Symphony Plus

HR Series control and I/O

Symphony Plus
HR Series control and I/O

Achieving total plant automation with a single control and I/O

platform. 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 6,500
Symphony DCS installations in operation all over the world, more
than 4,500 of which are in power and water applications.

ABB’s industry leading ‘Evolution without obsolescence’

life cycle policy, the HR Series represents yet another step
in this contiguous evolution by delivering products that
are backward compatible with previous generation rack
products. 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
1 HR Series control and I/O and field devices via PROFIBUS, HART and Modbus TCP
communication protocols.
No other automation platform has such a long field record
and large global installed base as ABB’s Symphony Plus Together, HR Series control-based solutions lower system
family. For more than 30 years, the system has progressed life cycle costs and total cost of ownership by delivering the
through several evolutionary steps. From Network 90 in value needed to remain competitive in today’s challenging
1980, through INFI 90TM, INFI 90TM Open, and Symphony, business environments: increasing reliability, minimizing
to Symphony Plus, the system progression has followed equipment downtime, improving production yields, reducing
ABB’s long-held policy of ‘Evolution without obsolescence,’ maintenance and support costs, reusing physical and
ensuring that each new generation enhances its predecessor intellectual asset investments, and adding new products and
all the while maintaining full compatibility with them. features with ease.

Included in Symphony Plus is a comprehensive suite of

standards-based control and I/O hardware and software that
meet the requirements of total plant control. Within this suite,
S+ Control and I/Os expanded 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. Following

2 Symphony Plus
 2 S+ Engineering workstations S+ Operations workplaces
To Office Remote workplace

System Servers

HR Series
Communications
NIS21 IET800 NIS21 IET800

1 1
2 2
3 3

ICI800
4 A 1 4 A 1
5 2 5 2
3 CH 1 3 CH 1
6 6
7 4 7 4
8 5 8 5
6 6
1 7 1 7
8 8

Ethernet CIU
2 2
3 CH 0 3 CH 0
4 B 4 B
5 5
6 6
7 7
8 8

INFI-NET (redundant)

Process Control Unit (PCU) Process Control Unit (PCU)

HR Series HR Series
Communications Communications
NIS21/NPM22 NIS21/NPM22

Controlway Controlway

HR Series Controller HR Series Controller HR Series Controller HR Series Controller

BRC 300/400/410 BRC410 only BRC 300/400/410 BRC 300/400/410
BRC410 BRC410 BRC410 BRC410 BRC410 BRC410 BRC410 BRC410

1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 3
4 4 4 4 4 4 4 4
5 5 5 5 5 5 5 5
6 6 6 6 6 6 6 6
7 7 7 7 7 7 7 7
8 8 8 8 8 8 8 8

