Month: April 2025

Device model description
The Industrial Ethernet series MICE (Modular Industrial Communication Equipment) consists of basic switching modules and media modules.

These devices are manageable
The basic module contains all the functions of this industrial switch except for the interfaces to the LAN.
Pluggable media modules provide these interfaces.
They differ in the number of interfaces and the type of media connected to the network segments.
Expansion modules add 2 media module slots to the basic module.
For simplicity, basic switching modules with various plug-in media modules are referred to as MICE in this document.

MS20-… Device variants are modular switches with up to 8 ×, 16 ×, or 24 × 10/100 Mbit/s Ethernet ports. You can select the media for the ports via the media module.
MS30-… The device model is a modular switch with up to 8 ×, 16 ×, or 24 × 10/100 Mbit/s Ethernet ports. 24 × 10/100 Mbit/s Ethernet ports and up to 2 × additional Gigabit ports (1000 Mbit/s Ethernet) modular switch. (1000 Mbit/s Ethernet). You can select the media for the ports using the media module. The media module selects the media for the ports.
The basic module of the MS20/MS30 contains all functional units such as: switching functions, management functions, redundancy functions:
switching functions, management functions, redundancy functions, display controls, voltage connections, management connections, adjustable controls, and media module slots.

MS20
Optional additional number of ports, preferred number of 100 Mbit/s ports, temperature range, voltage range, certificates and software variants.
More port numbers, temperature range, voltage range, certificates and software variants can be selected.
MM22-T1T1T1 PoE Media Module
The MM22-T1T1T1 PoE Media Module (deep module design) supports Power over Ethernet (PoE) according to the IEEE 802.3af standard.
It allows, for example, the connection and remote provisioning of IP telephones (voice over IP), webcams, sensors, printer servers, and WLAN access points via 10BASE T/100BASE-TX. With PoE, these end devices can be powered by twisted pair cables.

The MM22-T1T1T1 Media Module has four 10BASE-T/100BASE-TX ports (RJ45 connections) for connecting network segments or PoE end devices (PDs, Powered Devices) up to Category 0 (or Category 3, respectively).
The current is supplied via a free pair (spare pair); there is no electrical insulation between the individual ports.
The Hirschmann MM20 – G2 t1 t1 sahh media converter is a key device for industrial networks from Hirschmann and plays an important role in enabling the conversion of data transfer between different network media and protocols. As an experienced manufacturer of solutions for industrial networks, Hirschmann has developed a number of features for this media converter.

I. Ports and Connectivity
MM20 – G2 t1 t1 sahh Media converters are usually equipped with several types of ports to suit the connectivity needs of different network devices. They may have Ethernet ports, which often support 10/100/1000Base – T adaptive rate, and can be easily connected to all kinds of devices that use Ethernet connection, such as computers, industrial controllers, servers and so on. The Ethernet ports can transmit data over distances of up to 100 metres when using standard Cat5e and above cables, allowing for short distance connections between devices in common industrial environments.

At the same time, the media converter is likely to be equipped with a fibre optic port, which supports both singlemode and multimode fibre optic connections. In the case of multimode fibre, the 50/125μm format allows for transmission distances of up to 550 metres at a data rate of 1000Mbps, while single-mode fibre and 1310nm wavelengths allow for distances of up to several kilometres.

This long-distance transmission capability enables high-speed and stable data transmission between devices in different areas in large factory parks, intelligent traffic systems, energy and power scenarios. For example, in an intelligent traffic system, widely distributed traffic cameras can be connected to the media converter via optical fibre, and the collected HD video data can be transmitted to a monitoring centre several kilometres away for processing and storage.

Second, the data conversion function
Signal conversion: One of the core functions of the media converter is to convert different network signals to each other. In industrial automation lines, where one end of the line uses fibre optics to transmit data and the other relies on Ethernet for communication, the MM20 – G2 t1 t1 sahh media converters precisely convert optical signals transmitted by fibre optics into electrical signals for Ethernet and vice versa, ensuring a smooth transfer of data between the different media.

For example, in a factory automation system, where the front-end sensors used to collect production data form a high-speed backbone network via optical fibre, and the back-end production management computer is connected using Ethernet, the media converter can establish a stable data transmission bridge between the two, ensuring that the production data can be transmitted to the management system in a timely and accurate manner, providing a basis for production decision-making.

Rate Adaptation: In the actual network environment, there may be differences in the transmission rate of different devices. mm20 – g2 t1 t1 sahh media converter is equipped with a rate adaptation function, which is able to automatically identify the transmission rate of the devices connected to it, and carry out matching and coordination.

Assuming that in the process of upgrading the network of an enterprise, the transmission rate of some old devices is 100Mbps, while the newly purchased high-performance devices can reach a rate of 1,000Mbps, through the media converter, it can make these devices with different rates work together in the same network, avoiding the problem of data transmission lagging or interruption due to the mismatch of rates, and guaranteeing the stability and compatibility of the network data transmission.

Network Extension and Security Enhancement
Extend transmission distance: Taking advantage of optical fibre transmission, MM20-G2 t1 t1 sahh media converter effectively solves the problem of limited transmission distance of Ethernet twisted-pair cable.
In some large industrial facilities, such as steel mills, petrochemical plants, etc., the plant area is vast and the distribution of equipment is relatively scattered.
The traditional Ethernet twisted pair connection is difficult to meet the demand for long-distance data transmission, but the media converter with optical fibre can transmit data to several kilometres away, greatly expanding the network coverage.
In the case of a steel mill, for example, the distance between the equipment in the production halls and the central control room on the other side of the mill is relatively long. With the media converter and fibre optics, the operating data of the production equipment can be transmitted stably to the central control room, making it easier for the operators to monitor and manage the production process in real time.

