ABB HPC800K02 High Performance Redundant Controller Kit

Kit Contents and Components

The HPC800K02 redundant controller kit includes the following components:

Redundant Controller Pair: 2x HC800 CPU modules (primary and redundant controllers)

Redundant Communication Modules: 2x CP800 communication modules

Redundant Mounting Bases: 2x MB810 mounting bases for controller installation

Termination Units: 1x CTB810 and 1x CTB811 termination units for I/O connections

I/O Termination Modules: 4x TER8x0 series termination modules for field wiring

Battery Backup: 4x lithium button cell batteries for memory retention

Technical Specifications

Processor Architecture:

• Processor Type: 32-bit PowerPC 603e processor or Freescale ColdFire processor running at 256 MHz

• Processor Speed: 256 MHz to 1 GHz depending on revision (PowerPC e500 core at 1 GHz in later versions)

Memory Specifications:

• User Memory: 128 MB to 512 MB DDR2 SDRAM depending on configuration

• Flash Memory: 16 MB to 2 GB user flash for program storage

Power Requirements:

• Input Voltage: 24 V DC (±5%) with dual redundant power inputs

• Power Consumption: Maximum 3.5W to 4W, supporting installation in sealed enclosures without forced cooling

• Voltage Isolation: DC 1500 V isolation with reverse polarity protection

Physical Dimensions (individual components):

• Product Net Depth / Length: 32.26 mm

• Product Net Height: 129.03 mm

• Product Net Width: 129.03 mm

• Product Net Weight: 0.88 kg (complete kit weight varies from 0.88 kg to 5.5 kg depending on included components and packaging)

Environmental Specifications:

• Operating Temperature: -20°C to +60°C

• Operating Humidity: 5% to 95% non-condensing

• Protection Rating: IP20 for cabinet installation

• RoHS Status: RoHS compliant

Key Features & Functions

True Hardware Redundancy: Provides 1:1 redundant controller configuration with automatic failover capability. When the primary controller experiences a fault, the secondary controller assumes control within milliseconds, ensuring uninterrupted process operation .

High-Performance Processing: Delivers exceptional computational power for complex control algorithms, executing closed-loop control of more than 5,000 I/O points in less than 250 milliseconds. The advanced 32-bit processor architecture handles data-intensive and program-intensive process control applications with ease .

Passive Cooling Design: Features ultra-low power consumption below 4W, allowing installation in sealed enclosures without requiring fans, louvers, air filters, or other forced cooling techniques. This eliminates a common failure point and reduces maintenance requirements .

Comprehensive Communication Support: Integrates multiple communication interfaces and protocols including:

• Ethernet: 2x RJ45 ports supporting 100Base-TX with integrated Ethernet switch for daisy-chain and ring topologies

• Profinet: Supports Profinet v2.31 protocol with real-time (RT) communication functionality

• Fieldbus Protocols: PROFIBUS DP and HART communication protocols for field device integration

• Serial Communication: RS-232, RS-422, RS-485 interfaces

• USB: USB ports for local programming and data transfer

Extensive I/O Subsystem Support: Compatible with multiple I/O platforms including SD series I/O, Harmony rack I/O, and S800 I/O subsystems, providing flexibility for various application scales and requirements .

Rich Function Block Library: Configured through S+ Engineering tools with access to over 150 pre-defined control algorithms and function codes. In addition to standard function blocks, supports C programming, batch processing, and user-defined function codes for customized control strategies .

Advanced Network Architecture: Based on a network-centric architecture that allows simple, scalable, seamless, and secure integration of field devices, process systems, electrical system areas, and enterprise-level systems .

Integrated Turbine Control Functions: Includes specialized algorithms for turbine control applications, supporting precise speed, torque, and position adjustments for turbomachinery .

Comprehensive Diagnostics and Fault Management: Features real-time self-monitoring capabilities with LED indicators for power, run, error, and bus status. Detected faults trigger automatic redundancy switching and provide detailed diagnostic information through communication interfaces .

Application Scenarios

Power Generation Plants: Deployed in thermal, nuclear, and combined-cycle power plants for turbine control, boiler management, and generator synchronization. The redundant architecture ensures continuous operation critical for power generation .

Oil and Gas Processing Facilities: Installed in refineries, petrochemical complexes, and natural gas processing plants to control distillation columns, cracking units, and pipeline systems where process interruptions cannot be tolerated .

Chemical Manufacturing: Applied in chemical production facilities for reactor control, batch processing, and continuous process management, leveraging the extensive function block library for complex chemical reactions .

Water and Wastewater Treatment: Utilized in municipal and industrial water treatment facilities for pump control, filtration management, and chemical dosing systems requiring high reliability and precise control .

Metallurgical and Mining Operations: Implemented in steel mills, aluminum processing plants, and mining operations for conveyor control, crusher management, and material handling systems operating in harsh environments .

Transportation Infrastructure: Deployed in tunnel ventilation systems, railway electrification, and traffic control systems where fail-safe operation is essential for public safety .

Large-Scale Manufacturing: Applied in automotive plants, electronics manufacturing, and industrial production lines requiring coordinated multi-axis motion control, energy optimization, and centralized supervision .

Data Center Infrastructure: Used for critical facility management including cooling systems, backup power control, and environmental monitoring in data centers requiring maximum uptime .

Renewable Energy Systems: Implemented in wind farms and solar power plants for power conversion control, grid synchronization, and remote monitoring applications .