Overview
The BRC300 (P-HC-BRC-30000000) is a high-performance, rack-mounted process controller designed
for ABB’s Symphony™ Enterprise Management and Control System. It serves as a core control unit
that integrates with both Harmony block I/O, Harmony rack I/O, and S800 I/O, while maintaining full
functional, communication, and packaging compatibility with the legacy INFI 90® OPEN system.
Physically, the controller occupies one slot in a standard Module Mounting Unit (MMU), featuring a
35.56 mm (1.4 in) wide × 177.80 mm (7.0 in) high faceplate with latching screws for secure mounting.
Its circuit board uses surface-mount technology, housing a 32-bit Coldfire microprocessor (160 MHz),
8 MB SDRAM, 2 MB flash ROM, and 512 KB NVRAM (with backup battery for configuration retention).
A front-panel window provides visibility to 17 LEDs (1 red/green status LED, 8 red Group A LEDs, 8
green Group B LEDs) for operational feedback, plus a stop/reset pushbutton for orderly shutdown.
Key design highlights include redundancy support (two controllers required for hot standby),
enhanced EMI protection, and simultaneous communication via Hnet (for block I/O) and I/O Expander
Bus (for rack I/O). It operates in harsh industrial environments (0–70°C ambient temperature, 0–95%
non-condensing humidity) and is certified to CSA C22.2 No. 1010.1-92 (non-hazardous locations) and
FM Class I, Division 2 (Groups A–D), with CE compliance for EMC (EN 50081-2/EN 50082-2) and Low
Voltage (EN 61010-1) directives.
The BRC300 requires a PBA-200 Processor Bus Adapter for Hnet communication, serial ports, and
IISAC01 analog control station links. It can directly replace legacy BRC-100 controllers (with
exceptions for Batch 90™, BASIC, or simulation applications) but is not compatible with BRC-200
models. Its high processing capacity enables data-intensive tasks like supervisory control,
optimization, and process modeling—eliminating the need for external mainframes in most industrial
scenarios.
Core Functionality
2.1 High-Speed Process Control & I/O Integration
The BRC300’s primary role is to execute control strategies, acquire process data, and drive field devices, with key capabilities:
Multi-I/O Bus Support: Simultaneously communicates with Harmony block I/O (via Hnet) and Harmony rack I/O (via I/O Expander Bus), enabling mixed I/O architectures. Hnet operates at 16-bit width with shared SDRAM (1 MB memory space) for block I/O data, while the 8-bit parallel I/O Expander Bus supports up to 64 low-power rack I/O devices (e.g., IMDSO14 digital output modules).
Control Language Flexibility: Executes control strategies using Function Codes (FCs, compatible with INFI 90 OPEN) and C programming language, supporting analog loops, sequential control, and batch applications (future firmware for Batch 90). It handles up to 128 IISAC01 analog control stations (64 at 40 kbaud or 8 at 5 kbaud) via direct link or Hnet-to-CIO-100 block I/O.
Data Import/Export: Exchanges process data with other controllers and system nodes via Controlway (1 Mbaud redundant peer-to-peer bus) and INFI-NET/Plant Loop. It also accepts operator commands from OIS (Operator Interface Station) or EWS (Engineering Work Station) connected to the network.
2.2 Redundancy for High Availability
To minimize process downtime, the BRC300 supports hot standby redundancy (two controllers required), with core features:
Redundancy Link: A dedicated front-panel cable connects primary and redundant controllers, enabling real-time synchronization of block outputs, configuration, and dynamic data. The redundant controller remains in standby mode, receiving checkpoint data from the primary to ensure bumpless failover.
Failover Logic: If the primary controller fails (detected via 10 ms bus fault timer), the redundant controller immediately takes over control without process interruption. Firmware revisions must match between controllers to avoid erratic operation post-failover.
Dual Hnet Support: Redundant PBAs enable dual Hnet buses, ensuring single-point failures (e.g., cable break) do not disrupt block I/O communication. The controller automatically switches to the redundant Hnet channel if the primary fails.
2.3 Communication & Network Integration
The BRC300 acts as a communication hub within the Symphony system, supporting multiple protocols and buses:
Controlway: A redundant, 1 Mbaud peer-to-peer bus for high-speed data transfer between up to 32 controllers in a Process Control Unit (PCU). It uses two independent channels on the MMU backplane to prevent communication loss from backplane faults.
