0, V1, V2• Downloadable firmware• BRC400 / BRC410 specific enhancements: – Extended user configuration memory (2 MB NVRAM) – Support for 30,000 function blocks – Flexible online configuration capability – Modbus TCP device integration via 100 MB Ethernet port (BRC410 only)
  • High reliability and availability With redundant controller, communication, I/O and power options such as the recently released MPS IV (Modular Power System), HR Series controller subsystems provide the highest level of availability. Compliance with international standards assures the highest level of reliability and quality needed to meet the most rigorous global specifications and requirements. Backward compatibility through ABB’s ‘Evolution without obsolescence’ life cycle program ensures protection of installed investments while providing the most cost-effective and seamless way of introducing new functions and technology into a running plant. Together, the HR Series provides users with fast, accurate, uninterrupted control of their process, resulting in greater production efficiency, increased availability, and lower maintenance costs.
  • Soft controller reduces commissioning times For new plant, upgrade, or expansion projects, HR Series soft controllers can dramatically reduce commissioning and start-up time and costs by permitting thorough testing and pre-tuning of control loops prior to its implementation in the field. The HR Series soft controller uses the same control logic (ie, function block configuration) as the physical HR Series controllers. Coupled with virtual communication devices, the entire HR Series control-based system can be implemented within one or more PCs which allow for testing results made in the virtual environment to be directly transferable to the operating system environment.

Comprehensive I/O product portfolio S+ I/O, available for local and remote mounting, provides a wide variety of input/output and signal conditioning capabilities. In combination, these rack and DIN I/O modules can be combined to form the optimal automation solution. HR Series controllers can communicate with up to 64 rack I/O modules locally with additional remote rack I/O modules connected via the RIO22 module. Use of rack sequence of events (SOE) I/O modules provides one millisecond timestamp resolution across the entire rack system.

HR Series I/O module types include: 

• Analog input (ASI, FEC) 

• Analog output (ASO) 

• Control input/output (CIS, QRS)

• Digital input (DSI) 

• Digital output (DSO) 

• Pulse input (DSM)

• SOE digital input (SED)

Turbine control In addition to traditional signal-type I/O, HR Series provides for integrated turbine control via a series of turbine control-specific modules, including: 

• Hydraulic servo module (HSS) 

• Turbine protection module (TPS)

• Turbine auto synchronization module (TAS) 

• Condition monitoring module (CMM) These unique modules make it possible to provide a fully integrated single-vendor solution for all aspects of turbine automation. HR Series turbine modules are based on proven technology that controls steam turbines, gas turbines and hydroelectric turbines in more than 15 different countries around the world, and have been tested, accepted, and used by several major global turbine manufacturers as part of their standard offering. The combination of HR Series controllers and turbine I/O results in a powerful governor control system solution.

SD Series remote I/O option HR Series remote I/O capabilities are further expanded with use of the SD Series DIN rail mounted I/O products. Compatible with all HR Series controllers, BRC300 / 400 / 410, SD Series I/O connects directly to the controller via the HN800 I/O network without the need for an intermediate interface or gateway. SD Series I/O is configured using standard function blocks and includes traditional analog and digital I/O as well as integration with intelligent field devices via PROFIBUS DP and HART. 24 VDC power requirements, low module power consumption, and a module temperature rating of 70 DEGC (ambient) makes SD Series I/O the optimal choice for remote I/O applications. G3 coating makes SD Series I/O suitable for use in corrosive environments without requiring costly sealed cabinets or purging systems.

HR Series Integrating field devices seamlessly

  • Device integration capability In today’s power generation and process industries, only about 10% of field instruments have a digital pathway back to the control system. This reduces smart devices to underutilized assets where the existing diagnostic and connection information residing in the field instruments is not utilized in system operations.
  • The HR Series seamlessly integrates intelligent field devices and protocols using PROFIBUS DP, HART, and Modbus TCP and RTU. This provides access to a wide range of intelligent field devices from both ABB and other third-party vendors including transmitters, actuators, motor control centers (MCC) and flame scanners. Each device’s resident information can then be used in control strategies and higher level applications. In addition to producing tighter and more reliable process control solutions, these solutions lower installation costs by reducing wiring and system footprint
  • Intelligent Hart I/O HR Series controllers seamlessly integrate HART field devices through a variety of SD Series HART analog input and output modules. Besides the 4-20 mA primary variable, all secondary, tertiary and quaternary variables in a HART device can be accessed by Function Code control applications in the HR Series controller. Data can be calculated, used as part of a control strategy, or for display and alarm purposes at the system’s HMI console.
  • SD Series HART I/O features include:• Each channel’s secondary/tertiary/quaternary variables are available for use in control applications• Update rate of secondary/tertiary/quaternary variables is less than one second (AI05 and AO05)

HR Series Securing your control investments

Protecting the integrity and confidentiality 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. All Symphony Plus Ethernet-based devices – including HR Series products such as the BRC410, ICI800, and IEB800 – 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

Seamless upgrade path protects investments True to ABB’s ‘Evolution without obsolescence’ commitment, HR Series products provide backward compatibility to previous generation Network 90, INFI 90, INFI 90 Open and Harmony hardware and software, including support for existing function code executions, custom user programs, and all foreign device interfaces. ABB’s ‘Evolution without obsolescence’ ensures the protection of installed investments while providing the most predictable, cost-effective, risk-averse, and seamless way of introducing new functions and technology into a running plant.