X-BUS Modbus TCP 100 MB Ethernet SD Series SD Series

HN800 PDP800 HART I/O HN800

HR Series I/O
with Turbine I/O

AC500 IED

SD Series I/O Third-party PLC’s Wireless

Gateways
HART Instruments
RLM01

To PROFIBUS PA
Devices

PROFIBUS DP/PA
Linking Device
HART Wireless
Transmitters

2 HR Series control communications functional architecture

Simple, scalable, seamless, The Harmony OPC server provides OPC connectivity between
and secure devices on the INFI-Net control network and OPC client
applications. In non-redundant and redundant configurations,
Overview it can be used in conjunction with ABB products such as
Symphony Plus’ HR Series provides a scalable solution that DataLink and popular non-ABB products such as OSIsoft PI
spans and integrates loop, unit, area, plant and interplant System and Aspen InfoPlus.21.
controls. Its system communication architecture is based on
a high-speed, high-throughput and highsecurity redundant HR Series ICI800 Ethernet CIU provides Ethernet-based
INFI-Net control network. The scalable network supports any communication between INFI-Net and the system’s
combination and quantity of control, engineering, operation engineering tools, HMI and the Harmony OPC server for
and application interface nodes. Each node on the control connection to third-party applications. As per NERC
network operates independently of other nodes. Acting as CIP-007-2 R5, SSL certifications authenticate its connections
its own communication manager, the system requires no with interface applications, further safeguarding the integrity
traffic directors. INFI-Net to INFI-Net communication modules and privacy of the ICI800 communication path.
support multi-network system topologies that provide a
system capacity of more than 62,000 nodes. Protecting the integrity and confidentiality of system data
The process and power industries face intensifying cyber
High system reliability and availability are key characteristics of security risks. In order to increase stability, security and
this mission-critical control network. Reliability is bolstered by robustness in its solutions, ABB has established an
redundant hardware and communication paths. Extensive use of independent Device Security Assurance Center (DSAC)
error checking and message acknowledgment assures accurate where cyber security robustness is tested as part of the
communication of critical process data. Patented exception product development process. The DSAC test facility uses
reporting technology optimizes the use of control network state-of-the-art open source, commercial and proprietary
bandwidth. The store and forward ring topology of INFI-Net, robustness and vulnerability analysis tools. All Symphony Plus
along with multi-master and multi-cast messaging features result Ethernet-based devices - including HR Series products such
in INFI-Net having an effective bandwidth that exceeds 300 as the BRC410, ICI800, and IEB800 - are continually tested
Mbaud. INFI-Net communications are also highly deterministic. at the DSAC center in different configurations and with an
explicit focus on operational performance. This ensures that
HR Series process control unit (PCUs) communication all Symphony Plus products are robust, secure and of the
products including the NIS21/NPM22 modules provide highest quality.
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 (INFINet over
Ethernet) Bridge modules are available.

Symphony Plus 3
Symphony Plus
HR Series control and I/O

3 4

3 HR Series scalable controllers BRC300, BRC400, and BRC410 | 4 S+ Engineering tool

Powerful process controllers High reliability and availability

HR Series controllers are the latest in a long line of field- With redundant controller, communication, I/O and power
proven multi-function rack process controllers, and include options, HR Series controller subsystems provide the
the BRC300, BRC400, and the BRC410 bridge controllers highest level of availability. Compliance with international
(figure 3). This scalable family of controllers, based on standards assures the highest level of reliability and quality
a 160 MHz, 32-bit Freescale Coldfire processor, can be needed to meet the most rigorous global specifications
adapted to a broad spectrum of applications and process and requirements. Backward compatibility through ABB’s
requirements. Configured by the S+ Engineering tool, the ‘Evolution without obsolescence’ life cycle program ensures
HR Series controllers feature an extensive library of more protection of installed investments while providing the most
than 150 predefined control algorithms or function codes cost-effective and seamless way of introducing new functions
(figure 4). These functions enable easy building block design and technology into a running plant. Together, the HR Series
of complex control strategies to fit any control application, provides users with fast, accurate, uninterrupted control
including continuous, sequential, batch and advanced control. of their process, resulting in greater production efficiency,
In addition to standard function blocks, HR Series controllers increased availability, and lower maintenance costs.
support C programming and batch functions.
Soft controller reduces commissioning times
HR Series controller features include: For new plant, upgrade, or expansion projects, HR Series
−− Enhanced controller reliability soft controllers can dramatically reduce commissioning and
− − More than 10x performance of previous generation start-up time and costs by permitting thorough testing and
controllers pre-tuning of control loops prior to its implementation in the
− − Simultaneous support for all HR Series I/O, SD Series I/O field. The HR Series soft controller uses the same control logic
and S800 I/O subsystems (ie, function block configuration) as the physical HR Series
−− Intelligent device integration via HART I/O and PROFIBUS controllers. Coupled with virtual communication devices, the
DP V0, V1, V2 entire HR Series control-based system can be implemented
−− Downloadable firmware within one or more PCs which allow for testing results made
− − BRC400 / BRC410 specific enhancements: in the virtual environment to be directly transferable to the
-- Extended user configuration memory (2 MB NVRAM) operating system environment.
- - Support for 30,000 function blocks
- - Flexible online configuration capability
- - 100 MB Ethernet port using the Modbus TCP protocol
(BRC410 only)

