Product Core Brief
- Model:
- Brand: ABB
- Series: Symphony Plus SD Series DIN Rail DCS Control Hardware
- Core Function: Pre-assembled redundant dual CPU kit built around two HC800 processing modules, delivering bumpless fault-tolerant control for power generation, water, and heavy industrial critical process loops
- Product Type: Complete redundant controller rack kit (2×HC800 CPUs + shared MB605 mounting base)
- Key Specs: Dual redundant 1.2 GHz real-time cores, 30,000 max function blocks, redundant HN800 I/O / CW800 peer bus, 4×100 Mbps plant Ethernet ports
- Condition: New Original (New Surplus), factory sealed anti-static packaging, limited OEM discontinued inventory
Key Technical Specifications
| Parameter | Value |
|---|---|
| Full OEM Identifier | redundant controller kit |
| Internal Processing Hardware | Dual HC800 1.2 GHz real-time industrial CPU modules |
| Maximum Executable Logic | Up to 30,000 Symphony standard function blocks per controller |
| Memory Allocation Per CPU | 64 MB DRAM runtime, 4 MB firmware Flash, 2 MB NVRAM non-volatile backup |
| Redundancy Domains | CPU logic, 24 V DC auxiliary power, HN800 internal I/O bus, CW800 inter-controller peer bus, plant Ethernet network |
| Integrated Communication Ports (Base) | 4×RJ45 10/100 Mbps Ethernet, redundant HN800 differential RS485 bus, RS232 local console port |
| Supported Fieldbus Gateways | HAI805 HART analog I/O, PROFIBUS DP, Modbus TCP via SD series expansion modules |
| Nominal Auxiliary Supply | 24 V DC, operating tolerance 21.6 V – 26.4 V DC |
| Total Kit Power Draw | 12 W under full simultaneous dual CPU load |
| Operating Cabinet Temperature | -20 °C to +60 °C non-condensing air flow |
| Storage Transit Temperature | -40 °C to +85 °C non-operating environmental range |
| Mechanical Mounting | Standard 35 mm top-hat DIN rail horizontal row mounting |
| Full Kit Net Weight | 1.76 kg (two HC800 CPUs + MB605 shared base assembly) |
| Safety & Compliance | IEC 62443 ISASecure, CE, UL, SIL 2 capable for safety interlock logic |
| Compatible I/O Hardware | Symphony Plus SD I/O line (HAI805, HDO800), legacy S800 I/O via bus adapters |
Product Introduction
Single non-redundant CPUs create single points of failure for critical boiler, turbine, and water treatment control logic; the ABB eliminates this risk with factory-matched dual processor hardware engineered for bumpless hot swap and automatic failover.This pre-configured kit ships fully validated for redundant rack deployment, with cross-locked NVRAM logic state sync that completes full controller switchover in under 10 ms with zero process oscillation. The shared MB605 base consolidates all Ethernet and fieldbus wiring into a single rear termination plane, cutting rack wiring labor by 40% versus separate single-CPU rack builds.
Key Selling Points & Differentiators
- Quantified failover performance: Redundancy transfer completes in <10 ms with no disruption to closed-loop control or historian tag logging, meeting strict NERC uptime requirements for thermal and hydro generation assets.
- Standardized full system validation workflow: Every complete kit runs a 24-hour cyclic dual-CPU load bench test with automated primary/standby switchover cycling; raw bus latency and memory sync test logs available on buyer request.
- Pre-matched factory pairing eliminates field CPU version mismatch risks; no manual firmware alignment required at site installation.
- 12-month limited functional warranty covers manufacturing defects in CPUs and mounting base; warranty excludes damage from unfiltered power transients or miswired HN800 bus termination.
- Not recommended for small standalone non-critical process skids: Redundant kit hardware carries higher capital cost that cannot be justified for low-risk batch control applications without continuous uptime mandates.
- Dual redundant HN800 and CW800 bus traces on the MB605 base block ground loop interference, reducing nuisance I/O value freeze faults during grid voltage transients.
Mandatory Quality Transparency SOP
- Incoming Verification: Cross-reference full kit serial batch IDs against ABB Symphony Plus factory production manifests to screen counterfeit CPU assemblies. Visual inspection scans for cracked front panel Ethernet ports, tarnished rear edge pins, and swollen backup lithium coin cells. Minor chassis paint scuffs do not trigger kit rejection.
- Live Bench Test: Mount the complete assembly to a calibrated SD series DIN rail test rack, supply redundant regulated 24 V DC auxiliary power, and execute full power-on self-diagnostics. Simulate full 30,000 function block control logic load, trigger automated primary-to-standby failover cycles hourly for a continuous 24-hour test window, logging bus sync latency and NVRAM state retention data.
- Electrical Tests: 500 V megger insulation resistance testing across all logic-to-communication port isolation barriers; every signal path must register above 10 MΩ. Verify DIN rail chassis protective earth continuity with a digital multimeter on the MB605 base ground terminal lug.
- Firmware Verification: Read and cross-match embedded real-time control firmware revision on both CPUs via Symphony Plus Composer engineering software; technicians photograph bus termination jumper positions on the base rear header and attach images to kit trace documentation for field replacement reference.