Specifically, HR Series products:

Replace previous generation rack products on a form/fit/function basis 

• Preserve installed I/O through simultaneous connection to HR Series I/O, previous generation rack and block I/O, SD Series I/O and S800 I/O 

• Use the same field-proven INFI 90 function code algorithms as previous generation controllers (ie, MFCxx and MFPxx controllers) 

• 通过设备管理功能增强现有的 Composer 工程工具此外,HR 系列和 SD 系列控制网络、INFI-Net 和 PN800(INFI-Net over Ethernet)分别可以通过自配置的 INFI-Net 到以太网桥接器(IEB800 模块)连接。这允许使用 INFI-Net on Ethernet 技术和 SD 系列 DIN 导轨安装产品轻松扩展现有的 INFI-Net 通信网络。此外,来自任一网络的驻留数据可用于控制应用程序或在连接到另一个网络的应用程序中显示。

ABBitional terminals – Use connectors Slot1 … Slot3 for F-type I/O extension modules and F-type fieldbus adapters. – Connectors XC12, XS13, X14 and X38 connect the SDCS-CON-H01 to the SDCS-PIN-H01 or SDCS-POW-H01 for voltage, current, temperature measurem

Background and Company Performance Industry Challenges

了解年度公司如上所述,推动需求、品牌实力和竞争差异化在为客户提供独特价值方面都发挥着至关重要的作用。然而,理想情况下,这种三重关注必须辅之以同样严格的对远见创新和绩效的关注,以增强客户影响。

In 2016, the automation market was beset by several challenges, such as the plunge in oil prices, the economic slowdown in China, policy uncertainty caused by the new government in the United States, and political unrest in the Middle East. With the global investment climate improving following a rise in oil and commodity prices, there is new interest in automation projects that will boost production capacity and improve productivity. End-users are now looking for opportunities to evaluate their automation systems in light of recent advances in engineering methods, automation, and the connectivity provided by commercial information technology and the Industrial Internet of Things (IIoT), rather than simply returning to the methodologies of the past such as upgrading to the latest version of a control system provided by the current automation vendor

The process industries’ production assets have never been larger or more complicated, and with increased scale and complexity, there is a growing inability to predictably deliver capital projects on schedule and within budget. In this scenario, the primary concern of the end-users lies in deploying their resources in a cost-effective way and attaining high capital efficiency. This cannot be achieved by just squeezing prices. It requires new methods of executing projects and new ways of looking at things. The attempt to reduce project costs adds pressure to automation costs, which is a prime challenge to the growth of Distributed Control System (DCS) vendors. DCS vendors that address this challenge through the use of innovative technologies in the field of cloud engineering, digital marshaling, virtualization, and automated data management are expected to gain a competitive advantage

The process industries’ production assets have never been larger or more complicated, and with increased scale and complexity, there is a growing inability to predictably deliver capital projects on schedule and within budget. In this scenario, the primary concern of the end-users lies in deploying their resources in a cost-effective way and attaining high capital efficiency. This cannot be achieved by just squeezing prices. It requires new methods of executing projects and new ways of looking at things. The attempt to reduce project costs adds pressure to automation costs, which is a prime challenge to the growth of Distributed Control System (DCS) vendors. DCS vendors that address this challenge through the use of innovative technologies in the field of cloud engineering, digital marshaling, virtualization, and automated data management are expected to gain a competitive advantage

ABB aligns with market Mega Trends and develops industry-specific DCS solutions to address the demands of different end-user market segments. ABB’s product solution targets Mega Trends such as Urbanization and Innovation to Zero across the end-user industries, enabling them to create new opportunities and values for their customers. This has helped ABB to stay ahead of competition and retain a leadership position in the DCS market. With market growth drivers such as increasing demand to implement advanced control strategies, the need for software-based services, value-added services (including upgrading cyber security, consulting, and training), and optimizing lifecycle costs are

expected to be intact in the short term. ABB is well positioned to retain its leadership position in the future as it is primed to deliver value to its clients in this market.

Addressing Unmet Needs The increasing scale and complexity of automation projects has made it almost impossible to deliver capital projects on schedule and within budget. A key contributor to the growing risk of missing DCS project deadlines include late design changes, which tend to cascade throughout a project. A significant unmet need in the market is decreasing the dependency of the automation design on the process design. ABB took a significant step forward in streamlining the execution of its customers’ automation projects with the release of its Select I/O, an Ethernet-based single channel I/O solution for the ABB Ability™ System 800xA. This can be configured in the field to address the growing demand for full redundancy down to the signal conditioning module. Because the base hardware for every type of signal is the same, Select I/O effectively allows each I/O channel to remain flexible and “undeclared” until very late in the project, often up until just before commissioning. This effectively decouples I/O hardware engineering from software design, which lowers development costs and shortens the delivery schedule. The Select I/O, when coupled with the process know-how of ABB, improves the efficiency of DCS project execution and provides ABB a distinctive advantage in the DCS market with respect to competition.

Visionary Scenarios through Mega Trends The concept of a connected industry is increasingly becoming a reality as industries, such as oil and gas, chemicals, power, pharmaceuticals, steel, water, mining, food, and beverage, move towards a digital operating environment to improve connectivity, productivity, and cost-effectiveness. The recent launch of the ABB Ability platform in 2017 will provide ABB with a competitive edge over its competitors because it provides unified, cross-industry digital capability—extending from device to edge to cloud—with devices, systems, solutions, and services. While similar competitor offerings allow end-users to sense, analyze, and take actions to drive efficiency, ABB has added self-learning capabilities to its solution that allow it to harvest data, take control, and enable users to do more. This distinguishes ABB from the rest of the competition in the market.

Implementation of Best Practices Through its Next Level Strategy, which aims at profitable growth, relentless execution, and business-led collaboration, ABB has adapted to rapidly changing market dynamics to serve its clients with a combined power and automation portfolio. In October 2016, it launched its Stage 3 of the Next Level Strategy, which helps ABB rebuild its successful

transformation momentum and strengthen its position as a pioneering technology leader and global digital champion. ABB places a high focus on increasing its customer value proposition with the help of software-led differentiation, solutions-as-a-service, and technology leadership.

ABB’s dedicated service organization focuses on maintaining and continuously improving the performance of customer’s equipment and processes through a suite of services. Especially ABB’s advanced digital services are in continuous evolution, also in combination with new business models, to address opportunities through digitalization and unmet needs of customers. A key differentiator for ABB is its lifecycle policy. This policy aims at maximizing the useable life of a customer’s investment. This means that ABB is committed to maintaining full lifecycle integrity for its products and systems and supports any products for at least 10 years once removed from active sale and an equivalent replacement is available. In order to take complete advantage of digital transformation, a broader ecosystem of applications is required. For instance, start-ups foster innovation and help automation vendors scale up their digital offerings faster than they would with organic developments. As a leading automation vendor, ABB embraced this trend earlier than many other vendors in the automation space. ABB formed a strategic venture capital unit called the ABB Technology Ventures (ATV) in 2009. ATV focuses on many segments and automation is one core focus area for the organization. The primary objective is to seek out potential automation technology partners who are aligned seamlessly with ABB’s vision of industrial digitalization. Since its inception, ATV has invested about $150 million in technology companies that have a high potential in diverse sectors, including IIoT and cybersecurity. These start-ups function as an extension of ABB and offer innovative services and analytics capabilities to complement its existing digital portfolio. In October 2016, ABB entered into a strategic partnership with Microsoft to develop next-generation digital solutions on an integrated cloud platform that will enable digital transformation for its customers in businesses such as robotics, marine, and eMobility.