Network isolation and security enhancement: While converting signals, the MM20 – G2 t1 t1 sahh media converter also enables isolation between different networks, which is important for enhancing network security. It can effectively prevent unwanted network traffic from propagating between different network areas, reducing the scope of potential network attacks on the entire network system .

For example, in the power system, the networks of different functional areas in the substation are isolated by media converters, so that even if the network in a certain area is subjected to malicious attacks, the attacks can be prevented from spreading to other areas to the greatest extent possible, so as to ensure the stable operation of the power system network. In addition, some of the media converters may also have a simple protocol conversion function, so that network devices using different protocols can communicate, further improving the interoperability and overall security of the network.

Brand Technology Advantage: Hirschmann has rich experience in industrial networks, building the world’s first fibre-optic Ethernet in 1984, and launching the Ring Redundant Ethernet (HIPER – Ring) in 1990.

Its products are known for their reliability, and this media converter may use advanced technology to ensure stable and efficient data transmission, adapting to the complex needs of industrial environments.

Port Configuration and Connectivity: Common Hussmann media converters are equipped with a variety of ports, such as Ethernet ports and fibre optic ports. Ethernet ports may support 10/100/1000Base – T adaptive rate, can be easily connected to computers, industrial controllers and other devices, using standard Cat5e and above specification cable, the transmission distance up to 100 metres. Fibre optic ports, if available, may support single-mode and multi-mode fibre connection, multi-mode fibre in 50/125μm specifications, 1000Mbps transmission rate transmission distance of up to 550 meters; single-mode fibre using 1310nm wavelength, the transmission distance can be extended to several kilometres, to meet the needs of long distance, high bandwidth transmission.

Performance features: High-efficiency data conversion capability, can quickly and stably convert data between different network media. In the industrial automation production line, can ensure that the front-end sensor equipment through the optical fibre transmission of data, fast and accurate conversion into the back-end Ethernet equipment can receive the signal.

With high reliability and stability, the selection of high-quality industrial-grade electronic components, after rigorous screening and testing, can be such as the power industry substation of strong electromagnetic interference, metallurgical industry, high temperature furnace workshop, and other harsh industrial environments work stably.

Application Scenario: In the field of industrial automation, it can be used to connect the devices with different network media in the automated production line, such as connecting the high-speed sensors using optical fibre and the controller using Ethernet, to ensure the smooth transmission of data and improve the production efficiency.

In the intelligent traffic system, it can achieve a stable connection between traffic cameras (which may use optical fibre to transmit data) and the back-end data processing centre (which mostly uses Ethernet connection) to ensure the timely transmission and processing of traffic data. In the energy and power industry, it is suitable for the connection of all kinds of equipment in the substation, effectively converting data transmitted by different media to ensure the reliable operation of the power system.

Main functions of the media converter
Signal conversion: The ability to convert different types of network signals into each other, e.g. in industrial environments, optical signals transmitted by fibre optics are converted into Ethernet electrical signals and vice versa.

This enables devices that use fibre optics for long-distance, high-speed data transmission to communicate smoothly with devices that use Ethernet connections. For example, in a large factory campus, where production equipment forms a high-speed backbone network via optical fibre, and computers and other equipment in the office use Ethernet, the media converter can convert signals between the two to ensure that the data flow is transmitted.

Rate Adaptation: Support the connection between networks with different transmission rates. It can actively identify and match the rate of the connected devices, such as one end of the device’s transmission rate of 100Mbps, the other end of the 1000Mbps, the media converter can harmonise the data transmission between the two, to ensure the stability and compatibility of data transmission. In the process of upgrading the enterprise network, some of the old equipment rate is low, the new equipment rate is high, the media converter can make the different rates of equipment in the same network to work together.

Extend the transmission interval: Use the advantages of optical fibre transmission, useful to extend the network transmission interval. Single-mode optical fibre collaboration media converter, data transmission to several kilometres away, to solve the Ethernet twisted-pair transmission interval is limited (generally in the 100 m or so) of the problem. In ITS, traffic cameras are widely distributed, through the media converter and optical fibre, high-definition video data can be transmitted to the monitoring centre several kilometres away.

Network isolation and security enhancement: While converting signals, it can complete the isolation between different networks and enhance network security. It can block unnecessary network traffic and potential network infringement, to ensure the stable work of the network. In the power system, the media converter can isolate the network of different functional areas in the substation to avoid failure or infringement of discrete.

Protocol conversion (partially): In addition to the physical layer of the signal conversion, some media converters can also carry out a brief protocol conversion, so that different protocols of network equipment can communicate. For example, the Modbus TCP protocol network data into the PROFINET IO protocol recognised data format, to facilitate data interaction between devices of different protocols . In the industrial active production line, different brands and types of equipment may choose different protocols, this kind of media converter can complete the interconnection between the equipment.

ABB 3BUS094398 IndustrialIT System 800xA Harmony/INFI90 System

System Integration Overview: Industrial IT System 800xA integrates with Harmony/INFI90 and is designed to help organisations achieve Operational Excellence (OpX), such as increased Return on Net Assets (RONA) and reduced Total Cost of Ownership (TCO). It breaks through the limitations of traditional distributed control systems (DCS) and extends the scope of automation by providing personalised user workspaces, a wide range of control functions, equipment management, asset optimisation and information management. The integrated system is applicable to a wide range of industries, including power, chemical and pharmaceutical, and supports enterprises in different industries to respond to market changes and enhance competitiveness.