4 Symphony Plus
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5 HR Series Turbine control systems | 6 SD Series remote I/O

Comprehensive I/O product portfolio These unique modules make it possible to provide a fully
S+ I/O, available for local and remote mounting, provides integrated single-vendor solution for all aspects of turbine
a wide variety of input/output and signal conditioning automation. HR Series turbine modules are based on proven
capabilities. In combination, these rack and DIN I/O modules technology that controls steam turbines, gas turbines and
can be combined to form the optimal automation solution. hydroelectric turbines in more than 15 different countries
around the world, and have been tested, accepted, and used
HR Series controllers can communicate with up to 64 rack by several major global turbine manufacturers as part of their
I/O modules locally with additional remote rack I/O modules standard offering. The combination of HR Series controllers
connected via the RIO22 module. Use of rack sequence and turbine I/O results in a powerful governor control system
of events (SOE) I/O modules provides one millisecond solution.
timestamp resolution across the entire rack system.
SD Series remote I/O option
HR Series I/O module types include: HR Series remote I/O capabilities are further expanded
− − Analog input (ASI, FEC) with use of the SD Series DIN rail mounted I/O products.
− − Analog output (ASO) Compatible with all HR Series controllers, BRC300 / 400 /
− − Control input/output (CIS, QRS) 410, SD Series I/O connects directly to the controller via the
− − Digital input (DSI) HN800 I/O network without the need for an intermediate
− − Digital output (DSO) interface or gateway. SD Series I/O is configured using
−− Pulse input (DSM) standard function blocks and includes traditional analog and
− − SOE digital input (SED) digital I/O as well as integration with intelligent field devices
via PROFIBUS DP and HART. 24 VDC power requirements,
Turbine control low module power consumption, and a module temperature
In addition to traditional signal-type I/O, HR Series provides rating of 70 DEGC (ambient) makes SD Series I/O the optimal
for integrated turbine control via a series of turbine control- choice for remote I/O applications. G3 coating makes SD
specific modules, including: Series I/O suitable for use in corrosive environments without
− − Hydraulic servo module (HSS) requiring costly sealed cabinets or purging systems.
− − Turbine protection module (TPS)
− − Turbine auto synchronization module (TAS)
− − Condition monitoring module (CMM)

Symphony Plus 5
Symphony Plus
HR Series control and I/O

7 8

7 Remote field device management | 8 Proactive maintenance through system visibility of device performance

Device integration capability Data can be calculated, used as part of a control strategy, or
In today’s power generation and process industries, only for display and alarm purposes at the system’s HMI console.
about 10% of field instruments have a digital pathway HAI805 and HAO805 features include:
back to the control system. This reduces smart devices −− HAI805 (8 analog input channels)
to under-utilized assets where the existing diagnostic and − − HAO805 (8 analog output channels)
connection information residing in the field instruments −− Dedicated HART modem for each I/O channel
is not utilized in system operations. HR Series controllers − − Each channel’s secondary/tertiary/quaternary variables are
seamlessly integrate electrical systems, intelligent devices available for use in control applications
and fieldbus technology using standard protocols such as −− Update rate of secondary/tertiary/quaternary variables is
HART, PROFIBUS and Modbus TCP and RTU. This provides less than one second
access to a wide range of intelligent electronic devices from
ABB and other vendors including transmitters, actuators, PROFIBUS DP V0, V1, V2 can be seamlessly integrated using
motor control centers (MCC) and flame scanners, where the SD Series PDP800 module. This PROFIBUS interface
the resident information in each device can then be used in supports redundant and non-redundant connections:
control strategies and higher level applications. This reduces −− PROFIBUS DP V0, V1
installation costs, enhances maintenance capabilities and − − V2PROFIBUS PA devices through DP/PA linking device
provides a single window into the entire plant. − − 1ms time stamping of devices by PROFIBUS DP V2
−− Electric and fiber optic media for PROFIBUS DP link
Device integration details
HR Series controllers seamlessly integrate HART field devices All HR Series controllers support Modbus RTU with the
through SD Series HAI805 and HAO805 HART modules. BRC410 supporting Modbus TCP via its 100 MB Ethernet
Besides the 4-20 mA primary variable, all secondary, tertiary port. Modbus TCP interface features include:
and quaternary variables in a HART device can be accessed −− Bi-directional communication of up to 4,000 Modbus points
by Function Code control applications in the HR Series − − Availability of Modbus data as system points to be integra-
controller. Real-time use of this data is practical because of ted within the control application.
the modules’ individual HART modem per channel design. −− High availability and fault tolerance in a redundant pair
configuration
− − Ability to operate as client, server or server/client (concur-
rently) on the Modbus TCP network
− − Expanded number of concurrent connections