Financial Performance ABB’s penetration and expansion in emerging markets has helped it dominate the DCS market with a 20.5% market share in 2016 and continue its market dominance, while its two closest competitors hold market shares in the range of 15.2% and 14.5%. ABB has unswervingly lead the DCS market across power end-user segment. It’s expertise in developing innovative solutions that match the needs of energy and energy-intensive industries like oil and gas, utilities, and mining operations has reinforced its significant global market share. ABB has the best and widest DCS portfolio across the process automation market. The organization offers the customer-specific control platforms ABB Ability System 800xA, ABB Ability Symphony Plus, Freelance and a Compact Product Suite. ABB’s continued quench to stay ahead of the market is very clear here, as its competitors are progressively introducing compact and low-cost products in the years to come from now. While many competitors have had flat growth in recent years, ABB continues to steam ahead and build on its existing installed base. For instance, in the oil and gas enduser industry where safety is a primary concern, ABB astutely developed the System 800xA HI (High Integrity) solution. This integrates two previously independent automation platforms— safety and process control—into a single system. Also, with rising concerns over minimizing the carbon footprint, ABB has given its clients a greater visibility of energy use with the help of more integrated

assistance 24/7. Problems are solved before they become failures by utilizing data insights and advanced analytics and through remote collaboration that enables real-time customer interaction. With two DCS product lines – ABB Ability System 800xA and ABB Ability Symphony® Plus – ABB addresses the specific needs of various industries. Both DCS solutions are industryleading and proven over decades evident by their installed base. Symphony Plus is tailored to the power generation and water industries whereas System 800xA is targeted towards all other industries. Both solutions support customers by driving gains in performance, productivity, efficiency, and safety throughout the end-user business operations lifecycle, from the planning stage to the maintenance stage. With the help of domain expertise and process knowledge, ABB has developed an overarching digital architecture that augments the human expertise of the clients to deliver improved performance. ABB also has a footprint across a broad range of industry verticals, more than any other participant in the industrial space. ABB’s years of domain expertise, combined with its huge installed base, distinguishes it from other automation vendors in the Global DCS market. Further, it enables ABB to design its solutions based on the context of each end-user requirement.

Customer Service Experience In line with its growth strategy, ABB extends its expertise and resources into key target markets such as power generation, oil and gas, and metals and mining, where process automation systems have significant growth opportunities in both greenfield and brownfield projects. The ABB Value Provider Program (VPP), a one-of-its-kind program in the market, is aimed at developing ABB’s third-party channels including distributors, technical distributors, system integrators, panel builders, and service providers. With the help of this program, ABB locates a third-party provider in close proximity to its end-users in order to reduce the response time to its clients’ sales, support, service, and engineering needs. The value provider’s in-depth knowledge about local markets coupled with an expertise in ABB’s products enables it to function as an extension of ABB, resulting in extensive coverage in targeted regional segments. ABB has leveraged its decades of experience in the DCS market to develop the capability of a Main Automation Contractor (MAC). This means that ABB can offer a wider scope than conventional vendors by working proactively with clients to deliver a complete automation solution, from automation/instrumentation selection to commissioning and after-sales support. This helps end-users reduce the project schedule, engineering required, and change requests. Also, with the introduction of Ability, ABB is well qualified to deliver turnkey Main Automation, Electrical and Information Contractor (MAEIC) solutions. Only one other company, apart from ABB can deliver a similar solution. This is another critical differentiating factor for ABB.

Conclusion ABB equips industrial customers with the digital technology and cloud platform to empower every person, team, and business system within an organization to glean new insights and drive smarter, faster and simpler decision-making—thereby helping every customer seize new growth opportunities. By offering ultimate flexibility in the field, ABB sets a new standard in the execution of automation projects. ABB will continue to stay ahead of developments in the DCS market because it takes inspiration directly from evolving customer needs and industry standards. Continuing its decades of innovation history, ABB is a pioneering leader in DCS market and leads the digitalization of the energy industry. With its strong overall performance, ABB is recognized with Frost & Sullivan’s 2017 Company of the Year Award.

Conclusion ABB equips industrial customers with the digital technology and cloud platform to empower every person, team, and business system within an organization to glean new insights and drive smarter, faster and simpler decision-making—thereby helping every customer seize new growth opportunities. By offering ultimate flexibility in the field, ABB sets a new standard in the execution of automation projects. ABB will continue to stay ahead of developments in the DCS market because it takes inspiration directly from evolving customer needs and industry standards. Continuing its decades of innovation history, ABB is a pioneering leader in DCS market and leads the digitalization of the energy industry. With its strong overall performance, ABB is recognized with Frost & Sullivan’s 2017 Company of the Year Award.

ABBRER 133 总线连接模块

About this manual

Copyrights The information in this document is subject to change without notice and should not be construed as a commitment by ABB Oy. ABB Oy assumes no responsibility for any errors that may appear in this document. In no event shall ABB Oy be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB Oy be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without written permission from ABB Oy, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose. The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. Copyright © 2005 ABB Oy All rights reserved.

Trademarks ABB is a registered trademark of ABB Group. All other brand or product names mentioned in this document may be trademarks or registered trademarks of their respective holders.

Guarantee Please inquire about the terms of guarantee from your nearest ABB representative.

