The SPBRC410 is a high-performance, high-capacity process rack controller within the ABB Symphony Plus S+ Control series. It is designed to interface with Harmony block I/O, Harmony rack I/O, and S800 I/O in the Symphony Enterprise Management and Control System. The controller is fully compatible with the INFI 90 OPEN system in functionality, communication, and packaging, making it an ideal choice for modernizing and upgrading legacy INFI 90 systems.
As a standalone control device, the SPBRC410 can handle specific control and information processing applications in addition to complex tasks such as multi-loop analog control, sequential control, and batch control. Its powerful processing capability is sufficient to execute demanding process control applications that are data-intensive, program-intensive, or both. The controller supports multiple control languages, including C, Function Codes (FC), and Batch 90™.
The core design philosophy of the SPBRC410 is reliability and high performance. Its built-in redundancy circuitry supports controller redundancy configuration (requiring two controllers), enabling seamless switchover to the backup controller if the primary fails, significantly enhancing system availability. Furthermore, the controller integrates a 10/100 Mbps Ethernet interface supporting the Modbus TCP protocol, allowing communication with other Ethernet-enabled devices and facilitating system integration and remote access.
This product introduction provides a comprehensive overview of the SPBRC410 controller's features, hardware architecture, technical specifications, installation applications, and support services, offering detailed reference for user selection and application.
2. Key Product Features
Building upon all the features of INFI 90 OPEN multifunction processor controllers, the SPBRC410 adds several enhanced capabilities:
High-Performance Processing Core: Utilizes a 32-bit ColdFire microprocessor running at 160 MHz, coupled with a 32-bit wide memory design, delivering exceptional control performance capable of replacing traditional external mainframes or minicomputers.
Dual Communication Bus Support: Can simultaneously activate Hnet bus and I/O expander bus communication, enabling support for both Harmony block I/O and Harmony rack I/O controllers for flexible I/O architecture.
Integrated Ethernet Functionality: Features an onboard 10/100 Mbps Ethernet interface for communication with higher-level systems, other controllers, or intelligent devices via the Modbus TCP protocol. Requires the Harmony Gateway user interface software.
Robust Redundancy Function: Supports pairing with another BRC-410 or BRC-400 controller for redundancy. Real-time synchronization and bumpless transfer of control strategy and data are achieved via a front-panel redundancy cable.
Large Memory Configuration:
DRAM: 8 MB, providing ample temporary storage and system configuration copy space.
NVRAM: 2 MB, used to store the control system configuration (FC strategy), Batch 90, C, and UDF application files. Data is retained after power loss.
Flash ROM: 2 MB, stores the microprocessor operating system instructions and FC library.
High-Capacity Control Configuration: Capable of supporting configurations of up to 32,000 function blocks and 2,000 Batch 90, C program, and data files.
Online Diagnostics and Maintenance: Supports online Hnet communication bus diagnostics and fault isolation. Contains rich diagnostic routines accessible via dipswitches for convenient field maintenance.
Flexible Station Link: Supports connection to up to 128 IISAC01 analog control stations (40-kbaud) either via Hnet to Harmony control block I/O (CIO-100/110) or directly through a Termination Unit (TU).
Downloadable Firmware: Supports firmware updates via the S+ Engineering tool, facilitating feature upgrades and defect fixes.
Compatibility and Replaceability: Compatible with existing INFI 90 OPEN systems and provides a clear controller replacement compatibility matrix (see manual Table 1-1), simplifying system upgrades and spare part replacement.
3. Hardware Description
3.1 Faceplate
The controller faceplate measures 35.56 mm wide by 177.80 mm high. It is secured in the Module Mounting Unit (MMU) by two latching screws at the top and bottom. A transparent window reveals:
8 Red Group A LEDs: Display error codes, primary/backup status, and diagnostic information.
8 Green Group B LEDs: Display pass/fail counts in diagnostic mode.
1 Red/Green Status LED: Indicates controller operating state (Off, Solid Green, Flashing Green, Solid Red).
Stop/Reset Pushbutton: Accessed via a small hole, used for orderly stopping or resetting the controller.
The faceplate provides physical protection, locking, and promotes proper airflow within the enclosure.
3.2 Circuit Board and Core Components
The circuit board employs advanced surface-mount technology and integrates the following key components:
Microprocessor: 32-bit ColdFire, 160 MHz.
Memory: 2 MB Flash ROM, 8 MB DRAM, 2 MB NVRAM (for BRC-410).
Application-Specific Integrated Circuits (ASICs): Include Direct Memory Access (DMA) circuits, ABB custom bus circuits (for Controlway, Hnet, I/O expander bus), redundancy circuits, etc.
Communication Interfaces:
Controlway/Module bus interface.
Hnet interface (requires connection via a Processor Bus Adapter - PBA).
I/O expander bus interface.
Two auxiliary serial channels (RS-232-C/RS-485).
One IISAC01 station link.
One RJ-45 10/100 Mbps Ethernet port.
Battery: Provides backup power for the NVRAM to prevent configuration data loss.
3.3 Processor Bus Adapter (PBA)
The PBA (P/N: P-HC-BRC-PBA20000) is a critical component connecting the controller to the Harmony block I/O subsystem via Hnet. Its main functions include:
Providing Hnet physical layer functions, termination, and isolation relays.
Providing connection points for redundant Hnet buses (requires two PBAs).
Connecting via cable to the NTMP01 Termination Unit (TU) for access to two auxiliary serial ports and the station link.
Dimensions: 31.08 mm wide × 93.50 mm high × 130.50 mm long.
4. Application Areas
Leveraging its high performance, reliability, and flexible communication capabilities, the SPBRC410 controller is suitable for a wide range of demanding industrial automation and process control scenarios:
Power Generation: Auxiliary control systems (DCS), modulating control systems (MCS), and sequence control systems (SCS) in thermal, hydro, and nuclear power plants.
Oil, Gas & Chemicals: Continuous control, batch control, and safety interlock systems for refining, petrochemical, fertilizer, and chemical production processes.
Metals Industry: Automation control for steelmaking, continuous casting, and rolling processes.
Pulp & Paper: Distributed control systems for pulping and paper machines.
Water & Wastewater: Supervisory Control and Data Acquisition (SCADA) and process control for large water treatment and wastewater treatment plants.
Legacy System Modernization: Serves as an upgrade replacement controller for INFI 90 or Network 90 systems, protecting user's existing investment while enhancing system performance and supporting modern communication standards (e.g., Ethernet).
Its redundancy features are particularly suited for mission-critical process control applications requiring extremely high system availability to ensure continuous, uninterrupted production.
5. Support and Services
ABB provides comprehensive product support and services to ensure the stable operation of the SPBRC410 controller throughout its lifecycle:
Technical Assistance: ABB and its local sales or service offices provide assistance with product operation and repair.
Contract Services: Installation, repair, and maintenance contract services are available.
Spare Parts Supply: Recommended spare parts lists (including cables, termination units, batteries, etc.) are provided. Parts can be ordered through ABB sales offices. The manual includes detailed nomenclature and part numbers.
Training Services: ABB has modern training facilities and can provide on-site or plant-based training for customer personnel, covering system configuration, operation, and maintenance.
Documentation: Copies of this manual or other related instructions can be obtained from the nearest ABB sales office at a reasonable charge.
Software Tools: Configuration and programming require the S+ Engineering: Composer Harmony tool (version 5.1 or later). Firmware downloads and online configuration are also performed using this tool.