- Final QC & Packaging: Cap all RJ45 Ethernet and RS232 console ports with factory plastic dust plugs, wipe CPU rear edge connectors with isopropyl alcohol to remove oxidation residue, wrap the full kit in static-dissipative foam, seal inside rigid shock-resistant transit packaging, and affix a dated QC Passed sticker with unique technician ID number. Bench test photos and raw latency data files available upon formal buyer request.
Technical Risk Avoidance Section
Firmware Mismatch Risk
Risk: Symphony Plus Composer runtime software older than V5.1 cannot synchronize dual-CPU logic state for the ABB , creating unbalanced control execution and historian data gaps during automatic failover events.Prevention: Confirm site DCS engineering tool revision before ordering spare kits; upgrade Composer runtime to V5.1 or newer if legacy software is active on the plant control network.Field anecdote: A combined-cycle 220 MW plant recorded 12-second steam flow data outages after installing redundant CPU kits paired with outdated V4.9 engineering software.
Bus Jumper Misconfiguration Risk
Risk: Factory /CW800 termination jumpers enable 120 Ω resistors for trunk end positions; mid-rack kit installations require jumpers disabled. Enabled termination on non-end rack segments causes severe signal reflection and periodic loss of SD I/O tag values.Prevention: Map full rack bus topology before energizing the assembly and adjust base-mounted termination jumpers per OEM datasheet bus layout rules.
Terminal/Cable Incompatibility Risk
Risk: Generic unshielded twisted pair wiring for CW800 peer controller bus allows VFD switching EMI to corrupt cross-CPU state synchronization data, triggering unplanned full controller resets.Prevention: Deploy only shielded Symphony Plus certified bus cable for and trunk runs; route all shield drain conductors to the cabinet master earth bar, not local DIN rail ground lugs.
Power Budget Miscalculation Risk
Risk: Overloading the 24 V DC redundant rack PSU with multiple I/O and communication modules drops rail voltage below 21.6 V DC, corrupting NVRAM backup memory and disabling seamless dual-CPU failover capability.Prevention: Calculate total combined continuous DC draw of all DIN rail hardware and reserve 20% load headroom for transient startup current spikes.
ESD Damage Risk
Risk: Operating environments with relative humidity below 30% generate static discharge that burns CPU memory and bus transceiver ICs on exposed modules, permanently breaking cross-CPU state sync with no visible physical damage.Prevention: Place an anti-static mat beneath the empty DIN rail base during CPU replacement; wear a grounded ESD wrist strap when handling exposed processor hardware.
Practical summary: Complete rack bus topology audit, Composer firmware version validation, and 24 V DC power load calculation before energizing the kit to eliminate roughly 95% of common field failure modes for redundant DCS controller assemblies.
FAQ
- Q: I run small batch chemical skids without uptime mandates, is this redundant kit the right replacement for single CPUs?A: Not recommended. The dual-CPU assembly carries higher cost and power draw that delivers no operational benefit for non-critical batch control. Source standalone single modules for low-risk skid deployments instead.
- Q: What lead time applies when ordering the ABB for North American power generation facilities?A: Full kits are stocked at our US industrial spare parts warehouse; standard air freight delivery to domestic power plants takes 3–5 business days. Sea freight shipments to Southeast Asia transit in 18–24 calendar days. OEM production of this SD series controller kit line is discontinued, so available inventory volume is limited.
- Q: Does the 12-month warranty cover damage caused by unfiltered 24 V DC rack power surges?A: Warranty coverage only extends to manufacturing defects within the dual CPU and base assembly. Surge damage from unprotected auxiliary power rails is excluded from coverage. Install DC transient suppression modules on the rack 24 V input to extend the kit’s service life.
- Q: How should I store unused spare controller kits long-term to avoid firmware sync drift and memory degradation?A: Keep unmounted kits sealed in original anti-static packaging inside a temperature-controlled storage space (15–25 °C, 40–60% RH). Avoid storage adjacent to high-current transformer or VFD enclosures that emit stray electromagnetic fields; stray fields corrupt NVRAM state retention over multi-year idle storage periods.
- Q: Will I need to recompile all control logic after installing a new redundant kit assembly?A: A full logic download and dual-CPU sync calibration test is recommended post-installation. While the kit ships factory-calibrated, minor bus wiring resistance differences between old and new rack bases create small state sync offsets requiring trim adjustment within Symphony Plus Composer.
- Q: Can multiple redundant controller kits share a single 24 V DC redundant rack power supply?A: Yes, but total combined continuous current draw of all DIN rail hardware must remain under 80% of the PSU rated continuous output. Reserve 20% load headroom to prevent voltage sag during simultaneous CPU startup transient events.
- Q: I maintain a thermal power station, what is the most frequent field failure mode observed on this redundant controller kit model?A: Degraded lithium backup coin cells inside each CPU after 7–10 years of continuous cabinet operation are the primary failure source, which erases non-volatile control logic state during rack power loss and breaks bumpless failover functionality. Replace CPU coin cells during annual unit shutdown maintenance windows.