Use of symbols This document includes caution and information icons that point out safety-related conditions or other important information. The corresponding icons should be interpreted as follows: Although 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, comply fully with all caution notices. The 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 or property. The information icon alerts the reader to relevant facts and conditions

Safety information

General

The RER 133 Bus Connection Module acts as an interfacing unit between an RE_54_ host device and a SPA, Modbus or DNP 3.0 system. The RER 133 module converts RS-232 signals to RS-485 signals. RS-485 can be connected by using 2- or 4-wire mode. The RER 133 module is connected by a cable to the RS-232 D-type connector marked X3.2 on the rear panel of the RE_ 54_ host device. RER 133 is not a stand alone device. An RE_ 54_ host device is always required to power the module. No external power supply is supported. RER 133 supports communication speeds from 300 to 19200 bits/s. Collision detection and collision avoidance is supported for communication speeds 4800, 9600 and 19200 bits/s. A RER 133 delivery includes the RER 133 Bus Connection Module, a connection cable (1MRS120542) and this manual.

Principle of operation

The RER 133 Bus Connection Module is designed to work with RE_ 54_ products. The module utilizes the RS-232 communication port located on the rear panel of the RE_ 54_. The module is not designed to be connected to any other ABB product, nor to any third party products.

The RER 133 Bus Connection Module is designed to work with RE_ 54_ products. The module utilizes the RS-232 communication port located on the rear panel of the RE_ 54_. The module is not designed to be connected to any other ABB product, nor to any third party products.

The signal levels and the functionality of the RER 133 module are defined in the RS-485 standard. RER 133 module is a regular type of RS-485 interface, meaning that a maximum of 32 nodes can be connected in a daisy chain type of bus configuration. Collision detection on the RS-485 bus is supported when a maximum of 32 nodes are connected to the same daisy chain. In order for collision detection to operate, the communication speed has to be set to 4800, 9600 or 19200 bits/s. These speeds are set by using the DIP switches on the front of the module. For an example on how to set these DIP switches, please see section ìModule configurationî on page 9. When collision detection is not used, the communication speed does not have to be set

Construction and installation

The RER 133 module is mounted on the side of the RE_ 54_ host device and is connected by the supplied cable to the 9-pin female type D-connector (X3.2) of the RE_ 54_ host device

Only the cable supplied with the RER 133 may be used to connect the RER 133 module to the RE_ 54_.

The RER 133 module consists of a printed circuit board and is housed in a metal case. Because shielded cables and an RS-485 interface is used, special attention must be paid to the grounding. The dimensions of the case are: 95 mm x 101 mm x 30 mm (95 mm x 105 mm x 38 mm with mounting bracket).

Module configuration

The attributes for the RER 133 can be set through the two DIP switches on the front of the module. The DIP switches are labeled S1 and S2.

4 wire mode requires both the 2- and 4- wire switches for pull-down/ termination/pull-up to be set.

5.2. Configuration examples

Interfaces

The RS-485 bus used by SPA, Modbus and DNP 3.0 requires a daisy chain topology. A daisy chain topology means a node-to-node connection, where nodes are chained using cables of minimal length. The cables must be point to point, no stars, rings or other topologies are allowed. The bus must be terminated at both ends using 120Ω resistors. The RER 133 includes as an option the use of internal termination resistors. These resistors are enabled through DIP switch S2. Pull-up and pull-down resistors must be used in one of the nodes, in order for the receivers to be able to determine the state of the bus when it is idle. These resistors can be enabled through DIP switch S2. Please see sections ìModule configurationî on page 9 and ìConfiguration examplesî on page 10 for the correct settings. The RS-232 interface (X1) of the RER 133 module is shown in Fig. 6.-1.

Fig. 6.-1 Pin usage table for the 9-pin D-type connector (X1) The RS-485 interface of the RER 133 module is shown in Fig. 6.-2. The connector (X2) is an 8-pin Weidm¸ller terminal block. If GND (pin 5) is used, then it is required for all other nodes to be isolated as well.

The EIA RS-485 Specification labels the data wires “A” and “B”, but many manufacturers label their wires “+” and “-“. In our experience, the “+” wire should be connected to the “A” line, and the “-” wire to the “B” line. When wiring RS-485 , use a shielded twisted pair cable with an internal impedance of 100-120Ω. Examples of recommended cables are CAT 5, Belden RS-485 (9841- 9844) and Alpha Wire (Alpha 6222-6230)

The shield of the cables must be directly connected to ground in one of the nodes. In the other nodes the connection should be made via a capacitor, i.e. if the shield of the cable is connected to pin 1 in node 1, all the other nodes must be grounded using pin 2.

ABB分销控制系统生命周期零件服务

LifeCycle Parts Services Trouble-free operation

As a world-leading engineering company, ABB is committed to providing support and services to maximize its customers’ uptime.

To ensure the best possible accessibility and continuous trouble-free operation, we provide cost-efficient spare parts and services for your system. ABB offers a comprehensive range of spare parts with short lead times, which helps minimize downtime if a failure occurs. In addition, preventive maintenance kits make it possible to plan maintenance in advance. This maximizes availability and increases maintenance performance. Our LifeCycle Parts Services portfolio meets customers’ needs to minimize costs and maximize the value of their investments in ABB equipment. Whether you need to repair a broken part or purchase a spare part, our services achieve cost-efficient maintenance. ABB is highly qualified and provides a wide range of technical knowledge and support. We ensure that our customers receive the best possible return on their assets throughout the entire product life cycle.

Product portfolio ABB’s control systems portfolio ranges from stand-alone products to Distributed Control Systems (DCS). We also supply any size of application, from small systems to SIL3-certified Safety Instrumented Systems and Collaborative Process Automation Systems (CPAS) for an extended automation scope. The services highlighted in this brochure cover the following ABB Control Technologies families: 

• System 800xA 

• Freelance 

• Advant Master 

• Advant OCS with MOD 300 Software

• Satt 

• Symphony DCI System Six 

• Symphony Harmony/INFI 90 

• Symphony Melody

Service availability by system family

The product life cycle Secured Return On Investment Using the life cycle management model and the four-phase life cycle plan.

