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BROCHURE

ABB Ability™ Symphony® Plus

MR Series (Melody Rack)
2 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K )

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Scalable, highly available, easy to
configure and efficient control system
Continuous productivity improvements and increased profitability are the driving
force behind today’s automation system. Furthermore, systems must support users
with the power to react quickly to ever rising demands from the markets they serve.

Traditionally, production facilities maintained Comprehensive I/O system

many controller subsystems, each of which A wide range of local and remote I/O is available
had to meet specific plant needs. However, with integrated intrinsic safety design and
as business goals have changed, using a scalable transmitter power supply options. Features
controller platform that possesses multi- such as sequence of events (SOE) time stamping
functional capabilities, adapts to changing (1 ms resolution), monitoring, filtering, as well
requirements, and maximizes openness and as HART, PROFIBUS, Modbus RTU and TCP
availability, is paramount to success. communication are supported with a wide range
of I/Os such as Melody Rack local I/O, ABB’s S800
ABB Ability Symphony Plus MR Series (Melody and S900, and other remote PROFIBUS I/Os.
Rack) controllers, communication interfaces
and I/O modules meet the most challenging Distributed capability
requirements in each of these areas. ABB’s S800 and S900 remote I/O and Melody
Rack local I/O are connected via high-speed serial
Thanks to their modular design, MR Series communication buses. Local I/O offers a high
controllers can be adapted to a wide variety packing density to reduce mounting space to
of plant types and sizes. Supported by an a minimum, whereas remote I/O fully supports
efficient engineering workbench, MR Series distributed system configurations.
control based solutions contribute to a higher
return on assets by improving overall production Efficient field device integration
control, maximizing process availability, and Standardized field device tool/device type
minimizing maintenance. manager (FDT/DTM) interfaces enable plug-
and-play integration of field devices.
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Features and benefits Easy to configure
Module configuration and service is executed
Flexible, cost-effective assembly using S+ Engineering for Melody and its unrivaled
Decentralized, DIN rail-mounted controller library of fully tested and field-proven powerful
assembly can be combined with local or function blocks.
remote I/Os.
Inherent redundancy design
System-integrated redundancy options for power
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01 MR Series controller supply, hardware and communication networks
PM877 provide the highest level of availability.

High performance modular network

Symphony Plus MR Series based control systems
uses a redundant, high-speed serial communi-
cation network with inherent capability for
remote communication. The network is
easy to expand without requiring routing
configuration.
 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K ) 3

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02 Functional overview of MR Series capabilities

— • The MR Series control network uses a

Overview redundant, high-speed serial communication
network with inherent capability for remote
The MR Series includes a series of compact DIN communication. The network is easy to handle,
rail mounted controllers, a wide range of I/O without requiring routing configuration
modules and modern, standardized fieldbus • Flexible mounting alternatives such as cabinet,
interfaces. These modules offer all the DIN rail or 19” rack mounting. All three can be
functions required for data acquisition and signal combined in one project. This allows optimal
conditioning, as well as powerful open loop adaptation to all plant structures and supports
and closed loop control, sequence control and flexible upgrades of existing installations
monitoring. All process management • An unrivaled high packing density in the
tasks are executed on the basis of integrated system cabinets saves installation space
complex control strategies. Without the need • Controller time synchronization based on
for configuration, The MR Series inherent a time precision of 0.5 msec
redundancy design – including integrated • Sequence of events (SOE) time stamping
redundancy concepts for power supply, with a resolution of 1 ms is implemented
communication and I/O – provides the highest in the controller and local I/O module level
level of availability.

The control subsystem includes flexible

Key features include:
communication options to I/O and intelligent
• A wide range of I/O interfaces with optionally
field devices via system buses. HART as well as
integrated intrinsic safety (Ex i) design and
PROFIBUS information, including configuration
transmitter power supply. Features such as
time stamping with a 1 ms resolution, and diagnostic information, is communicated
monitoring, filtering and HART communication via the control network. This information is
are implemented directly in the I/O modules available to system controllers and system
• PROFIBUS interfaces provide connections to level applications such as asset optimization
ABB’s S800 and S900 remote I/O stations in and device management. The comprehensive
Ex and non-Ex versions, as well as other bus concept of the system controller allows
PROFIBUS devices for the easy integration of HART, PROFIBUS,
• IEC 61850 interface to intelligent electronic Modbus RTU and TCP field devices as well as
devices (IEDs) for the integration of electrical of PROFIBUS and IEC 61850 electrical assets.
subsystems The MR Series functional capabilities are
• Modbus RTU and TCP interfaces provide summarized in figure 2.
connections to 3rd party devices
4 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K )

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Wide range of intelligent I/Os,
standard interfaces and libraries

— additionally 6,000 analog and/or digital I/O

03 MR Series control
station (DIN rail housing) points connected via PROFIBUS DP. In addition
to the standard tasks such as signal processing,
loop and logic control, the MR Series controller
also performs complex computations such as
sequential, batch and advanced controls.