Harmony System Foundation and Development: Symphony Harmony is a proven process control system with a wide range of applications, and ABB continues to add traditional DCS functionality through its ‘Evolution through Enhancement’ strategy, including support for Rack I/O modules, Bridge Controllers, Bridge Controllers, and Rack I/O modules. ABB continues to add traditional DCS functionality through its ‘Evolution through Enhancement’ strategy, including upgrades to Rack I/O modules, Bridge Controllers, communication modules, Composer tools and operator consoles. For example, the redesigned Harmony Rack Module incorporates modern technology to maintain compatibility with older modules, and the Harmony Bridge Controller is continually being upgraded to support a wide range of functionality and ensure continuity of control logic configuration.

800xA Extensions to the Harmony System

Personalised User Workspace: Using the Aspect Object™ framework, the 800xA Process Portal collects information from multiple sources and transforms it into what the user needs, providing a personalised layout, intuitive and flexible navigation, integrated data to aid decision making, and a comprehensive range of operator functionality that can co-exist with existing consoles or provide an extended operating environment.

Control and I/O Expansion: The S800 I/O is designed in a modular small form factor, supports multiple signal types and event timestamping capabilities, and connects to the Harmony Bridge Controller via redundant communications configured by the Composer tool.The AC 800M controller and its I/O options are low-cost, high-quality, and efficient, and are available in a variety of configurations through the HPG800 and INFI90FCLib, among others. The AC 800M controller and its I/O options are low cost, high quality, and efficient, and can be integrated with Harmony systems through products such as the HPG800 and INFI90FCLib, protecting the user’s existing investment.

Device Management: The 800xA’s device management functionality connects HART devices via Fieldbus Management tools to support device parameterisation and remote monitoring, and interfaces with other fieldbuses via the AC 800M controller.

Asset Optimisation: HART/Fieldbus and advanced system information enables asset optimisation, including automatic monitoring of maintenance conditions, adoption of predictive maintenance strategies, reporting of asset health, optimisation of workflows to reduce repair time, and monitoring of the health of the Harmony control network.

Production Management: 800xA Production Management automates, monitors, controls, and documents production processes according to standards, with a Batch Management component that provides resource management, recipe management, and Batch Data Manager Tools for writing device stage logic.

Information Management: Collects, stores, and presents plant data into useful information, providing intuitive displays, automated system operations, flexible report generation and distribution, and secure access to data storage, integrating with Harmony to support corporate decision-making.

cpmPlus Smart Client: Provides Harmony users with a browser-based thin client that displays 800xA and third-party system information, eliminating duplicate engineering, simplifying display configuration, and eliminating the additional cost of tag counting.

ABB 3BUS092084R0001 IndustrialIT System 800xA Symphony Harmony

System core: ABB 3BUS092084R0001 refers to the Industrial IT System 800xA, an industrial information system. It combines advanced technologies to provide companies with a complete automation solution from the bottom of the machine to the top of the information management. Integration with SYMPHONY Harmony makes it even more powerful and adaptable to the needs of diverse and complex industries.
Key features

Personalised workspaces: 800xA Process Portal integrates multiple sources of data through the Aspect Object™ framework, allowing customised workspaces for maintenance, engineering, management and operations personnel. Easy to use web browser tools and right-click access to more detailed information help users make quick decisions.

Control functionality: The AC 800M control and I/O components are at the heart of all control and safety scenarios to meet plant automation needs. Integration into the Harmony system through the INFI90 function code base and communication with Harmony controllers improves control performance, and support for a wide range of interfaces, protocols, and fieldbuses facilitates the construction of reliable control solutions.

Device Management: The 800xA device management function runs through the entire lifecycle of the device, from design selection, implementation and commissioning, to connecting to HART devices during operation with Fieldbus Management tools, monitoring signals, variables and diagnostic information, detecting hidden problems in advance, reducing equipment failures and maintenance costs, and improving reliability.

Asset optimisation: Real-time monitoring of plant assets, automatic monitoring of key performance indicators, and automatic alarms for abnormalities. Long-term analysis of data, the use of predictive maintenance strategy, for large equipment to predict failures in advance, reasonable arrangements for maintenance, improve asset utilization, reduce operating costs.

Information Management: Collects, stores and visually presents data from all plant data sources, providing management with concise desktop displays and KPI scrolling displays, which can be supplemented with trend displays as needed. It supports automatic operation and flexible report generation to meet the needs of factories and regulatory documents, and provides data support for decision-making.

Application Industries
Power: Used in thermal, hydro and wind power generation scenarios. Taking thermal power generation as an example, equipment such as boilers and turbines can be monitored, and AC 800M can be used to analyse and process operating parameters to optimise the power generation process. Through asset optimisation and equipment management, equipment failures can be predicted in advance to reduce power generation losses.

Chemical industry: Due to the characteristics of chemical production, such as high temperature and high pressure, high automation is required. The system can accurately control the reaction parameters to improve product quality and yield. It manages a large number of equipments, ensures production safety and stability, and integrates data to help enterprises reduce costs and increase efficiency.

Pharmaceuticals: Meet the pharmaceutical industry’s strict requirements for quality control and compliance. Automatically control the parameters of all stages of pharmaceutical production to ensure quality. Through batch management to achieve full traceability, information management to help quality control and ensure drug safety.

Pulp and Paper: Connects pulp preparation and paper making equipment for automated production. AC 800M accurately controls key parameters of the paper machine to ensure paper quality. Asset optimisation monitoring equipment, information management to assist production decisions and reduce costs.

Water and wastewater treatment: S800 I/O connects water quality monitoring and treatment equipment, automatically adjusting operation status according to water quality. Asset optimisation and maintenance equipment and information management provide data to help optimise treatment processes and reduce operating costs.

ABB AC 800M 3BSE036352 Controller Hardware Product Guide System Version 5.1

Functional Description

Processor Unit: Divided into two types: PM8xx (except PM891), which consists of a processor unit and a TP830 baseboard with ports such as Ethernet and serial ports, and supports connection to the S800 I/O unit; and the PM891, which is a monolithic unit with stronger performance and unique redundant links and interfaces. Some processor units support redundant configurations with a switchover time of less than 10ms.