Hnet: A 16-bit interface for Harmony block I/O, managed by a dedicated ASIC (Application-Specific Integrated Circuit). Hnet and I/O Expander Bus can operate simultaneously (configured via FC 90 specification S3), optimizing I/O flexibility.
Serial Ports: Two auxiliary RS-232-C/RS-485 ports (via PBA and NTMP01 Termination Unit) support C program communication, with handshake options (RTS/CTS) and optical isolation to avoid ground loops. A dedicated IISAC01 station link handles up to 64 stations at 40 kbaud.
2.4 Fault Detection & Diagnostics
The BRC300 includes robust diagnostics to ensure operational integrity and simplify troubleshooting:
Hardware Diagnostics: Continuously checks microprocessor, memory, and communication buses. Critical faults (e.g., NVRAM checksum error, ROM failure) trigger a solid red status LED and display error codes via Group A LEDs (Table 5-1). Non-critical faults (e.g., NVRAM warning) cause a flashing green LED, with the controller continuing to operate from SDRAM.
Error Reporting: Generates detailed status reports (via Controlway or operator interfaces) with error codes for configuration issues (e.g., undefined function blocks), redundancy failures (e.g., link break), and I/O errors (e.g., missing I/O controller). FC 83 output block N (Logic 0 = good, Logic 1 = bad) provides a digital status flag for remote monitoring.
Diagnostic Tests: Supports 37 built-in diagnostic tests (Table 5-3) for memory, serial ports, redundancy links, and Hnet. Tests can be run manually via dipswitch settings, with results displayed on front-panel LEDs (pass/fail counts on Group B LEDs, test number on Group A LEDs).
2.5 Configuration & Maintenance Flexibility
The BRC300 simplifies system setup and upkeep with user-friendly features:
Online Configuration: Enables configuration changes (e.g., function block updates) on the redundant controller without interrupting the primary’s operation. After reconfiguration, the redundant controller can take over as primary, allowing the original primary to be updated—ensuring zero process downtime.
NVRAM Management: NVRAM stores the control strategy and C program files, with a backup battery to retain data during power loss. A “compact configuration” feature optimizes NVRAM space by organizing function blocks, while initialization (via dipswitch) erases the configuration for new setups.
Hot-Swapping: Controllers and PBAs can be installed/removed under power (after pressing the stop/reset button to halt operation), minimizing maintenance downtime. Edge connectors are cleaned using an 80/20 isopropyl alcohol/distilled water mixture to maintain signal integrity.
2.6 Power & Environmental Robustness
Power Requirements: Operates on 5 VDC (2 A typical, 10 W), with the PBA drawing 100 mA (0.5 W) from the controller’s power supply. Power is supplied via the MMU backplane (connector P1), with -30 VDC isolation (via jumper J3) for compatibility with legacy Network 90 MMUs.
Environmental Tolerance: Designed for industrial conditions, with operation at 0–70°C (32–158°F), 0–95% non-condensing humidity (up to 55°C), and atmospheric pressure from sea level to 3 km (1.86 miles). Air quality must be non-corrosive (per ISA S71.04 Class LA/LB/LC Level 1).
ABB Bailey INFI 90 Series: System Structure & Key Components
The ABB Bailey INFI 90 series is a modular distributed process control system (DCS) tailored for
industrial automation and safety-critical scenarios, featuring a hierarchical architecture that connects
field equipment, slave modules, master controllers, and operator interfaces. At its core, the system
relies on master-slave communication to enable process monitoring and control: the Multi-Function
Processor (MFP: IMMFP01/02) and Network 90 Multi-Function Controllers serve as central master
units, while the IMASI02 (Analog Slave Input Module) acts as a dedicated slave component that
inputs 15 channels of analog signals from field devices (e.g., sensors, Bailey smart transmitters) to the
master controllers. Critical supporting components include termination devices (NTAI05 Termination
Unit, NIAI04 Termination Module) that configure and route field signals to the IMASI02 via specialized
cables (NKTU01, NKTM01), and the Slave Expander Bus (a backplane-mounted parallel bus in the
Module Mounting Unit/MMU) that enables real-time data exchange between the IMASI02 and MFP.
Operator interfaces like the Operator Interface Station (OIS), Configuration and Tuning Terminal (CTT),
and Smart Transmitter Terminal (STT) further integrate with the system—allowing users to configure
the MFP (via FC 132/133), send commands to smart transmitters through the IMASI02, and monitor
process status, while the Controlway and INFI-NET/Plant Loop provide redundant, plant-wide
communication for seamless scalability.