Diagnostic routines periodically check the

hardware and firmware integrity. Any abnormal
conditions are automatically routed to the HMI
or other alarm or message collecting software.

The redundant design provides an automatic

one- to-one backup, thus ensuring high system
availability. If the primary controller is faulty, the
— hot standby controller, executing the same
Scalable control stations control strategy and process data, immediately
takes over control.
MR Series control stations are conveniently
set up according to project needs and are made MR Series controller key features include:
up of modular controllers and I/Os. Depending on • Large variety of powerful functions available
the scope of the automation task, the controller in tested libraries
is extended with I/O modules or communication • Easy configuration, service and commissioning
interfaces. with S+ Engineering
• Inherent redundancy without configuration/
The controllers are connected via the control wiring costs
network to ensure reliable, high speed and • Real-time multitasking operating system
system wide real-time signal exchange with • Up to 16 different cycle times
other control stations, with S+ Operations, • Comprehensive monitoring and diagnostic
with system level applications and with functions
S+ Engineering for Melody. • Interface for radio clock connection
• Bumpless downloadable firmware and
Each node on the control network operates application programs (no EPROMs)
autonomously. Acting as its own communication • Cyber security proven
manager, the system requires no traffic directors. • PM 877 without battery
The controller’s associated I/O modules are
connected using the high-speed redundant serial The range of available function blocks extends
field network or PROFIBUS DP (DPV1 as well as from simple control and individual drive functions
DPV2). to complex recipes based on S88 and NAMUR
using sequential function charts based on IEC
— 61131-3.
MR Series controllers
Function blocks may also be used to set up
customer-specific libraries in S+ Engineering
Melody controllers are designed for maximum
for Melody.
computing power and modular scalability.

Each controller can handle up to 2,000 analog

and/or digital I/O points from the local I/O, and
 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K ) 5

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04 MR Series process
interface modules
(from left to right:
CAO 10-P, CBI 20-P,
CBI21-P Ex, CAI10-P)

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defective modules without disconnecting the
MR Series process interface
field cable and without field interruption, thus
modules providing maximum availability.

The controller sets new standards for user Local I/O features
convenience with industrial process interface • A processor in each I/O module provides
modules. A large variety of I/O modules can advanced functions such as event detection
be combined to form an optimal automation and alarm generation, time stamping with 1 ms
solution. resolution and system diagnostics
• Downloadable firmware
Main components of the MR Series control • Local I/O modules provide integrated
station are the I/O modules and a high-speed, transmitter power supply, integrated intrinsic
redundant serial field network. Together they safety and HART communication
operate as a subsystem dedicated to the • HART variables can be used like the analog
controller. values within function plans
• Distribution of I/O modules reduces cable
Local I/O types and installation costs. A high-speed serial
The following local I/O types are available: communication bus (Fnet) that is designed
• Analog input (CAI) Ex and non-Ex for long distances combined with flexible
• Temperature input (CTI) cabinet mounting options enables both
• Analog output (CAO) Ex and non-Ex centralized and remote I/O locations
• Digital input (CBI) Ex and non-Ex • Simplified user configuration eliminates
• Digital output (CBO) the need for calibration or onboard jumper
• Control modules (CAC/CBC) settings
• Frequency input (CFI) • Maximum availability through inherent
• Serial communication interfaces (CCF) redundancy design including redundant
communications via Fnet and optionally
Redundant modular power supply is an option. redundant I/O modules
• All local I/O can be reconfigured and extended
All process signals are accessible from the front online with new I/O module while in full normal
panel. The field cables are connected to cable operation
termination units. For I/O redundancy, associated • Each input or output can go to a pre-defined
termination units are used. With these value in case of disturbed values or
termination units, it is possible to replace communication loss
6 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K )

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Wide range of intelligent I/Os,
standard interfaces and libraries

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05 Library of software
function modules
+-X÷ Limiter value Changeover Distributor
— sin cos tan
In log x ...
switch Trim, 1 to 1
Limiter
Split-range
06 I/o module Operation
MAX / MIN
automatic
Ex and non Ex <>= Integrator
AND 2 out of 3
OR Switchover
automatic Differentiatior
NOT Polygon curve
Dead time...
Dosing circuit Storage
Linearisation (Y, W, K)
Timer
Filtering ESF Controller
Non linear, PT1... P, PI, PID, Step
Counter Correction Sequence PI-Cascade
Operating hours, computing
Impulse,
Flow... PI
P
F PI
T IEC 1131-3

