Product Overview

The ABB HC800 is a high-performance controller designed for industrial automation and process control applications. Part of ABB’s Automation System 800M family, the HC800 serves as a versatile control node in complex automation architectures, enabling real-time data processing, advanced logic execution, and seamless integration with ABB’s ecosystem (e.g., System 800xA). It is widely used in industries such as power generation, oil and gas, water treatment, and manufacturing.

Technical Specifications

Hardware Specifications

• Processor:
  • Multi-core CPU optimized for real-time control tasks.
  • Clock Speed: High-speed processing for deterministic performance.
• Memory:
  • RAM: Up to 512 MB (expandable for large-scale applications).
  • Flash Storage: 1 GB for firmware, applications, and logs.
• Communication Interfaces:
  • Ethernet: Dual 10/100/1000 Mbps ports with redundancy support.
  • Fieldbus Protocols: PROFIBUS DP, Modbus TCP/RTU, CANopen, and OPC UA.
  • Redundancy: Supports hot-swappable redundancy via dedicated synchronization buses.
• I/O Capabilities:
  • Compatible with ABB’s S800 I/O modules for scalable digital, analog, and specialty signal handling.
  • Supports up to 1,000,000 I/O points in distributed systems (network-dependent).
• Power Supply:
  • Voltage: 24 V DC (18–32 V DC range).
  • Power Consumption: ~15 W (typical).
• Environmental Ratings:
  • Operating Temperature: -25°C to +70°C.
  • Humidity: 5–95% (non-condensing).
  • Certifications: CE, UL, ATEX/IECEx (for hazardous areas).

Software & Firmware

• Operating System:
  • Real-time OS (RTOS) for deterministic control cycles.
• Programming Standards:
  • IEC 61131-3 compliant (supports ladder logic, structured text, function blocks).
  • Advanced Control Libraries: PID loops, motion control, batch processing.
• Integration Tools:
  • Configured via ABB’s Control Builder M or Automation Builder software.
  • Seamless integration with System 800xA for plant-wide automation and visualization.

Key Functional Capabilities

1. Real-Time Control

   • Executes complex control strategies with microsecond-level precision.
   • Handles cyclic tasks, event-driven interrupts, and multi-variable control.

2. Redundancy & High Availability

   • Dual-CPU Redundancy: Automatic failover for mission-critical applications.
   • Network Redundancy: PRP/HSR protocols for zero-recovery-time networks.

3. Cybersecurity

   • Role-based access control with encrypted user authentication.
   • Secure communication via TLS/SSL, VPN, and firewall configurations.

4. Diagnostics & Maintenance

   • Built-in self-diagnostics for hardware and software health monitoring.
   • Event logging with time stamps for root cause analysis.

5. Scalability

   • Modular design supports expansion with additional I/O modules and communication interfaces.
   • Compatible with legacy systems through protocol converters.

6. Edge Computing

   • Local data processing for predictive maintenance and analytics.
   • Supports cloud connectivity via MQTT and REST APIs.

Applications

• Power Plants: Turbine control, grid synchronization, and load management.
• Oil & Gas: Pipeline monitoring, compressor control, and safety systems.
• Water Management: Pump stations, filtration, and distribution networks.
• Manufacturing: Robotics, assembly line automation, and quality control.

Ordering Information

• Model: HC800
• Typical Variants:
  • HC800 CPU: Base controller unit.
  • Redundancy Kits: Includes synchronization modules and cables.
  • Communication Add-ons: PROFIBUS, Ethernet/IP, or wireless modules.

Certifications & Compliance

• Standards: IEC 61131, IEEE 802.3 (Ethernet), RoHS, WEEE.
• Safety: SIL 2/3 certification achievable for safety-critical systems.

Documentation & Support

• Configuration Tools: Use ABB’s Control Builder M for programming and diagnostics.
• Technical Manuals: Refer to HC800 Hardware Guide and System Integration Handbook.
• Support: ABB’s global service network provides firmware updates, troubleshooting, and lifecycle management.

The ABB HC800 combines robustness, scalability, and cutting-edge automation capabilities, making it a cornerstone of modern industrial control systems.