  • The life cycle management model divides a product’s life cycle into four phases: active, classic, limited and obsolete. Each phase has different implications for the end user in terms of services and support provided.
  • All control systems effectively remain in Active phase, with individual component products (hardware and software) transitioning through the lifecycle phases of Active, Classic, Limited and Obsolete as they are superseded by newer technologies and offerings
  • Spare Parts availability is secured in the phases – Active, Classic and Limited. New Spare Parts are actively manufactured in the Active and Classic phases. In the Limited phase, stocked parts can be complemented with other Spare Parts Services, such as the Parts Repair Service and the Parts Refurbishment Service.
  • Spare Parts are supported for a period of 10 years from time when the product enters the Classic phase. When the product reaches the Obsolete phase the spare parts availability can no longer be guaranteed. However, the Service organization may still be able to support the product, or parts of it, on a best effort basis, limited to available parts and component inventory.
  • — We ensure that our customers receive the best possible return on their assets throughout the entire product life cycle.
  • Extended Life Cycle Support Upon individual customer request, ABB can offer Extended Life Cycle Support agreements to meet individual customer needs for Spare Parts Services beyond the standard product lifecycle commitment. The Extended Lifecycle Support agreements can include Parts, Parts Repair Services and Refurbished Parts Services during the product Life Cycle.
  • In each life cycle phase, ABB commits to supply, support and service delivered products to meet customer expectations throughout the product lifetime.Services portfolio
  • Services by life cycle state Services availability depends on the product’s life cycle state..The following table shows what services apply in each life cycle phase.* Stock dependant – ABB stocks sufficient inventory at the end of the Classic phase to support anticipated demand during the Limited phase. The available inventory level is one of the criteria used to determine the timing for transfer to the Obsolete phase. ** Component availability dependant – ABB will continue to provide repair services until it is no longer technically feasible to do so due to the lack of component availability. *** Only available for Advant Master and Advant MOD 300

Online tools

Business Online – Web ordering tool ABB offers quick and easily-accessible web-based information and order systems to facilitate spare part management. A comprehensive range of products are available with more than 100,000 spare parts and related Life Cycle Parts Services for a wide assortment of equipment

Through your web browser you can access key information, e.g. specific spare part availability, locate the equipment that utilizes the particular spare part, and view technical details and photographs of most spare parts. You can make inquiries, search for a spare part or place an order at your convenience 24 hours a day

Parts are arranged in a hierarchical structure that spans the entire product range – from equipment level to a single spare part. Searching for a part is simple: just enter its type, article number or description.

In most cases, you can also verify your choice by viewing a photograph of the part in question. In addition, several sort and search functions simplify the information management for you. To get access, please contact your local ABB office.

  • The myABB/ My Control System customer self-service tool, available 24/7, offers you a single point of online access to information, services and service contacts for the ABB family of control systems and all ABB products.
  • You’ll quickly find that new MyABB/ My Control System web portal is a great way to increase your productivity, minimize cost, and extend the useful life of your ABB control products and systems.
  • My Control System is a valuable source for maintenance information and for enhancement of the control system and provides ready answers to frequently asked questions, thus reducing the effort spent looking for information and shortening software delivery times. All relevant ABB control system information is in one place and just a couple of mouse clicks away. A basic version of My Control System (limited access) will be provided to all ABB customers.
  • Automation Sentinel subscribers will enjoy premium access, which includes features such as software downloads, access to validated security updates and documentation already filtered for each system.
  • Automation Sentinel Automation Sentinel is ABB’s subscription based control system lifecycle management and support program that assists system owners to actively manage their control system lifecycle, support and maintenance
  • With this program, system owners can keep their control software up-to-date and maintain a flexible path forward to new system software technology. Automation Sentinel provides exclusive services for the maintenance, evolution and continual enhancement of the installed base of ABB control systems.
  • System LifeCycle Fingerprint Report System Lifecycle Fingerprint, available for ABB control system customers with an myABB/My Control System account together with a Fingerprint license, provides a comprehensive strategic maintenance analysis of the installed ABB control system hardware. It extends the service of System Lifecycle Benchmark, with the benefit of providing the full scope of analysis and recommendations for taking actions.
  • Based on computer aided data collection from the installed ABB control system, an analysis and evaluation is performed by an ABB Field Service engineer. As a result, a System Fingerprint report is then presented by ABB Field Service authorities.
  • Based on the life-cycle status of the individual installed units and ABB Field Service Engineer’s experience with the customer plant, an evaluation will be conducted leading to a strategic hardware maintenance plan.
  • In addition to the current lifecycle status of the installed devices, the System Lifecycle Fingerprint report provides an easy to read table summary of the forecast lifecycle for the installed devices, and briefly summarizes key findings and recommended actions, helping to avoid unwelcome failures and production losses.

Spare parts

The Refurbished Parts Service is a cost-effective alternative to purchasing new spare part modules. Parts sold with this service are ‘like-new’ parts, recovered and updated by ABB. What’s more, the have been tested to meet the original equipment specifications and the current component standards

Spare Parts Service Spare parts are essential in maintaining a high system availability. The Spare Parts Services supplies brand new certified ABB spare parts shipped within a day, increasing reliability and leading to longer lifetime of your equipment.

With our large stock of ABB spare parts for all of ABB’s different control systems, we offer quick handling and shipping of your spare parts needs through our 24 hours web-based ordering process. The use of optimal means of transport results in cost-effective and quick arrival of your spare parts.

Emergency Parts Service For occasions when quickest possible delivery is the most important factor, we offer the Emergency Parts Service.

Spare Parts service availability is critical to on-going operations, not only during business hours. ABB maintains a complete stock of certified ABB parts to ensure availability

For emergency cases, our personnel and partners are available 24 hours to provide immediate response to your emergency parts request and our global logistics network ensures the quickest possible delivery.