Communication: By adding communication units to the CEX bus, the number of ports and types of protocols can be expanded to support a variety of field buses and communication protocols, such as PROFIBUS DP, FOUNDATION Fieldbus, etc., to achieve connection with remote I/O, field instruments and other devices.

Battery Backup: There are two types of backup methods, internal battery (except PM891) and external battery (SB821, SB822), which are used to supply power to RAM and real-time clock in case of power failure.

Power supply: The power supply unit (SD83x) converts AC power to 24V DC power and supports redundant configurations. The processor unit has an internal power reserve to cope with short-term power failures. Power can also be supplied from an external 24V DC source, but voltage stability should be taken into account.

I/O system: support a variety of I/O system connection methods, such as S100 I/O, S800 I/O, S900 I/O, etc., through different communication interfaces and protocols.S800 I/O supports hot configuration, redundancy and HART routing and other functions.

Drive system: ABB standard and customised drives can be connected to the AC 800M in a variety of ways, such as optical ModuleBus, PROFIBUS DP, etc. The CI858 DriveBus interface can control up to 24 drives.

Software Components: The software used with the AC 800M controller is the control software, which includes hardware functions, firmware functions, and applications. Firmware needs to be loaded and applications downloaded through the Control Builder interface, and the firmware version of the CPU and other hardware units should be checked before installation.

Hardware components: Introduction to the hardware components, such as the composition and functions of the processor units (PM8xx, PM891) in different configurations; CEX bus interconnection unit (BC810) for improved communication reliability; characteristics and parameters of the various communication interfaces (PROFIBUS DP, RS-232C, etc.); types of battery back-up components and their use; power supply components (SD83x, SS832); and the power supply components (SD83x, SS832). SD83x, SS832) specifications and functions.

Mechanical Design: Examples of cabinet design are provided, showing how controllers, power supply units, etc. are configured and installed in the cabinet. It is emphasised that a certain amount of space needs to be reserved above and below the equipment in order to ensure ventilation and cooling.

Technical data and performance: Performance data of the processor units (PM8xx, PM891) are given, including CPU model, memory, communication speed, etc.; technical parameters and performance indexes of each communication interface unit, battery back-up unit, power supply components, etc.; certification and environmental adaptability of the products are also introduced.

Technical specification parameters

Processor Unit

CPU performance: PM851/PM851A/PM856/PM856A/PM860/PM860A/PM861 adopts MPC860 microprocessor, running frequency 48MHz; PM864/PM865 adopts MPC862 microprocessor, running frequency 96MHz; PM866 adopts MPC866 microprocessor, running frequency 133MHz; PM891 adopts MPC8270 microprocessor, running frequency 450MHz. The PM866 uses the MPC866 microprocessor running at 133MHz and the PM891 uses the MPC8270 microprocessor running at 450MHz. different processor units execute applications at different speeds, e.g., the PM860 executes twice as fast as the PM851/PM856.

Memory Configuration: PM851/PM856/PM860 are equipped with 2MB Flash PROM (for firmware storage) and 8MB SDRAM; PM851A has 2MB Flash PROM and 12MB SDRAM; PM856A/PM860A has 2MB Flash PROM and 16MB SDRAM, etc., while PM891 has 16MB Flash PROM and 256MB SDRAM with integrity check. The PM891 has 16MB of Flash PROM and 256MB of DDR2 SDRAM with integrity check.

Port parameters: Ethernet ports (CN1, CN2), only CN1 is available on some models (e.g. PM851/PM851A) at 10Mbit/s (half-duplex), the PM891’s CN1+CN2 ports support 10/100Mbit/s; Serial port COM3 (available on some Processor Units) is available at a selectable communication speed of 75 – 19200 baud; COM4 is used for connection to Control Builder, communication speed 9600 baud.

Other parameters: Electrical ModuleBus for 1 S800 I/O basic cluster, up to 12 S800 I/O units, 192 I/O signals in total (PM891 does not have this interface); Optical ModuleBus for 7 S800 I/O clusters (PM851/PM851A only 1), 12 units in each cluster; CEX bus for up to 12 communication interfaces (PM851/PM851A, PM851A, PM851A, PM851A, PM851A, PM851A, PM851A, PM851A, PM851A, PM851A, PM851A). Up to 12 communication interfaces can be connected to the CEX bus (up to 1 for PM851/PM851A).

Communication interface units

PROFIBUS DP interface (CI851, CI854/CI854A): Supports the PROFIBUS DP protocol, with communication speeds of 9.6, 19.2, 93.75, 187.5, 500, 1500, 3000, 6000, 12000 kbit/s and other options, and a bus capacity of up to 32 nodes per segment with galvanic isolation. The CI851 is a DP Master Class I and the CI854/CI854A supports DP-V0 and DP-V1 services.

RS-232C interface (CI853): Provides dual non-isolated RS-232C ports with Hayes modem signals and selectable communication speeds from 75 to 19200 baud for protocols such as Modbus, Siemens 3964R, etc.

Other interfaces: e.g. MasterBus 300 interface (CI855) for connecting the AC 800M to a MasterBus 300 network; S100 I/O interface (CI856) for connecting the S100 I/O, supporting up to 5 I/O racks with 20 I/O units each; FOUNDATION Fieldbus High Speed Ethernet interface (CI860) for connecting the AC 800M to a MasterBus 300 network. The FOUNDATION Fieldbus High Speed Ethernet interface (CI860) supports FF HSE and communication speed of 10/100Mbit/s, etc. Each interface has corresponding parameters in terms of communication speed, number of ports, electrical isolation, status indication, and so on.