Calculating/Logic Measuring Open loop control Closed loop control

(96 modules) (109 modules) (26 modules) (40 modules)

Control modules PROFIBUS interface

The following control I/O modules are used for The MR Series controller integrates PROFIBUS-DP
closed loop and open loop control especially in communication, thus enabling system level
the power generation industry. engineering of devices and device communica-
tions. In addition to communication with the
The drive control (CBC 11-P) modules are used for: system engineering environment, fault and
• On/off actuators diagnostic messages are displayed at the
• Motor drives S+ Operations workplace or other ABB operator
• Solenoid valves console.
• Hardwired individual control stations
Features include:
The closed loop output (CAC 10-P) is used for: • PROFIBUS-DP (DPV0, DPV1 and DPV2)
• Continuous controller • Two PROFIBUS lines per controller
• PI step controller • Redundancy of each PROFIBUS line
• Current signal output to I/P converter for • Transfer rate adjustable in steps from
pneumatic actuators 9.6 kbit/s to 12 Mbit/s
• Three-position step controller with PI behavior • PROFIBUS-DP/PA converter
• Three-point switch as positioning circuit, or
• Hardwired individual control station Modbus RTU and TCP interface
A local interface card provides Modbus RTU
Both modules operate independently of the where the MR Series controller provides Modbus
controller. TCP on board.

Features of Modbus TCP:

• 128 Modbus TCP server per controller
• 16 Mobus TCP slaves per controller
 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K ) 7

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Network and communication

— Functional subdivision of the network is

9 MR Series controller
PM 877 effected in the control buses and operation
buses.

With respect to process visualization,

configuration and maintenance of the
system, all information is routed via the
operation bus.

This division of tasks permits control loops

to be closed via control buses and protective
signals to be transmitted. No influx of messages,
irrespective of their size, impedes the automation
of the process.
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Network and communication Without additional configuration, a signal
marshalling function automatically establishes
S+ Control: Melody control network is subdivided the bus interconnection of the conditioned
with respect to hierarchy and functionality. measured value (signal source) with all
subsequent processing functions (signal sinks)
The network is adapted to the plant size throughout the system.
according to a hierarchical grouping into
stations, plant areas and the entire For each established interconnection, the active
plant. Hierarchical grouping supports signal is cyclically and spontaneously transmitted
automatic data transfer between the individually from a signal source to a signal sink.
MR Series stations.

— The following variants are available:

10 MR Series DIN rail
housing with extension • Controllers housing: The housings are
mounted on standard rails.
The controllers are easily connected via
redundant interfaces. Each controller
provides two redundant PROFIBUS DP
interfaces, which may be used
independently
• Extension housing: In addition to the
redundant controller, up to eight local
I/O interfaces may be added to the
— extension housings. Furthermore, the
Decentralized assembly system redundant Fnet may be attached to the field
via repeaters (coaxial or fiber optic cable),
Common features include: in order to connect additional MR Series
• Modules with 7 height units controllers.
• Front panel width 8 or 16 rack units
• Light emitting diodes for fault signaling Thus, the housings may be used with the proven
• Selective module protection local I/O as cost-efficient remote I/O, without the
need for additional controllers.
The assembly system of the MR Series is
designed for decentralized applications.
8 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K )

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Evolution without obsolescence

Maestro 800xA Process Portal S+ Operations

HMI CS-O
Process Portal B (PPB) Process Portal B (PPB) 800xA Operations

Engineering CS-E Composer Composer S+ Engineering

CMC 50 S+ Control:
Controllers CS-C CMC 60 AC870P MR Series (PM877)
CMC 70

1980's – 1990's – 2000's – Today –

System Contronic 3 Contronic E Symphony Melody Symphony Plus
Contronic S

Protects capital and intellectual investments through seamless lifecycle management

