Month: August 2025

MR Series controllers

Melody controllers are designed for maximum

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

additionally 6.000 analog and/or digital I/O

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. 

Each node on the control network operates

autonomously. Acting as its own communication

manager, the system requires no traffic directors.

The controller’s associated I/O modules are

connected using the high-speed redundant serial

field network or PROFIBUS DP (DPV1 as well as DPV2).

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

Scalable control stations

MR Series control stations are conveniently

set up according to project needs and are made

up of modular controllers and I/Os. Depending on

the scope of the automation task, the controller

is extended with I/O modules or communication interfaces.

The controllers are connected via the control

network to ensure reliable, high speed and

system wide real-time signal exchange with

other control stations, with S+ Operations,

with system level applications and with

S+ Engineering for Melody.

Each node on the control network operates

autonomously. Acting as its own communication

manager, the system requires no traffic directors.

The controller’s associated I/O modules are

connected using the high-speed redundant serial

field network or PROFIBUS DP (DPV1 as well as DPV2).

The control subsystem includes flexible

communication options to I/O and intelligent

field devices via system buses. HART as well as

PROFIBUS information, including configuration

and diagnostic information, is communicated

via the control network. This information is

available to system controllers and system

level applications such as asset optimization

and device management. The comprehensive

bus concept of the system controller allows

for the easy integration of HART, PROFIBUS,

Modbus RTU and TCP field devices as well as

of PROFIBUS and IEC 61850 electrical assets.

The MR Series functional capabilities are

summarized in figure 2.

Key features include:

• A wide range of I/O interfaces with optionally

integrated intrinsic safety (Ex i) design and

transmitter power supply. Features such as

time stamping with a 1 ms resolution,

monitoring, filtering and HART communication

are implemented directly in the I/O modules

• PROFIBUS interfaces provide connections to

ABB’s S800 and S900 remote I/O stations in

Ex and non-Ex versions, as well as other PROFIBUS devices

• IEC 61850 interface to intelligent electronic

devices (IEDs) for the integration of electrical subsystems

• Modbus RTU and TCP interfaces provide

connections to 3rd party devices

• The MR Series control network uses a

redundant, high-speed serial communication

network with inherent capability for remote

communication. The network is easy to handle,

without requiring routing configuration

• Flexible mounting alternatives such as cabinet,

DIN rail or 19” rack mounting. All three can be

combined in one project. This allows optimal

adaptation to all plant structures and supports

flexible upgrades of existing installations

• An unrivaled high packing density in the

system cabinets saves installation space

• Controller time synchronization based on

a time precision of 0.5 msec

• Sequence of events (SOE) time stamping

with a resolution of 1 ms is implemented

in the controller and local I/O module level

Overview

The MR Series includes a series of compact DIN

rail mounted controllers, a wide range of I/O

modules and modern, standardized fieldbus

interfaces. These modules offer all the

functions required for data acquisition and signal

conditioning, as well as powerful open loop

and closed loop control, sequence control and

monitoring. All process management

tasks are executed on the basis of integrated

complex control strategies. Without the need

for configuration, The MR Series inherent

redundancy design – including integrated

redundancy concepts for power supply,

communication and I/O – provides the highest

level of availability.

ABB Ability Symphony Plus MR Series (Melody

Rack) controllers, communication interfaces

and I/O modules meet the most challenging

requirements in each of these areas.

Thanks to their modular design, MR Series

controllers can be adapted to a wide variety

of plant types and sizes. Supported by an

efficient engineering workbench, MR Series

control based solutions contribute to a higher

return on assets by improving overall production

control, maximizing process availability, and minimizing maintenance.

Traditionally, production facilities maintained

many controller subsystems, each of which

had to meet specific plant needs. However,

as business goals have changed, using a scalable

controller platform that possesses multi

functional capabilities, adapts to changing

requirements, and maximizes openness and

availability, is paramount to success.

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

Continuous productivity improvements and increased profitability are the driving

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

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

Traditionally, production facilities maintained

many controller subsystems, each of which

had to meet specific plant needs. However,

as business goals have changed, using a scalable

controller platform that possesses multi

functional capabilities, adapts to changing

requirements, and maximizes openness and

availability, is paramount to success.

Thanks to their modular design, MR Series

controllers can be adapted to a wide variety

of plant types and sizes. Supported by an

efficient engineering workbench, MR Series

control based solutions contribute to a higher

return on assets by improving overall production

control, maximizing process availability, and minimizing maintenance.

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

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

communication between ModbusTCP devices and Symphony® Plus Controllers.

The Symphony® Plus Gateway Software (SGS) con

sists of two main components: Engineering Utilities

and Runtime software. The Engineering Utilities of

SGS provide a full function menu driven interface

that simplifies configuration for startup engineer

ing, commissioning and ongoing maintenance of the

ModbusTCP interface. With first time configura

tions, as only minimum parameters are required, en

gineering hours can be reduced by using the Quick

Config feature to generate the Mapping and Client

Definition tables. Individual interface points can

then be configured using the SGS menus.

The Runtime portion of SGS performs ModbusTCP

communications to other ABB equipment (e.g.

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

Ethernet network and remote wireless gateways.

The Symphony Plus Gateway Software is licensed

based on the number of function block outputs and

inputs the interface exchanges. 

Protecting the integrity and confi dentiality of system data

The process and power industries face intensifying cyber

security risks. In order to increase stability, security

and robustness in its solutions, ABB has established an

independent Device Security Assurance Center (DSAC)

where cyber security robustness is tested as part of the

product development process. The DSAC test facility uses

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

robustness and vulnerability analysis tools in its certification

testing. All Symphony Plus Ethernet-based devices –

including SD Series products such as the HPC800. and

CI850 – are continually tested at the DSAC center in different

configurations and with an explicit focus on operational

performance. This ensures that all Symphony Plus products

are robust, secure and of the highest quality.

The HPC800 controller uses ABB’s extensive set of

field-proven standard function code algorithms and

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

strategies. By using the same function code algorithms as

previous generation Harmony and INFI 90 rack controllers,

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

tested, field proven control application solutions.

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

accurate and uninterrupted control of their process.

S+ Operations, S+ Engineering and other applications

communicate with HPC800 controllers over the system’s

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

Fast Ethernet-based redundant communication Plant

Network (PN800). The network-centric architecture allows

for integration of field devices, process and electrical system

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

seamless and secure manner.