6 Symphony Plus
 9 10
Engineering and Operator Engineering and Operator
Workstations Workstations

INFI-Net to
Ethernet Bridge
10/100 MB PN800
Ethernet Plant Network

SD Series
HC800 CP800 HC800 CP800
Controllers

SPC700 SPC700

HPC800 SPC700

Harmony
PCU’s

9 S+ Engineering Field Device Management Tools | 10 INFI-Net to Ethernet bridge (IEB800)

Field device management way of introducing new functions and technology into a
HART and PROFIBUS devices are fully integrated with running plant.
Symphony Plus, yielding benefits far beyond reduced
footprint and cable costs. The S+ Engineering tool suite Specifically, HR Series communication, control, and I/O
supports configuration, commissioning and maintenance of products:
HART and PROFIBUS devices using device type manager −− Replace previous generation rack products on a form / fit /
(DTM) technology. For field devices that have conventional function basis
device description files (GSD), a basic PROFIBUS DTM is − − Preserve installed I/O through simultaneous connection to
available to allow standardized configuration. HART devices HR Series I/O, previous generation rack and block I/O, SD
are integrated, configured and parameterized via standard Series I/O and S800 I/O
HART protocol without the need for additional tools by using −− Use the same field-proven INFI 90 function code algorithms
a standard HART DTM. Individual DTMs can be accessed as previous generation controllers (ie, MFCxx and MFPxx,
from the engineering tool’s multiple data views, such as the controllers)
system or location overview and others. S+ Engineering − − Enhance existing Composer engineering tools with device
includes automatic net calculation and loading of process management capabilities
items by using the device specific channel configuration
generated from the DTM. Further, HR Series and SD Series control networks, INFI-Net
and PN800 (INFI-Net over Ethernet) respectively can be
Seamless upgrade path protects installed investments connected via a self-configuring INFI-Net to Ethernet bridge
True to ABB’s ‘Evolution without obsolescence’ policy, HR (IEB800 module). This allows for the easy expansion of
Series products provide backward compatibility to previous existing INFI-Net communication networks with INFI-Net
generation Network 90, INFI 90, INFI 90 Open, and Harmony on Ethernet technology and SD Series DIN rail mounted
hardware and software, including support for all existing products. Additionally, resident data from either network
function code executions, custom user programs, and all is available for use in control applications or for display in
foreign device interfaces. Staying true to this policy ensures applications connected to the other.
the protection of installed investments while providing the
most predictable, cost-effective, risk-averse, and seamless

Symphony Plus 7
Contact us

ABB Inc.

2VAA005093 EN A4 Power Generation 0915

© Copyright 2015 ABB
All rights reserved. Specifications subject to change without notice.
Power Generation Pictures, schematics, and other graphics contained herein are published
Wickliffe, Ohio, USA for illustration purposes only and do not represent product configurations
or functionality. User documentation accompanying the product is the
Phone: +1 440 585 3087 exclusive source for functionality descriptions.
Email: [email protected] Symphony is a registered trademark of ABB S.p.A.

ABB S.p.A.
Power Generation
Genoa, Italy
Phone: +39 01060731
Email: [email protected]

ABB Pte. Ltd.

Power Generation
Singapore
Phone: +65 6776 5711
Email: [email protected]

ABB AG
Power Generation
Mannheim, Germany
Phone: +49 621 381 3000
Email: [email protected]

www.abb.com/symphonyplus