Power Supply Unit

SD83x series power supply units: different input voltage ranges, such as SD831 supports AC 100 – 240V or DC 110 – 300V input, the output is 24V DC, and the rated output currents are of different specifications, such as 3A, 5A, 10A, 20A, etc. The power supply units are equipped with soft-start function, and the output voltage is 10V DC, and the output voltage is 10V DC. With soft start function, stable output voltage and LED to indicate whether the output voltage is normal or not.

Voting unit (SS823, SS832): SS823 is used for redundant power output combination, with double over-voltage protection circuits, which can detect short-circuit and open-circuit; SS832 can be directly used for loads below 10A, and two modules are needed for 20A loads, which have specific parameters in rated output current, voltage, power, and so on.

Battery Backup Components

Internal Battery: Located in the processor unit, some models (e.g. PM891) do not have an internal battery and are used to power the RAM and real-time clock in the event of a power failure.

External Battery (SB821, SB822): SB821 is a non-rechargeable Li-ion battery (3.6V 16Ah), the battery memory backup time varies with different processor units, e.g., at least 4 weeks for PM851/PM856/PM860; SB822 is a rechargeable Li-ion battery (3.75V 2.3Ah), which is used in the PM891 and other scenarios requiring long backup time. Other components

Other Components

CEX-Bus Interconnection Unit (BC810): Used to split the CEX bus into two independent segments to improve system availability, with status indicators, 24V DC power input, 50mA typical current consumption and 1.2W power loss.

SM810 and SM811: for intelligent monitoring of the controllers, with memory, status indicators and specific I/O interfaces, current consumption of 160 mA typical, power loss of 3.8 W, hot-plugging support (backup unit in redundant configuration).

Product Overview: Symphony Plus is a new generation of ABB’s distributed control system, which is widely used in power generation and water management. HR series control and I/O system meets the needs of full automation of the plant, protects the user’s upfront investment, and is characterised by high performance, high reliability and large capacity.

System Architecture: The communication architecture is based on high-speed, high-throughput and high-security redundant INFI-Net control network, supporting multi-node combinations, with high communication certainty and bandwidth of over 300 Mbaud. ICI800 Ethernet CIU of HR series realises Ethernet communication between INFI-Net and engineering tools, HMI, etc., and safeguards communication security through SSL certification.

Functional Features
Controllers: BRC300, BRC400, and BRC410 controllers are based on 160MHz, 32-bit processors with more than 150 predefined control algorithms, support for multiple programming languages and smart device integration, and BRC400/410 have enhanced features such as expanded memory and support for more functional blocks.

I/O Modules: Provide many types of I/O modules, support local and remote installation, HR series controllers can be connected to a large number of I/O modules, and SD series remote I/O is directly connected to HR series controllers, which is suitable for a variety of environments.

Device Integration: Integrate intelligent field devices via protocols such as PROFIBUS DP, HART, and Modbus TCP, and obtain device information for use in control strategies, reducing installation costs.
Engineering Tools: S+ Engineering is a comprehensive engineering toolset for the HR series, providing a unified workbench with multi-user, remote access, version control, and support for visual creation and editing of control logic, as well as the ability to manage field devices to improve engineering efficiency.

Application Cases
Power Generation Projects
Coal power generation: Upgrading and expansion of 4x730MW coal-fired power plant in Italy; phased upgrading of 565MW coal-fired power plant in the United States; construction of a new 2x600MW ultra-supercritical coal-fired power plant in China; phased upgrading of a 160MW coal-fired power plant in Austria; renovation and expansion of a 6x500MW coal-fired power plant in India; and a 3,600MW coal-fired power plant in South Africa.

Gas-fired power generation: Italy’s 836MW gas-fired combined cycle power plant phased upgrading; Mexico’s 235MW gas-fired power plant phased upgrading; Algeria’s new 340MW gas-fired open-cycle power plant; UAE’s 1027MW gas-fired combined cycle and seawater desalination plant phased upgrading; Indonesia’s new 120MW gas-fired combined cycle power plant; New Zealand’s 44MW gas-fired cogeneration plant New 120MW gas-fired combined cycle power plant in Indonesia; 44MW gas-fired cogeneration power plant in New Zealand; 215MW diesel power project in the Philippines.

Other energy power generation projects: 87MW waste-to-energy incineration power project in the United States; 200MW waste-to-energy incineration power project in Italy; 320MW dual-fuel cycle power plant upgrading in Mexico; 2x58MW oil-fired power generation project in the United States; a new 4x150MW gas-fired simple-cycle power plant in Egypt; and the upgrading and expansion of a 400MW coal-fired power plant in Bangladesh, among others.
Water treatment projects: new district heating plant project in China; upgrading and expansion of wastewater treatment plant in Hong Kong.

Functionality Changes
Harmony Gateway software version 6.0 adds the following functionality:

• Support for up to eight (8) Modbus TCP Servers and one hundred twenty eight (128) Clients (applicable for the HPC800 module only).
• Support for the Harmony Process Controller (HPC800) Module.
• Support for 10,000 points (applicable to the HPC800 module only).
• On/Off Client connection scan for pre-configuring at the unit level within a Client connection and adding units during
  commissioning. This functionality permits a function block to turn off a client connection from sending a Modbus command to a unit.
• Triggered Write (FNC 5, 6, 15, 16) allows the function block to control precisely when the write command is sent.
• Optionally each command (all FNC’s) can have a separate enable block if the Trigger option is not used.
• A Client Connection Status Page tab has been added to the Monitor Link Status Window to monitor the status of the 128 available clients.
• Client Heartbeat Timeouts: The Heartbeat Parameter Table enables an individual unit timeout and a quality
  override block for each Heartbeat to be configured. There can be 256 individual Heartbeat Timeouts. Individually
  configured Override Blocks replace the global override feature previously defined at block 31022.
  NOTE: Configurations that previously used block 31022 must reconfigure the Heartbeat using the Heartbeat
  Parameter Table.
• The status of each Modbus command can be monitored if required. If the redundancy option is selected, then the
  status output contains the Modbus Reply status for both the primary and secondary TCP ports. A Composer macro “HGS_CMD_STATUS” can be used to separate the status for each port.