A DCS is a significant capital investment. Plant A good example is the new controller PM 877
engineers add to this investment by enhancing • Replacement of former controllers fully
the control system components, tuning and supported by S+ Engineering for Melody
refining control application code and developing • Replacement of CMC 50 and CMC 60 incl.
knowledgeable staff who operate and maintain communication modules CCO 30 and CCO 30-2
the plant and control system. One of the results as well as CMC 70, PM 875(-x) and PM 876(-x)
of these initial investments is the creation of site • Existing I/O cards remain in place (375kBaud
specific control strategies and procedures that (option) and 2Mbit cards)
enable the plant to maintain high availability and • Value add
excellent operational performance. – Lower maintenance and support costs
because no battery is needed
Since its introduction, Melody Rack has followed – Higher performance compared with CMC 50
the ABB vision “evolution without obsolescence”. and CMC 60
New MR I/O cards, interfaces and controllers are – 50% less power consumption compared with
usually fit, form and functional compatible with PM 875(-x) and PM 876(-x)
their predecessor modules or ABB provides an – Cyber Security compliant (DSAC)
easy way of evolution. – Additional interfaces
- PROFIBUS DP
S+ Engineering for Melody fully supports the - Modbus TCP
replacement of former modules or the extension - IEC 61850
with new modules of a system with easy to use
replacement features. Our support team helps In summary, MR Series (Melody Rack) reduces
customers to evolve and extend their existing deployment costs and reduces total life cycle
systems. costs associated with system evolution. It
preserves decades of intellectual know-how
By adding new features to existing or new specific to the specific plant by allowing the
modules, the system can be updated and existing configuration to be re-used.
extended by new functionalities without
changing the existing system topology or
control logics.
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S+ Engineering for Melody

I/O Family Computer System server

SD Module I/O Family Computer System server

— Changes in the runtime environment are deployed

11 Building blocks
App icon - PowerGen
of an efficientApp icon - Oil & Gas App icon - Misc. smoothly and securely. The strict separation
engineering platform. of engineering and runtime enables offline
engineering, makes the engineering workflow
App icon - Service App icon - PowerGen Common
App user App icon - Misc.flexible, and integrates externally delivered
icon - Oil & Gas
interface lots without process interruption. During
commissioning, S+ Engineering’s multi-user and
PowerGen & Water Common remote access capabilities are critical to on-time
database delivery. Especially during hot commissioning and
project finalization, the ability of the engineer to
PowerGen & Water commission and de-bug from loop level down to
controller base functionality through a common
tool ensures timely and on-budget startup.

S+ S+ Engineering’s seamless tool integration,

powerful workflow automation and compre-
Security
management
Engineering hensive bulk import/export functions improve
overall engineering efficiency. Integrated
version control, version comparison and
rollback framework offer progress tracking and
significantly reduce commissioning time. Using
intelligent bulk interfaces, S+ Engineering allows
for full control of engineering data consistency
in each phase of the project life cycle.
Lifecycle
management

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Intuitive engineering interface –
Efficient
Reuse
engineering
for today and tomorrow
S+ Engineering’s comprehensive workbench
— provides a comprehensive range of engineering
Robust – efficient – comprehensive tools. These tools provide a visual environment
for easy configuration of control system
S+ Engineering applications use client/server strategies and global configuration databases.
technology to support multiple users operating Management of system libraries of reusable
in a networked environment. The configuration software components as well as integration
server hosts/manages the configuration and management of intelligent field devices
information. It can support up to ten is also readily accomplished through a single,
simultaneous client connections and provide unified platform.
users with shared access to a system’s
configuration information and real-time plant
data (via separate or combined communication
server). This configuration server stores the
data in a single database per system. Providing
a single source of truth for all data within the
system, S+ Engineering eliminates duplication
of data entry, simplifies database management
and automates configuration tasks. Information
can be imported and exported in many of the
commonly used file formats.
 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K ) 10

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MR Series
Field proven technology

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NAM
10 units

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SAM
10 units

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ABB Ability Symphony Plus
Simple, scalable, seamless, secure
 A B B A B I L I T Y S Y M P H O N Y P L U S M R S E R I E S ( M E LO DY R A C K ) 11

ABB has delivered or is delivering ABB Ability Symphony Plus solutions that
control more than 60,000 MW of new power generation. These solutions
range in complexity from the simplest to the most challenging of automation
requirements, and for power and water facilities of all sizes. Below is a sample
of the breadth of Symphony Plus MR Series based solutions selected for power
generation and water installations around the world.

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NEU
50 units

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CEU
860 units

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NAS
40 units

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More than 1,200
units worldwide
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MED
120 units

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IMA
40 units
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abb.com/symphonyplus
abb.com/powergeneration
abb.com/water

3BUS095394 REV A Power Generation & Water 0118

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Note:
We reserve the right to make technical changes to the products or modify the
contents of this document without prior notice. With regard to purchase orders,
the agreed particulars shall prevail. ABB does not assume any responsibility for
any errors or incomplete information in this document.

We reserve all rights to this document and the items and images it contains.
The reproduction, disclosure to third parties or the use of the content of
this document – including parts thereof – are prohibited without ABB’s prior
written permission.

Copyright© 2018 ABB

All rights reserved

ABB Ability is a trademark of ABB.

Symphony and Symphony Plus are registered or pending trademarks of ABB.
All rights to other trademarks reside with their respective owners.