Description
1. Product Overview
Model: HC800
Brand: ABBSystem Affiliation: Core CPU master controller for AC 800M DCS, Symphony Plus SD and Freelance 800F distributed control systems. It is not a general-purpose small PLC, but a plant-level core control unit dedicated to closed-loop process control, interlock logic, batch calculation and multi-system gateway communication for large-scale process industries. serving as the standard critical spare part for thermal power, chemical, oil & gas and other process facilities.
2. Six Core Hardware Functional Units
2.1 Multi-Core Real-Time Calculation & Task Scheduling Unit
Adopts 256MHz ColdFire 32-bit PowerPC architecture or 1.2GHz dual-core 64-bit industrial processor with dedicated real-time kernel. Up to 8 independent task segments are configurable with a minimum task cycle of 1ms, supporting 30,000 standard control function blocks and closed-loop calculation for over 5000 I/O points within 250ms, suitable for strongly coupled control scenarios such as distillation columns and boiler combustion coordination. An on-board hardware watchdog automatically resets the module upon program crash or process deadlock to prevent system out-of-control.
2.2 Hierarchical Storage & Power-Down Data Protection Unit
Configurable storage options: basic version with 512MB RAM + 2GB Flash, high-end version up to 4GB RAM + 16GB Flash. A 2MB NVRAM non-volatile memory retains key parameters, fault events and interlock status after power failure; the system automatically resumes operation after power restoration without re-downloading project files to avoid loss of process breakpoint data. Firmware supports online remote upgrade without equipment shutdown or module disassembly.
2.3 Multi-Link Redundant Communication Interaction Unit
Dual gigabit Ethernet ports for redundancy, natively supporting Modbus TCP, SNTP time synchronization and IEC 60870-5-104. Integrated Profibus DP master interface directly connects DP field instruments; reserved RS232/RS485 serial port and USB debugging interface for connection to third-party SCADA, relay protection and upper monitoring systems. An extended CEX-Bus enables cascaded expansion of communication and I/O backplanes. Multiple links serve as mutual backups, and single port disconnection will not interrupt overall control.
2.4 Multi-Series I/O Subsystem Compatible Driver Unit
Natively compatible with three mainstream I/O backplane systems: S800 distributed I/O modules, Harmony Rack rack-mounted I/O and SD compact I/O. No additional gateway is required to issue acquisition commands and output control signals via backplane bus, seamlessly interfacing with analog input/output, DI/DO, pulse counting and safety interlock terminal boards. It supports both centralized cabinet wiring and remote station distributed wiring architectures.
2.5 Dual Redundant Hot-Standby Fault Switchover Unit
A dedicated peer-to-peer redundant high-speed bus enables parallel operation of primary and standby modules with real-time mirroring of all calculation data and program logic from the primary unit to the backup unit. Upon hardware failure or communication loss of the main controller, the system switches to the standby unit within 100ms without process bump or output jitter, complying with SIL2 and above functional safety interlock requirements for trip and reactor interlock loops that cannot be interrupted.
2.6 Industrial Reinforced Conformal Coating & Environmental Adaptation Unit
The PCB is fully coated with moisture, salt-fog and corrosion resistant conformal coating. Fanless passive heat dissipation relies on cabinet airflow. No aging-prone components such as electrolytic capacitors and adjustable potentiometers are used. Standard operating temperature ranges from -20℃ to +60℃, tolerating cabinet dust accumulation, long-term low-frequency vibration from unit bases and humid coastal environments, enabling 24/7 unattended maintenance-free continuous operation.
3. Technical Specifications
3.1 Basic Hardware Specifications
| Item | Specification |
|---|---|
| Model | HC800 Symphony Plus Process Controller |
| Mounting | Standard DIN rail slot installation |
| Dimension | 211mm × 244mm × 79mm |
| Net Weight | 0.88kg |
| Power Supply | DC24V (±10%), typical power consumption 5~10W |
| Ingress Protection | IP20, for installation only inside sealed control cabinets |
| Origin | Original ABB production in Finland / USA |
3.2 Core Performance Parameters
- Processor: 32-bit ColdFire / 1.2GHz dual-core 64-bit industrial CPU
- Memory: 512MB~4GB RAM, 2GB~16GB Flash, 2MB NVRAM power-off persistent storage
- Task Capacity: 8 task segments, minimum scan cycle 1ms, max 30000 control function blocks
- I/O Loading: Up to 5000 I/O points per controller, closed-loop cycle ≤250ms
- Redundancy: Primary-backup hot standby, switchover time ＜100ms with real-time data mirroring
3.3 Communication Interfaces
- Dual redundant Gigabit Ethernet: Modbus TCP, SNTP, upper system networking
- Profibus DP: Bus master for DP protocol field devices
- RS232/RS485 Serial Port: Local debugging, Modbus RTU slave communication
- USB Port: Local program download, firmware upgrade, log export
- Dedicated Redundancy Bus: Data synchronization link between primary and backup controllers
3.4 Environmental & Safety Compliance
- Operating Temperature: -20℃ ~ +60℃
- Storage & Transport Temperature: -40℃ ~ +85℃
- Humidity: 5%~95%RH non-condensing, free of corrosive gas
4. Product Advantages
- Cross-system full compatibility: A single HC800 supports AC800M, Symphony Plus and Freelance800F three mainstream DCS architectures, requiring no hardware replacement during project renovation and system upgrade.
- Large-point computing capacity: One main CPU covers the entire process control of small and medium-sized units, reducing controller quantity in cabinets and simplifying network topology and configuration structure to lower later maintenance workload.
- Triple protection of hardware dual redundancy, dual Ethernet redundancy and power-off data storage eliminates unplanned shutdown caused by single-point hardware failure for continuous production facilities.
- Standard IEC61131-3 programming standard supporting LD, FBD, ST and SFC languages, paired with Control Builder M configuration software for low development and learning threshold.
- Full-link self-diagnosis and alarm uploading accurately locate fault points on central control DCS screens to shorten troubleshooting time.
- Plug-and-play modular design enables spare part replacement via slot insertion only without rewiring or underlying program download to minimize emergency maintenance downtime.
5. Application Scenarios
1. Power & Energy Industry
DCS core main control unit for thermal power boiler, turbine, denitrification & desulfurization auxiliary systems; hydropower unit speed regulation and gate control; wind & photovoltaic station centralized control; non-safety-level process systems of nuclear power plants.
2. Petrochemical & Oil & Gas Industry
Process regulation and SIS safety interlock for cracking units, distillation towers, polymerization reactors, natural gas compressor stations and long-distance pipeline valve chambers.
3. Metallurgy Industry
Coal feeding system of blast furnaces, continuous casting production lines, hot & cold rolling lines and heating furnace coordinated control, adapting to high EMI, dusty and strongly vibrating factory environments.
4. Public Utilities & Water Treatment
Centralized SCADA management of large municipal water plants, wastewater advanced treatment and pump station clusters for automatic dosing, liquid level and flow regulation & remote operation.