HGS Compatibility
Harmony Gateway Software version 6.0 can co-exist on the same server machine based on computer capacity with the following versions:

• HGS 5.1
• HGS 5.1 SP1
• HGS 5.1 SP2
• GPI 4.0
• GPI 4.0 RU1

specificities
Powerful connection support: Supporting up to 8 Modbus TCP servers and 128 clients, this large-scale connectivity enables HPC800 to communicate with many external devices and meet the needs of multi-device interaction in complex industrial environments, such as in large-scale factories, where a large number of sensors, actuators, and other devices can be connected at the same time to realise comprehensive data acquisition and transmission of control commands. Only for HPC800 module, highlighting its unique advantages in connection, which are not available in other modules, in the construction of specific industrial systems, HPC800 can assume the role of the core connection hub, providing a guarantee for the stable operation of the entire system.

High point processing capacity: Supporting 10,000 points means that it can process a large amount of process data and accurately monitor and control many parameters in industrial production. In the process of chemical production, it can monitor and control various parameters such as temperature, pressure, flow rate, etc. in real time to ensure the safety and stability of the production process.

Flexible Connection Configuration: The On/Off Client connection scanning function allows you to pre-configure units at the unit level and add units during commissioning. Through this function, you can flexibly turn on or off the client connection according to the actual demand, avoiding unnecessary waste of communication resources, and in the maintenance or debugging phase of certain equipment, you can temporarily turn off its connection and reconnect it after the equipment is normal.

Allowing the function block to close the client connection to send Modbus commands to the unit provides the possibility of fine control of the system, and the operator can dynamically adjust the communication strategy according to the changes in the production process.

Compact HMI 800: is een pc-gebaseerd SCADA-systeem gebaseerd op ABB’s System 800xA DCS-technologie, met gebruiksvriendelijke, krachtige grafische weergave, ondersteuning voor een groot aantal Windows-systemen en de mogelijkheid om verbinding te maken met een groot aantal controllers. Omvat producten zoals het basissysteem (met media en licenties), signaaltoevoegingsopties, snapshotrapportage, HMI-client, kantoorwerkruimte en dongle, met functies en configuraties die variëren van versie tot versie.

Panel 800 versie 6.2: is een gebruiksvriendelijk bedieningspaneel dat verkrijgbaar is in standaard, zwarte en robuuste versies met een groot aantal afmetingen en functies. De configuratie wordt uitgevoerd via Panel Builder 800, met het bijbehorende lifecycle managementprogramma, en er is een breed scala aan accessoires beschikbaar, zoals communicatie-interfaces, aansluitkabels, frontbeschermers, enz.

AC 800M Processor Unit: Er zijn verschillende CPU-modules beschikbaar, variërend in verwerkingskracht, geheugen, redundantieondersteuning, enz. Er zijn diverse communicatie- en I/O-modules beschikbaar en diverse communicatieprotocollen worden ondersteund. Selectiegidsen voor voeding en stemeenheden zijn beschikbaar, evenals bijbehorende gebruikersdocumentatie, softwaretools en

ondersteuningsprocedures voor de levenscyclus.
S800 I/O-module: Een uitgebreid modulair proces I/O-systeem dat communiceert met een groot aantal controllers, de bedradingskosten verlaagt en hot-swapping ondersteunt. Het bevat een verscheidenheid aan digitale, analoge en pulstellende modules, met verschillende communicatie-interfaces en moduleafsluitingseenheden. Sommige modules ondersteunen redundantie en intrinsieke veiligheid, voldoen aan diverse normen en worden geleverd met uitgebreide garantieservices.

NE800 Netwerkcomponenten: Omvat netwerkschakelaars, routers/firewalls, etc., met verschillende beheermethoden, afmetingen, gewichten, beschermingsniveaus en elektrische parameters. Met verschillende beheermethoden, afmetingen, gewicht, beschermingsniveaus en elektrische parameters. Ondersteunt een breed scala aan Ethernet-interfaces en netwerkredundantie, sommige producten bieden digitale I/O- en console-interfaces, met bijbehorende netwerkaccessoires en modulaire transceivers.

Compact HMI 800 Specificaties en Prestatievoordelen
Specificatie: Windows-gebaseerd, ondersteunt Windows 8.1, Windows 10 2016 LTSB, Windows Server 2012 R2 en Windows Server 2016. Er zijn verschillende versies, zoals 6.0.3.2, 6.0.3 Extended, enz., en elke versie bevat verschillende basissystemen, aantal signalen, HMI-clientconfiguratieopties en signaaltellingen variërend van 50 tot 10000, Er zijn verschillende versies zoals 6.0.3.2, 6.0.3 Extended, enz. Elke versie bevat verschillende configuratieopties voor het basissysteem, aantal signalen, HMI-clients, enz. en het aantal signalen varieert van 50 tot 10.000.

