Description

TheHPC800K02is a high-performanceprogrammable logic controller (PLC) CPU modulefromABB, belonging to theAC 800M familywithin the broaderSystem 800xAintegrated automation platform. Designed for demanding industrial applications, it delivers fast scan cycles, large program capacity, and seamless integration with distributed I/O, drives, and enterprise systems—making it ideal for continuous process control, batch operations, and hybrid manufacturing.

Application Scenarios

At a municipal wastewater treatment plant in Scandinavia, aging relay-based controls caused frequent overflow incidents during storm surges due to slow response times. The facility upgraded to anABB System 800xAarchitecture centered on theHPC800K02controller, which coordinated over 2,000 I/O points across pumping stations, clarifiers, and chemical dosing units. With its100 ns instruction cycleand deterministic Profibus DP communication, theHPC800K02enabled real-time flow balancing and predictive surge management—reducing emergency discharges by 95% and cutting energy use by 18%. In this mission-critical setting, theHPC800K02proved to be more than a logic engine—it became thecentral nervous system of environmental compliance.

Parameter

Main Parameters

Value/Description

Product Model

HPC800K02

Manufacturer

ABB (now part of Hitachi Energy)

Product Category

PLC Central Processing Unit (CPU) – AC 800M Series

Processor Type

32-bit RISC, optimized for industrial control

Scan Cycle Time

As low as 100 nanoseconds per instruction

User Program Memory

64 MB RAM (battery-backed), expandable via flash cards

Retentive Memory

512 kB (retains data during power loss)

Communication Interfaces

Dual Ethernet (10/100 Mbps), RS-232 (service port), supports Profibus DP, Modbus TCP/RTU

I/O Capacity

Up to 64,000 digital / 32,000 analog points via remote I/O modules

Redundancy Support

Yes – hot-standby CPU redundancy with <100 ms switchover

Safety Certification

IEC 61508 SIL 2 (when used with ABB safety libraries and I/O)

Operating Temperature

0°C to +60°C

Mounting

DIN rail in AC 800M modular chassis

Technical Principles and Innovative Values

Innovation Point 1: TheHPC800K02leveragesdual independent Ethernet portswith built-in switch functionality, enablingring topologyfor high-availability networks without external switches—reducing cost and single points of failure in distributed plants.

Innovation Point 2: Unlike standard PLCs, it supportsonline change download—engineers can update logic, HMI tags, or alarm configurations while the system runs, eliminating costly production stops during optimization or troubleshooting.

Innovation Point 3: Tight integration withABB System 800xAallows unified engineering: control logic, HMI graphics, alarm management, and historian data are developed in a single environment, drastically reducing project engineering time.

Innovation Point 4: TheHPC800K02’shigh-speed execution enginesupports complex algorithms like PID with feedforward, cascade loops, and motion coordination—enabling advanced process control (APC) directly in the PLC without external computers.

Application Cases and Industry Value

In a global beverage bottling line, inconsistent fill levels led to product giveaway and customer complaints. By deploying theABB HPC800K02to manage synchronized servo drives and high-speed valve banks, the plant achieved±0.5 mL fill accuracy at 40,000 bottles/hour. The controller’s deterministic timing ensured perfect coordination between conveyor speed, filling nozzles, and capping stations. Maintenance teams appreciated thehot-swap I/O capability—failed modules were replaced during operation with zero downtime. Over two years, the line saved $1.2M in product waste and reduced changeover time by 35%, demonstrating how theHPC800K02turns precision control into direct profitability.

Related Product Combination Solutions

CI854A: Profibus DP communication module—extendsHPC800K02connectivity to legacy field devices.

AI810 / AO810: Analog I/O modules—commonly used withHPC800K02for process signal handling.

DI810 / DO810: Digital I/O modules—support high-density discrete control.

PM864A: Lower-cost AC 800M CPU—ideal for non-redundant applications; shares programming environment withHPC800K02.

TB850: Redundancy link module—enables hot-standby configuration forHPC800K02pairs.

System 800xA Engineering Workplace: Unified software suite for configuringHPC800K02logic, graphics, and alarms.

ABB Ability™ Genix: Industrial analytics platform—ingests data fromHPC800K02for predictive maintenance.

AC 800M Rail Chassis (e.g., TK811V015): Modular backplane for mountingHPC800K02and I/O.

Installation, Maintenance, and Full-Cycle Support

Installing theHPC800K02requires placement in an AC 800M rail chassis with proper ventilation—each unit dissipates up to 15 W under load. Configuration begins inControl Builder M, where engineers define tasks, I/O mapping, and communication parameters. The dual Ethernet ports simplify network design: one can connect to the plant LAN, the other to a local I/O ring. Firmware updates and program downloads are performed via the service port or Ethernet, with full version rollback support.

For maintenance, theHPC800K02features extensive diagnostics: LED indicators show CPU status, battery health, and communication errors, while System 800xA logs detailed event histories. Battery-backed memory retains programs for up to 30 days during outages. In redundant setups, automatic failover ensures uninterrupted operation, and the standby unit continuously synchronizes application state.

We provideHPC800K02modules with full traceability, pre-installation validation (including memory test and communication loopback), and compatibility assurance for your existing 800xA version. Our team includes certified ABB system integrators who offer commissioning support, migration planning from legacy PLCs (e.g., Advant Controller), and lifecycle extension strategies. All units are stored in climate-controlled, ESD-safe facilities and backed by a 12-month operational warranty.

Contact us for a customized solution to modernize your automation infrastructure with the proven reliability and scalability of theABB HPC800K02.