Description

Product Overview

HC800A is the control processor module for ABB Symphony Plus HPC800 DCS controller, serving as the core computing unit of Symphony Plus S+ distributed control system. It executes function‑block application logic, real‑time I/O processing and field‑device communication. The conformal‑coated variant is available for high‑humidity, corrosive cabinet environments, supporting up to 30 000 function blocks and native Modbus‑TCP client/server communication for third‑party instrument integration.

Many power‑plant and pulp‑paper sites running legacy Symphony Plus systems face spare‑part obsolescence risk. HC800A addresses this pain‑point: it supports 1:1 hot‑standby redundant configuration, delivering bumpless switch‑over upon primary CPU failure. Multiple independent Ethernet ports separate control network, HMI network and Modbus‑TCP external instrument network. It works cooperatively with MB810A base unit, S800 I/O and INFI‑NET fieldbus to complete closed‑loop regulation, sequence control and interlock protection. It is widely used as drop‑in spare for existing HPC800 racks during plant overhaul and outage maintenance。

Technical Specifications

Parameter name	Parameter value
Product model	HC800A
Manufacturer	ABB
Product type	Symphony Plus HPC800 Control Processor Module
Supported function blocks	Max. 30 000 function blocks
Communication interfaces	3 × 10/100 Mbps Ethernet, INFI‑NET interface
Supported protocol	Modbus‑TCP (Client / Server), INFI‑NET, DNP3 optional
Redundancy mode	Hot‑standby dual‑CPU bumpless switch‑over
Installation base	MB810A mounting base unit
Power supply	24 V DC back‑plane power supply
Conformal coating	Standard for HC800A, HC800A‑SEC enhanced G3 coating
Mounting	DIN‑rail mount via MB810A base
Operating temperature	‑20 °C ~ +60 °C
Dimensions (W×H×D)	54 mm × 119 mm × 78.7 mm
Net weight	249 g
Certifications	CE, RoHS, compliant for Symphony Plus DCS

Key Features and Advantages

large capacity function‑block runtime: HC800A supports up to 30 000 function blocks, suitable for medium‑to‑large‑scale process control applications in power and pulp‑paper industries.

multi‑port network isolation: Three independent Ethernet ports realise physical segmentation between control network, operator HMI network and Modbus‑TCP instrument network, reducing cross‑network interference and improving system cybersecurity performance.

ABB HC800A

hot‑standby redundant capability: Two HC800A modules run in hot‑standby pair on MB810A base. Application logic, I/O data and Modbus‑TCP connection status synchronise in real‑time; bumpless switch‑over occurs when main processor fails, no process interruption.

native Modbus‑TCP bidirectional integration: Operates as Modbus‑TCP client / server / mixed mode, connecting IEDs, meters and third‑party instruments, supports up to 4000 Modbus data points bidirectionally.

conformal coating option: Conformal‑coated hardware resists dust, moisture and corrosive gas; HC800A‑SEC G3 version adapts to harsh cabinet environment such as paper mill and coastal power plants.

drop‑in spare for Symphony Plus: Form‑factor and pin‑out match original unit. After downloading project from Composer Field engineering tool, it can replace old processor without modifying rack layout or field wiring.

Application Fields

HC800A is installed inside Symphony Plus HPC800 DCS cabinets, widely deployed for thermal power plants, combined‑cycle units, pulp‑and‑paper mills, water‑treatment and chemical‑process facilities.

In thermal‑power‑generation sites, HC800A undertakes boiler combustion regulation, turbine auxiliary control, interlock protection and data acquisition. Redundant CPU configuration guarantees continuous control for critical boiler and turbine auxiliary loops.

Within pulp‑and‑paper mills, it executes pulping, papermaking‑line sequence and PID closed‑loop control. Conformal‑coated hardware adapts to high‑humidity, corrosive cabinet atmosphere. Via Modbus‑TCP interface, it communicates with field transmitters, drives and intelligent electric devices.

For DCS modernisation and spare‑replacement projects, HC800A replaces ageing processors on existing Symphony Plus racks, re‑using MB810A base, S800 I/O modules and field wiring, extending service‑life of DCS assets without full‑system migration.

Installation and Maintenance

pre‑installation preparation: Power‑down HPC800 rack before inserting HC800A onto MB810A base unit. Check base‑unit back‑plane connector for dust and oxidation. After physical installation, download complete Composer Field project, verify redundant sync status and Modbus‑TCP communication. Perform cold‑start and loop test before putting DCS online.

maintenance recommendations: Inspect front‑panel LED status during routine plant inspection. Keep complete project backup file for fast spare‑unit restoration. Do not hot‑swap HC800A without following Symphony Plus redundant swap procedure; incorrect hot‑swap may cause control‑loop disturbance. The processor module contains no field‑serviceable assemblies; return defective hardware to ABB‑authorised repair centres.

Product Warranty & Support

Each HC800A passes factory function‑block runtime testing, redundant‑switch‑over validation and Modbus‑TCP communication check before shipment. Standard equivalent warranty covers manufacturing defects for 12 months from delivery date. Spare‑part sourcing, remote‑technical guidance and SAT‑support services are available for spare‑replacement, project download and redundant‑system commissioning. Application engineers offer support for network partition configuration and Modbus‑TCP point setup. Long‑term spare‑parts inventory mitigates obsolescence risk for installed Symphony Plus DCS assets.

HC800A Symphony Plus HPC800 Control Processor Module