Prestatievoordelen: Gebaseerd op ABB’s System 800xA DCS-technologie, met een hoogwaardige vooraf gebouwde, herbruikbare grafische bibliotheek voor eenvoudige bediening. Dankzij de directe aansluiting op een groot aantal OPC-compatibele controllers en ingebouwde regelaars voor aansluiting op grote PLC’s is het systeem geschikt voor gebruik in een groot aantal industrieën en kan het worden opgeschaald van een enkel operatorwerkstation tot grootschalige toepassingen.
Panel 800 versie 6.2 Specificaties en prestatievoordelen

Specificaties: Standaard, zwarte en robuuste panelen zijn verkrijgbaar. Standaard paneelformaten variëren van 7“ tot 21,5” met verschillende resoluties, ARM9 (1 GHz) processors en geheugen van 512 MB tot 2,0 GB. Er zijn verschillende goedkeuringen beschikbaar, zoals CE, FCC, KCC, enz., en de bedrijfstemperaturen variëren van -10°C tot +60°C (0°C tot +50°C in sommige gevallen).

Prestatievoordeel: Gebruiksvriendelijk en intuïtief ontwerp, dat een slank en ruimtebesparend ontwerp combineert met een schat aan geavanceerde functies. Stabiele werking in veeleisende omgevingen, zoals zwaar buitengebruik, explosiegevaarlijke omgevingen en cockpits op zee.

Specificaties en prestatievoordelen van AC 800M processorunit
Specificaties: Diverse CPU-modules met klokfrequenties van 24 MHz tot 450 MHz, geheugen van 8 MB tot 256 MB en gedeeltelijke ondersteuning voor CPU-redundantie, met omschakeltijden van slechts 10 ms. Er zijn diverse communicatie-interfaces beschikbaar die PROFIBUS DP, PROFINET IO en andere protocollen met verschillende transmissiesnelheden ondersteunen.

Prestatievoordelen: sterke verwerkingscapaciteit, kan voldoen aan verschillende industriële besturingsvereisten. Ondersteunt verschillende communicatieprotocollen en kan communiceren met gegevens van verschillende apparaten en systemen. Sommige modules ondersteunen een redundantiefunctie, wat de betrouwbaarheid en stabiliteit van het systeem verbetert.

Specificaties en prestatievoordelen van de S800 I/O-module
Specificaties: Bevat verschillende typen modules, zoals digitale in-/uitgang, analoge in-/uitgang, pulstelling en andere modules. Het spanningsbereik van digitale ingangsmodules is van 24 V DC tot 230 V AC, analoge ingangsmodules ondersteunen diverse signaaltypen en nauwkeurigheden en uitgangsmodules hebben verschillende belastingscapaciteiten. Er is een breed scala aan communicatie-interfaces beschikbaar, met ondersteuning voor protocollen zoals PROFIBUS – DPV1.

Voordelen: zeer modulaire en flexibele configuratie, geschikte modules kunnen worden geselecteerd op basis van verschillende toepassingsvereisten. Ondersteunt hot-swapping, online herconfiguratie en redundantie om stilstand te verminderen. Uitgerust met HART straight-through functie, kan communiceren met intelligente apparaten en wordt wereldwijd veel gebruikt in de industrie.

Specificaties en prestatievoordelen van NE800 netwerkcomponenten
Specificaties: Netwerkswitches en routers/firewalls zijn verkrijgbaar in verschillende modellen, zoals NE801, NE802 enzovoort. Er zijn licht beheerde en beheerbare types met verschillende afmetingen, gewicht, beschermingsniveau, werkspanning, nominale stroom en andere parameters. Er zijn verschillende soorten Ethernet-interfaces die snelheden ondersteunen zoals 10/100 Mbit/s, 10/100/1000 Mbit/s, etc.

Sommige hebben digitale I/O en console-interfaces.
Prestatievoordelen: Netwerkredundantiefuncties, zoals Fast Network Topology Reconfiguration (FRNT) en Redundant Network Routing Protocol (RNRP), verbeteren de betrouwbaarheid van het netwerk. Sommige producten ondersteunen verschillende Ethernet-interfacesnelheden om te voldoen aan verschillende netwerkvereisten, zijn gecertificeerd door classificatiebureaus en zijn geschikt voor verschillende industriële omgevingen.

Performance Advantages
High-speed communication: PROFIBUS DP supports a transmission rate of up to 12 Mbit/s, which can quickly realise data interaction between the controller and decentralised peripheral devices, meet the strict requirements for real-time in industrial sites, and transmit data in time to ensure efficient system operation in production scenarios that require high response speed.

Powerful diagnostic function: the slave can provide rich diagnostic data, covering channels, modules and a variety of error messages related to the slave. The system can effectively process and map these data, and clearly present errors or warnings in Control Builder M, making it convenient for engineers to quickly locate and solve problems, and improving system maintenance efficiency.

Highly redundant design: Supports a variety of redundancy methods, including master unit, slave unit and line redundancy. Different types of redundancy can be configured independently or in combination. For example, in critical production processes, redundancy can ensure stable operation of the system in the event of partial equipment failure, which greatly improves the reliability and availability of the system.

Flexible Configuration Capability: With Control Builder M, it is easy to insert and manage master and slave units, and to set the parameters of the equipment flexibly. It also supports online change of part of the configuration without interrupting the system operation, which improves the maintainability and adaptability of the system and facilitates timely adjustment of the system configuration according to the production demand.

Specification
Hardware related: Master unit CI854/CI854A node address range is 1 – 125; baud rates of 9.6, 19.2, 93.75, 187.5, 500, 1500, 3000, 6000 and 12000 kbit/s are supported; parameters such as slot time, min. station delay, max. station delay, and so on, have corresponding ranges of values, and some of the parameters will be automatically calculated according to the configuration. Some of the parameters are calculated automatically according to the configuration.

Data transmission: In cyclic data communication between master and slave units, the master unit can write up to 244 bytes of output data and read up to 244 bytes of input data to the slave unit each time; in acyclic data communication, the maximum data block size is 244 bytes, and the transmission priority is lower than that of cyclic data communication.

