Description:

The ABB 216NG61A,HESG441633R1,and HESG216875/K are core hardware components of the ABB AC 800M programmable automation controller(PAC)platform—part of the broader 800xA integrated control system.The 216NG61A is a redundant-capable 24VDC power supply,the HESG441633R1 is a high-performance CPU module with embedded safety functionality,and the HESG216875/K serves as a dual-channel PROFIBUS DP communication interface.Together,they form a robust,scalable foundation for process automation in demanding industrial environments.

These modules exemplify ABB’s commitment to reliability,functional safety,and seamless interoperability across hybrid control architectures—from discrete manufacturing to continuous process plants.

Application Scenarios:

At a major pharmaceutical facility in Switzerland,batch consistency failures were traced to intermittent communication losses between the central ABB 800xA system and remote reactor skids.The legacy controller lacked true redundancy,and fieldbus dropouts during sterilization cycles caused recipe deviations.The plant upgraded its AC 800M rack with a new HESG441633R1 CPU,added a HESG216875/K for dual-redundant PROFIBUS DP connectivity to valve islands and temperature transmitters,and powered the entire chassis with dual 216NG61A supplies in N+1 configuration.Post-upgrade,communication uptime reached 99.999%,and the SIL3-certified safety logic in the HESG441633R1 enabled automated emergency cooling during overpressure events—reducing manual intervention by 70%.In this case,the trio of 216NG61A,HESG441633R1,and HESG216875/K didn’t just restore reliability—they elevated the entire production line to Pharma 4.0 standards.

Main Parameters Value/Description

Product Model 216NG61A/HESG441633R1/HESG216875/K

Manufacturer ABB Ltd.

Product Category Power Supply/CPU Controller/Communication Module(AC 800M Series)

Input Voltage(216NG61A)85–264 VAC,47–63 Hz(auto-ranging)

Output(216NG61A)24 VDC/10 A,with overload&short-circuit protection

CPU Performance(HESG441633R1)32-bit RISC,100 MHz,4 MB program memory,SIL3 per IEC 61508

Safety Certification(HESG441633R1)TÜV-certified SIL3(process shutdown applications)

Communication Ports(HESG216875/K)Dual isolated PROFIBUS DP(RS-485),up to 12 Mbps,master/slave configurable

Redundancy Support All three support hot-swap and system-level redundancy in AC 800M architecture

Operating Temperature 0°C to+60°C(derated above 50°C)

Mounting DIN rail or ABB PM86x/PM866 backplane(for CPU&comms);standalone or redundant rack(for PSU)

Certifications CE,UL,CSA,ATEX(for hazardous variants),IEC 61508,IEC 61131-3

Technical Principles and Innovative Values:

Innovation Point 1:Integrated Safety Without Separate Hardware–The HESG441633R1 runs standard control logic and safety applications(e.g.,ESD,BMS)on the same processor using ABB’s certified safety runtime.This eliminates the need for a separate safety PLC,reducing footprint,cost,and engineering complexity—while maintaining full SIL3 compliance.

Innovation Point 2:True Power Redundancy with Load Sharing–The 216NG61A features active current sharing when used in parallel,ensuring balanced thermal stress and extended service life.In the event of a single unit failure,the remaining supply instantly assumes 100%load without voltage sag—critical for CPU and I/O stability.

Innovation Point 3:Dual PROFIBUS with Automatic Failover–The HESG216875/K supports ring or linear redundant topologies.If one cable is severed,communication reroutes through the second port within 100 ms—ensuring uninterrupted data flow to critical field devices like motor starters or positioners.

Innovation Point 4:Unified Engineering in 800xA–All three modules are fully supported in ABB’s System 800xA engineering environment,enabling single-point configuration,diagnostics,and firmware updates—dramatically simplifying lifecycle management.

Application Cases and Industry Value:

In a greenfield LNG liquefaction project in Qatar,the EPC contractor selected the HESG441633R1 CPU paired with dual HESG216875/K modules to manage over 5,000 I/O points across cryogenic compressors and flare systems.The 216NG61A power supplies were deployed in N+1 racks across three control buildings.During commissioning,the integrated safety logic in the HESG441633R1 successfully executed a full plant shutdown within 180 ms during a simulated gas leak—well under the 250 ms SIL3 requirement.Meanwhile,the redundant PROFIBUS network maintained communication even when construction crews accidentally cut one trunk cable.Project engineers noted that the“plug-and-trust”reliability of these ABB modules shaved three weeks off the FAT schedule.Today,the system operates at 98%availability,with zero unplanned trips attributed to control hardware.

Related Product Combination Solutions:

ABB PM866AK01–Alternative high-end CPU for larger AC 800M applications(compatible with HESG216875/K)

ABB 216NG62A–Higher-current(20 A)version of the 216NG61A for large I/O chassis

ABB CI854A–Redundant Ethernet/IP or Modbus TCP communication module(complements HESG216875/K)

ABB DI810/AI810–Digital and analog I/O modules that connect via the AC 800M backplane managed by HESG441633R1

ABB TB820V1–Terminal base for I/O modules,supporting hot-swap and diagnostics

ABB 800xA System Platform–Full DCS environment where these modules deliver unified HMI,historian,and alarm management

ABB FS240–Safety input/output modules for use with the safety runtime in HESG441633R1

ABB 216NG91A–Diagnostic power supply monitor that reports 216NG61A health to the controller

Installation,Maintenance,and Full-Cycle Support:

Installation of the 216NG61A,HESG441633R1,and HESG216875/K follows ABB’s modular AC 800M guidelines:power supplies mount in dedicated PSU slots or external DIN rails with parallel wiring;the CPU and comms modules slide into the controller backplane and lock with front levers.All support hot-swap—enabling replacement during operation without system halt.Before powering up,verify firmware compatibility across all modules using ABB’s Control Builder M software to avoid communication mismatches.

Routine maintenance is minimal due to solid-state design and conformal coating.However,periodic checks of PSU fan operation(if equipped),PROFIBUS termination resistors,and CPU diagnostic LEDs are recommended.In case of failure,each module provides detailed fault codes via 800xA or local status indicators—accelerating troubleshooting.

We supply only genuine,factory-new or ABB-certified refurbished units of 216NG61A,HESG441633R1,and HESG216875/K,each subjected to full functional testing:PSU load/ripple validation,CPU boot and safety logic verification,and PROFIBUS traffic simulation under noise injection.Every shipment includes a test report,compatibility matrix,and 12-month warranty.Our global technical team offers pre-deployment validation,on-site commissioning support,and rapid exchange services for critical outages.

Contact us for a customized solution—whether you’re building a new AC 800M system,modernizing legacy ABB controllers,or securing long-term spares for your 800xA infrastructure.With decades of expertise in ABB automation ecosystems,we ensure your control backbone remains resilient,compliant,and future-ready.

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