Refurbished Parts Service For cases when new spares a no longer manufactured or no longer available, or when if you need to acquire a brand new spare part in the most cost-effective way

ABBMark* VIe 和 Mark VIeS 控制系统第一卷:系统指南

Safety Symbol Legend

Control System Warnings

Control System Overview

Introduction

The Mark* VIe control system is a flexible platform used in multiple applications. Its architecture enables unique engineered solutions for a variety of large industrial applications. It features high-speed, networked input/output (I/O) for Simplex, Dual, and Triple Modular Redundant (TMR) systems. Industry-standard Ethernet communications are used for I/O, controllers, and supervisory interface to operator and maintenance stations, as well as third-party systems. The Mark VIeS Safety controller and I/O can operate independently or integrated with the rest of the Mark VIe controllers for safety-critical applications that conform to IEC® 61508. The ControlST* Software Suite, which contains the ToolboxST* application software, is used or programming, configuration, trending, and analyzing diagnostics for Mark controls and related systems. It provides quality, time-coherent data at controller and plant level for effectively managing control system equipment. ControlST simplifies maintenance while retaining a unique set of certified hardware and software blocks. ToolboxST provides a means to lock or unlock the Mark VIeS Safety controller for configuration and Safety Instrumented Function (SIF) programming The Universal I/O (UIO) control cabinet provides a platform for an independent, miniature version of the Mark VIe or Mark VIeS Safety control. The PUAA module is the standard Mark VIe compatible module, while the YUAA module is the companion module that is used in the Mark VIeS Safety control system. The UIO control cabinet is a lower cost, smaller footprint alternative to the standard Mark control cabinet. The control cabinet is installed at sites when there are I/O, power, and/or space limitations in the existing Mark VI, Mark VIe, or Mark VIeS control cabinet. This is especially required for upgrades when there are space restrictions. This unit may also be used as an independent Mark VIe or Mark VIeS control system, communicating directly with the Unit Data Highway (UDH) or Plant Data Highway (PDH), regardless of the existing controller at the site. The UIO control system supports specific I/O. For a list of supported I/O, refer to the Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II). ToolboxST is used to set up, configure, and download to the UIO Mark VIe controller.

The information in this document applies to the overall Mark* VIe control system or Mark VIeS Functional Safety System control products; however, your application may not be licensed to access full system capability and I/O packs as described in this document. For example, the Mark VIeS Functional Safety System for General Markets only utilizes the following I/O packs:

• Analog I/O (YAIC) 

• Universal Analog (YUAA) 

• Vibration Input Monitor (YVIB) 

• Relay Output (YDOA)

• Discrete Contact Input (YDIA) 

• Power Distribution System Diagnostics (PPDA) 

• Serial Modbus Communication (PSCA)

 • Mark VIeS Safety Controller (UCSCS2x)

• Mark VIe Controller for Gateway (UCSCH1x)

The Mark VIe and Mark VIeS control systems are used in a wide range of process control and protection applications, including steam, gas, and wind turbines, power generation balance of plant (BoP), deep sea drilling, desalinization, gas compression, and other facility-wide equipment management systems. The control system primarily consists of three hardware components: controller(s), I/O network (IONet) switches, and I/O modules. The control system provides more options for redundancy, better maintainability, and greater capability for locating I/O modules closer to the controlled equipment. It provides quality, time-coherent data at controller and plant level for effectively managing control system equipment. ControlST, which include the ToolboxST and WorkstationST applications, is used for programming, configuration, trending, and troubleshooting the Mark control product line. The following are two commonly used ToolboxST configuration screens.

Controllers

The Mark VIe controller is a stand-alone, single-board controller with scalable processing power. It includes built-in power supplies and requires no batteries or jumper settings. Controllers run the ControlST* Software Suite, providing a common software environment for turbine and generator excitation controls in the power island and balance of plant equipment to simplify operations and maintenance. The Mark VIeS Safety controller is IEC 61508 certified to SIL 3.

Controllers are loaded with software specific to its application, such as steam, gas, land-marine (LM), Balance of Plant (BoP), offshore drilling, desalination, CS, and Wind Power Conversion. It can run Relay Ladder Diagrams (RLD) or blocks. The IEEE® 1588 protocol is used through the R, S, and T I/O networks (IONet) to synchronize the clock of the I/O modules and controllers to within ±100 microseconds. Data is transferred to and from the control system database in the controller over the I/O networks (IONet). IONet data includes process inputs/outputs to the I/O packs.

In a dual system, IONet data also includes:

• Internal state values and initialization information from the designated controller • Status and synchronization information from both controllers In a triple module redundant (TMR) system, IONet data also includes: • Internal state values for voting and status and synchronization information from all three controllers • Initialization information from the designated controller

Note For more information on the Mark VIe controller, refer to the Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II), the chapter Controllers. More more information on the Mark VIeS Safety controller, refer to the Mark VIeS Control Functional Safety Manual (GEH-6723). For a list of controllers that are available for each control system, including the supported and unsupported features the controllers offer for that control system, refer to the ToolboxST User Guide for Mark Controls Platform (GEH-6700 or GEH-6703).

IONet Switches

GE’s Industrial Ethernet 10/100 switches (ESWA and ESWB) provide the performance and features needed in today’s real-time industrial control systems. Use 8-port ESWA or 16-port ESWB Ethernet switches in all control system I/O networks to maintain the reliability needed for I/O module reception of controller outputs.

1.4 Distributed I/O Modules

The I/O modules contain three basic parts: terminal board, terminal block, and I/O pack. The terminal board mounts to the cabinet and comes in two basic types: S and T. The I/O pack mounts to the terminal board J-port connector. Both terminal board types provide the following features:

• Terminal blocks for I/O wiring 

• Mounting hardware

• Input isolation and protection 

• I/O pack connectors 

• Unique electronic ID

I/O packs have a common processor board and a data acquisition board that is unique to the type of connected device. I/O packs on each terminal board digitize the I/O variables, perform algorithms, and communicate with the controller. The I/O pack provides fault detection through a combination of special circuitry in the data acquisition board and software running in the Central Processing Unit (CPU) board. The fault status is transmitted to and used by the controllers. The I/O pack transmits inputs and receives outputs on both network interfaces if connected.

Each I/O pack also sends an identification message (ID packet) to the main controller when requested. The packet contains, the hardware catalog number of the I/O board, the hardware revision, the board barcode serial number, the firmware catalog number, and the firmware version. The I/O packs have a temperature sensor that is accurate to within ±2 °C (±3.6 °F). Every I/O pack temperature is available in the database and can be used to generate an alarm.

Terminal Boards

Signal flow begins with a sensor connected to a terminal block on a board. Wide and narrow terminal boards are arranged in vertical columns of high and low-level wiring. An example of a wide board is a board that contains magnetic relays with fused circuits for solenoid drivers. A shield strip is provided to the left of each terminal block. It can be connected to a metal base for immediate grounding or floated to allow individual ground wires from each board to be wired to a centralized, cabinet ground strip.