Time parameters: watchdog time should be set reasonably according to the baud rate and system reaction time; target rotation time TTR is used to plan the network cycle time, which needs to be considered for all kinds of communication requirements in the system; quiet time, setup time and other parameters have their own roles and ranges of values, which work together to ensure the stability and accuracy of data transmission.

PROFIBUS Technical Basics
Overview of the protocol: PROFIBUS is the fieldbus standard for industrial automation and consists of two protocols, DP and PA. DP is used for communication between controllers and decentralised peripheral devices and has a high transmission rate, while PA is specially designed for the process industry and supports bus power supply and intrinsic safety, has a transmission rate of 31.25 kbit/s, and can be integrated into the DP network by means of a link device.

Technical terminology: ISO/OSI reference model, bus-specific access control and addressing. Device addresses are 7-bit, range 0 – 127, some addresses have special uses, functions vary between protocols, AC 800M/CI854 (A) supports basic and extended functions.

Transmission technology: RS485 is widely used and supports a variety of rates, the cable type affects the transmission distance and performance; RS485 – IS is used in intrinsically safe areas; MBP adopts Manchester encoding and supports bus power supply and intrinsic safety; fibre-optic transmission is suitable for strong electromagnetic interference or long-distance scenarios, and there are a variety of cable types to choose from.

Fieldbus Topology
Common topologies: point-to-point, line, line with branch, tree, star and ring topologies. Each topology has different characteristics and is applicable to different scenarios, e.g. point-to-point is used for specific sub-segment connections, ring topology has high network security.

RS485 (PROFIBUS DP) topology: the bus length is related to the transmission rate, correct terminal matching is required, 9-pin D-Sub connectors are used, attention is paid to the shielding and data line connection, avoiding the use of passive branch cables, the maximum number of devices to be connected to the network segment is 32, which can be extended by repeaters.

MBP (PROFIBUS PA) topology: Tree or line structure, fixed transmission rate, cable length subject to a variety of factors, intrinsically safe installation needs to follow the FISCO model, both ends of the bus need to be correctly terminated to match the length of the branch line has a limit.

Fibre optic topology: bus, star or ring network can be constructed, with various transmission rates, anti-interference, long distance transmission and other advantages, through the optical link module to achieve the electrical and optical network conversion, different topologies have different settings and requirements.

System redundancy design
Redundancy concept: covers controller, line and slave redundancy. Controller redundancy is realised by the CI854A module, which is automatically activated in the event of a failure; line redundancy requires redundant transmission media and bus connections, which are supported by the CI854A, and single-interface slaves can be connected to the redundant line with the help of the RLM 01 module; slave redundancy consists of redundant links/gateways and optional I/O modules.

RLM 01 module: Converts redundant and non-redundant PROFIBUS lines, supports a wide range of rates, communication monitoring, relaying, etc. Attention should be paid to port connections, terminating resistor settings and transmission rate selection during installation.
PROFIBUS device commissioning

Cable Installation: Electrical data cable installation should avoid damage and follow the operation specification; fibre optic cable installation should pay attention to cleanliness, avoiding stress, and selecting appropriate cables for different scenarios; PROFIBUS DP installation has special grounding and shielding requirements, and devices such as the CI854 (A), RLM 01, and LD 800P have specific steps and

precautions for installation.
Network Testing and Problem Solving: Test bus cables and connectors after installation to troubleshoot common errors. The document provides solutions and recommendations for common installation problems, such as address conflicts and polarity errors, as well as ways to obtain more information and purchase related components.

Technical Characteristics
Transmission technology: MBP (Manchester Coded, Bus Powered) transmission technology, i.e. Manchester Coded and Bus Powered. The transmission rate is fixed at 31.25 Kbit/s. This synchronised transmission allows intrinsically safe communication in potentially explosive areas. Shielded twisted-pair cables are used as the transmission medium. The cables have specific parameters, such as a conductor cross-section of 0.8 mm², a wave impedance of 100 Ω ± 20%, etc., and the cable colours are differentiated in different areas, black in non-hazardous areas and blue in hazardous areas.

Network structure: Supports tree or line structure, or a combination of both. In the tree structure, the devices are connected to the trunk cable through branch lines, similar to the traditional on-site installation method; in the line structure, the devices are connected to the trunk cable sequentially. These two structures facilitate the flexible construction of the network according to the layout of the field equipment, but in the calculation of the total length of the bus, you need to take into account the maximum permissible length of the branch line.

Intrinsically safe: The design is based on the FISCO (Fieldbus Intrinsically Safe Concept) model, which is based on a number of prerequisites to ensure intrinsic safety. For example, only one active source (usually a link device) is allowed on the bus segment, the other components are passive current absorbers; the basic current consumption of the bus station is at least 10 mA; specific voltage, current and power relationships are met, as well as capacitance and inductance limits.

Device connection and power supply: PROFIBUS PA devices are mostly connected to the network by means of multibarries or T-junctions; the branch lines can be connected directly to the connector blocks inside the device, or M12 plugs are used. The power supply of the devices is realised via the bus. In intrinsically safe applications, there are limits on the supply voltage and current, e.g. 100mA in hazardous areas and 400mA in non-hazardous areas.

Data communication: The format of the data telegrams is similar to asynchronous RS-485 transmission, but the transmission of the MBP segments is bit-synchronous and the telegrams are supplemented with a leading code and start and end delimiters. Data security is achieved by parity and block checking with a Hamming distance HD = 4 and up to three errors can be detected.

Network limitations: up to 32 devices per network segment, but the actual number is limited by the type of protection and bus power. The maximum line length of the network can be up to 1900 m in non-intrinsically safe areas and 1000 m in intrinsically safe areas, depending on the power consumption of the devices and the type of cable selected.