T-type

T-type terminal boards typically fan the sensor inputs to three separate I/O packs. Usually, the TMR board hardware votes the outputs from the three I/O packs. T-type boards contain two, 24-point, barrier-type, removable, terminal blocks. Each point can accept two 3.0 mm (0.12 in) (#12 AWG) wires with 300 V insulation per point with either spade or ring-type lugs. In addition, captive clamps are provided for terminating bare wires. Screw spacing is 9.53 mm (0.375 in) minimum and center-to-center

These terminal blocks have the following features:

• Black in color with white number labels 

• Terminal rating is 300 V, 10 A 

• UL recognized 

• Recommended screw tightening torque is 7 lb-in (0.8 Nm)

S-type

S-type boards provide a single set of screws for each I/O point and allow a single I/O pack to condition and digitize the I/O. They are half the size of T-type boards and are standard base mounted but can also be DIN-rail mounted. These boards can be used for simplex, dual, or dedicated triple redundant sensors by using one, two, or three modules. S-type boards have Euro-style, box type terminal blocks. Some boards are available as either removable or fixed terminal block versions. S-type board terminal blocks accept one 2.05 mm (0.08 in) (#12 AWG) wire or two 1.63 mm (0.06 in) (#14 AWG) wires, each with 300 V insulation per point. Screw spacing is 5.08 mm (0.2 in) minimum and center-to-center.

These terminal blocks have the following features:

• Green in color with number labels. 

• Terminal rating is 300 V, 10 A 

• UL and CSA recognized 

• 推荐的螺钉拧紧扭矩为 5 lb-in (0.5 – 0.6 Nm

ABB Ability™ Symphony® Plus

HR Series Control and I/O Achieving total plant automation with a single control and I/O platform

ABB Ability™ Symphony® Plus is the new generation of ABB’s highly acclaimed Symphony family of distributed control systems – the world’s most widely used DCS in power generation and water management applications. In all, there are more than 7,000 Symphony DCS installations in operation all over the world, more than 5,000 of which are in power and water applications.

  • No other automation platform has such a long field record and large global installed base as ABB’s Symphony Plus family. For more than 35 years, the system has progressed through several evolutionary steps. From Network 90 in 1980, through INFI 90TM, INFI 90TM Open, and Symphony, to Symphony Plus, the system progression has followed ABB’s long-held policy of ‘Evolution without obsolescence,’ ensuring that each new generation enhances its predecessor all the while maintaining full compatibility with them.
  • Symphony Plus includes a comprehensive suite of standards-based control and I/O hardware and software that meets your requirements for total plant control. The suite’s HR Series (Harmony Rack) meets the past, present and future needs of its users by protecting their previous control investments while delivering higher performance, reliability, and capacity. HR Series control-based systems feature scalable,
  • high-performance controllers, a comprehensive set of I/O options, fast, secure and redundant communications, an efficient easy-to-use engineering tool, and a state-of-the-art HMI workplace. Newest additions to the HR Series portfolio include an environmentally hardened DIN-rail mounted native remote I/O option and integration of intelligent electrical and field devices via PROFIBUS, HART and Modbus TCP communication protocols.
  • high-performance controllers, a comprehensive set of I/O options, fast, secure and redundant communications, an efficient easy-to-use engineering tool, and a state-of-the-art HMI workplace. Newest additions to the HR Series portfolio include an environmentally hardened DIN-rail mounted native remote I/O option and integration of intelligent electrical and field devices via PROFIBUS, HART and Modbus TCP communication protoco
  • Overview Symphony Plus HR Series provides a scalable solution that spans and integrates loop, unit, area, plant and interplant controls. Its system communication architecture is based on a high-speed, high-throughput and highsecurity redundant INFI-Net control network. The scalable network supports any combination and quantity of control, engineering, operation and application interface nodes. Each node on the control network operates independently of other nodes. Acting as its own communication manager, the system requires no traffic directors. INFI-Net to INFI-Net communication modules support multinetwork system topologies that provide a system capacity of more than 62,000 nodes.
  • High system reliability and availability are key characteristics of this mission-critical control network. Reliability is bolstered by redundant hardware and communication paths. Extensive use of error checking and message acknowledgment assures accurate communication of critical process data. Patented exception reporting technology optimizes the use of control network bandwidth. The store and forward ring topology of INFI-Net, along with multi-master and multi-cast messaging features result in INFI-Net having an effective bandwidth that exceeds 300 Mbaud. INFI-Net communications are also highly deterministic.
  • HR Series process control unit (PCUs) communication products including the NIS21/ NPM22 modules provide significant increases to performance and capacity compared to previous generations. Additionally, new HR Series INFI-Net to Computer Interface (ICI), INFINet to INFI-Net Local and Remote Bridge modules, and INFINet to PN800 (INFI-Net over Ethernet) Bridge modules are available.
  • The Harmony OPC server provides OPC connectivity between devices on the INFI-Net control network and OPC client applications. In non-redundant and redundant configurations, it can be used in conjunction with ABB products such as DataLink and popular non-ABB products such as OSIsoft PI System and Aspen InfoPlus.21.
  • HR Series ICI800 Ethernet CIU provides Ethernetbased communication between INFI-Net and the system’s engineering tools, HMI and the Harmony OPC server for connection to thirdparty applications. As per NERC CIP-007-2 R5, SSL certifications authenticate its connections with interface applications, further safeguarding the integrity and privacy of the ICI800 communication path.

HR Series Achieving greater levels of performance

  • Powerful, scalable control platform HR Series controllers are the latest in a long line of field-proven multi-function rack process controllers, and include the BRC300, BRC400, and the BRC410 bridge controllers (figure 3). This scalable family of controllers, based on a 160 MHz, 32-bit Freescale Coldfire processor, can be adapted to a broad spectrum of applications and process requirements. HR Series controllers feature an extensive library of more than 150 predefined control algorithms or function codes. These functions provide the power to easily design complex control strategies to fit any control application, including continuous, sequential, batch and advanced control. In addition to standard function blocks, HR Series controllers support C programming and batch functions.
  • HR Series controller features include:• Enhanced controller reliability• More than 10x performance of previous generation controllers• Simultaneous support for all HR Series I/O, SD Series I/O and S800 I/O subsystems• Intelligent device integration via HART I/O and PROFIBUS DP V0, V1, V2• Downloadable firmware• BRC400 / BRC410 specific enhancements: – Extended user configuration memory (2 MB NVRAM) – Support for 30,000 function blocks – Flexible online configuration capability – Modbus TCP device integration via 100 MB Ethernet port (BRC410 only)
  • High reliability and availability With redundant controller, communication, I/O and power options such as the recently released MPS IV (Modular Power System), HR Series controller subsystems provide the highest level of availability. Compliance with international standards assures the highest level of reliability and quality needed to meet the most rigorous global specifications and requirements. Backward compatibility through ABB’s ‘Evolution without obsolescence’ life cycle program ensures protection of installed investments while providing the most cost-effective and seamless way of introducing new functions and technology into a running plant. Together, the HR Series provides users with fast, accurate, uninterrupted control of their process, resulting in greater production efficiency, increased availability, and lower maintenance costs.
  • Soft controller reduces commissioning times For new plant, upgrade, or expansion projects, HR Series soft controllers can dramatically reduce commissioning and start-up time and costs by permitting thorough testing and pre-tuning of control loops prior to its implementation in the field. The HR Series soft controller uses the same control logic (ie, function block configuration) as the physical HR Series controllers. Coupled with virtual communication devices, the entire HR Series control-based system can be implemented within one or more PCs which allow for testing results made in the virtual environment to be directly transferable to the operating system environment.

Comprehensive I/O product portfolio S+ I/O, available for local and remote mounting, provides a wide variety of input/output and signal conditioning capabilities. In combination, these rack and DIN I/O modules can be combined to form the optimal automation solution. HR Series controllers can communicate with up to 64 rack I/O modules locally with additional remote rack I/O modules connected via the RIO22 module. Use of rack sequence of events (SOE) I/O modules provides one millisecond timestamp resolution across the entire rack system.

HR Series I/O module types include: 

• Analog input (ASI, FEC) 

• Analog output (ASO) 

• Control input/output (CIS, QRS)

• Digital input (DSI) 

• Digital output (DSO) 

• Pulse input (DSM)

• SOE digital input (SED)

Turbine control In addition to traditional signal-type I/O, HR Series provides for integrated turbine control via a series of turbine control-specific modules, including: 

• Hydraulic servo module (HSS) 

• Turbine protection module (TPS)

• Turbine auto synchronization module (TAS) 

• Condition monitoring module (CMM) These unique modules make it possible to provide a fully integrated single-vendor solution for all aspects of turbine automation. HR Series turbine modules are based on proven technology that controls steam turbines, gas turbines and hydroelectric turbines in more than 15 different countries around the world, and have been tested, accepted, and used by several major global turbine manufacturers as part of their standard offering. The combination of HR Series controllers and turbine I/O results in a powerful governor control system solution.

SD Series remote I/O option HR Series remote I/O capabilities are further expanded with use of the SD Series DIN rail mounted I/O products. Compatible with all HR Series controllers, BRC300 / 400 / 410, SD Series I/O connects directly to the controller via the HN800 I/O network without the need for an intermediate interface or gateway. SD Series I/O is configured using standard function blocks and includes traditional analog and digital I/O as well as integration with intelligent field devices via PROFIBUS DP and HART. 24 VDC power requirements, low module power consumption, and a module temperature rating of 70 DEGC (ambient) makes SD Series I/O the optimal choice for remote I/O applications. G3 coating makes SD Series I/O suitable for use in corrosive environments without requiring costly sealed cabinets or purging systems.

HR Series Integrating field devices seamlessly

  • Device integration capability In today’s power generation and process industries, only about 10% of field instruments have a digital pathway back to the control system. This reduces smart devices to underutilized assets where the existing diagnostic and connection information residing in the field instruments is not utilized in system operations.
  • The HR Series seamlessly integrates intelligent field devices and protocols using PROFIBUS DP, HART, and Modbus TCP and RTU. This provides access to a wide range of intelligent field devices from both ABB and other third-party vendors including transmitters, actuators, motor control centers (MCC) and flame scanners. Each device’s resident information can then be used in control strategies and higher level applications. In addition to producing tighter and more reliable process control solutions, these solutions lower installation costs by reducing wiring and system footprint
  • Intelligent Hart I/O HR Series controllers seamlessly integrate HART field devices through a variety of SD Series HART analog input and output modules. Besides the 4-20 mA primary variable, all secondary, tertiary and quaternary variables in a HART device can be accessed by Function Code control applications in the HR Series controller. Data can be calculated, used as part of a control strategy, or for display and alarm purposes at the system’s HMI console.
  • SD Series HART I/O features include:• Each channel’s secondary/tertiary/quaternary variables are available for use in control applications• Update rate of secondary/tertiary/quaternary variables is less than one second (AI05 and AO05)

HR Series Securing your control investments

Protecting the integrity and confidentiality 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. All Symphony Plus Ethernet-based devices – including HR Series products such as the BRC410, ICI800, and IEB800 – 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

Seamless upgrade path protects investments True to ABB’s ‘Evolution without obsolescence’ commitment, HR Series products provide backward compatibility to previous generation Network 90, INFI 90, INFI 90 Open and Harmony hardware and software, including support for existing function code executions, custom user programs, and all foreign device interfaces. ABB’s ‘Evolution without obsolescence’ ensures the protection of installed investments while providing the most predictable, cost-effective, risk-averse, and seamless way of introducing new functions and technology into a running plant.

Specifically, HR Series products:

Replace previous generation rack products on a form/fit/function basis 

• Preserve installed I/O through simultaneous connection to HR Series I/O, previous generation rack and block I/O, SD Series I/O and S800 I/O 

• Use the same field-proven INFI 90 function code algorithms as previous generation controllers (ie, MFCxx and MFPxx controllers) 

• Enhance existing Composer engineering tools with device management capabilities Further, HR Series and SD Series control networks, INFI-Net and PN800 (INFI-Net over Ethernet) respectively can be connected via a self-configuring INFI-Net to Ethernet bridge (IEB800 module). This allows for the easy expansion of existing INFI-Net communication networks with INFI-Net on Ethernet technology and SD Series DIN rail mounted products. Additionally, resident data from either network is available for use in control applications or for display in applications connected to the other.

Search for products

Back to Top
Product has been added to your cart