Symphony Plus

S+ Control: HPC800
Harmony Process Controller
User Manual

D1

Symphony Plus
 Symphony Plus

S+ Control: HPC800
Harmony Process Controller
User Manual
NOTICE
This document contains information about one or more ABB products and may include a description of
or a reference to one or more standards that may be generally relevant to the ABB products. The
presence of any such description of a standard or reference to a standard is not a representation that all
of the ABB products referenced in this document support all of the features of the described or referenced
standard. In order to determine the specific features supported by a particular ABB product, the reader
should consult the product specifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intellectual property in
the ABB products described in this document.

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

Products described or referenced in this document are designed to be connected and to communicate
information and data through network interfaces, which should be connected to a secure network. It is the
sole responsibility of the system/product owner to provide and continuously ensure a secure
connection between the product and the system network and/or any other networks that may be
connected.

The system/product owners must establish and maintain appropriate measures, including, but not limited
to, the installation of firewalls, application of authentication measures, encryption of data, installation of
antivirus programs, and so on, to protect these products, the network, its system, and interfaces against
security breaches, unauthorized access, interference, intrusion, leakage, and/or theft of data or
information.
ABB performs functionality testing on the products and updates that we release. However system/product
owners are ultimately responsible for ensuring that any product updates or other major system updates
(to include but not limited to code changes, configuration file changes, third-party software updates or
patches, hardware change out, and so on) are compatible with the security measures implemented. The
system/product owners must verify that the system and associated products function as expected in the
environment in which they are deployed.

In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any
nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential
damages arising from use of any software or hardware described in this document.

This document and parts thereof must not be reproduced or copied without written permission from ABB,
and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose.

The software or hardware described in this document is furnished under a license and may be used,
copied, or disclosed only in accordance with the terms of such license. This product meets the
requirements specified in EMC Directive 2004/108/EC and in Low Voltage Directive 2006/95/EC.

TRADEMARKS
Symphony is a registered or pending trademark of ABB S.p.A.

All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.

Copyright © 2016 ABB.

Release: January 2016

Document number: 2VAA001586 C
Preface
The Harmony Process Controller, HPC800K0[], consists of a control processor (HC800), a communication processor
(CP800), a dual module mounting base for the HC800 and CP800 (MB810), network terminators (TER800), and
communication termination units (CTB810 and CTB811). The HPC800K01 is used for non-redundant applications,
HPC800K02 is used for redundant applications and contains two HC800 modules, two CP800 modules, two MB810
mounting bases, communication bus terminators (TER800), and communication termination units (CTB810 and CTB811).

The HC800 is a high-performance, high-capacity process control processor. The HC800 can handle specific control and
information processing applications in addition to multiple-loop analog, sequential, and batch control. It has the power to
execute demanding process control applications that are data intensive, program intensive or both. The HC800 supports
multiple control languages such as C, function codes (FC), and Batch 90™. The Symphony Plus system uses a variety of
analog, control, and digital I/O devices to interface with the process. The system also supports integration of PROFIBUS
and HART protocols intelligent field and electric devices.The HPC800 communicates to control I/O, HART and PROFIBUS
master modules using the Harmony communication bus (HN800).

The CP800 communication processor provides interfaces to the Ethernet based Symphony Plus Plant Network (PN800),
the peer-to-peer communication bus (CW800).

The MB810 dual module mounting base provides power and network connections for the HC800 and CP800 modules. In
addition to a 24VDC power input, the base has four RJ45 Ethernet ports and a 9-pin serial communications port. The RJ45
Ethernet ports on the MB810 are used for SOE time synchronization, foreign device interfaces through Ethernet, and
primary and redundant PN800 network connection. The 9-pin serial sub connector is reserved for future use. Four side
mounted connectors provide interconnectivity to other MB810 or CTB810 and CTB811 terminations.

All Symphony Plus bases, including the MB810, are quickly attached to standard DIN rail by the turn of a single screw.

The CTB800 and CTB811 and din rail mounted modules which connect to either side of the MB810 mounting base. These
termination bases provide connections to the HN800 and the CW800 buses.

This user manual explains the features, specifications, and operation of all components that make up the HPC800. It
includes installation, troubleshooting, maintenance, and replacement procedures.
Support Services

ABB will provide assistance in the operation and repair of its products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.

When ordering parts, use nomenclature or part numbers and part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service office. Recommended spare parts lists, including prices are
available through the nearest sales or service office.

ABB has modern training facilities available for training your personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and scheduling.

Additional copies of this instruction, or other instructions, can be obtained from the nearest ABB sales office at a reasonable
charge.
Trademarks and Registrations
Registrations and trademarks used in this document include:

Composer™ Trademark of ABB.

INFI 90® Registered trademark of ABB
INFI-NET® Registered trademark of ABB.
Network 90® Registered trademark of ABB.
Symphony™ Trademark of ABB S.p.A.
Symphony™ Plus Trademark of ABB S.p.A.
HART™ Trademark of HART Communication Foundation
PROFIBUS® Registered trademark of PROFIBUS International (P.I.)
 TABLE OF CONTENTS

TABLE OF CONTENTS

Safety Summary.......................................................................................................1

About This Book ......................................................................................................5

Document Conventions .......................................................................................5
Document Icons....................................................................................................5

1. Introduction.................................................................................................... 1-1
1.1 Overview ..............................................................................................................1-1
1.1.1 HPC800 Overview ...........................................................................................1-2
1.1.2 Harmony Process Controller............................................................................1-2
1.1.3 PN800 Network................................................................................................1-2
1.1.4 CW800 Communication Bus............................................................................1-3
1.1.5 PN800 and CW800 Peer-to-Peer Communications.........................................1-4
1.1.6 HN800 Communication Bus.............................................................................1-4
1.1.7 SOE Time Synchronization Network................................................................1-5
1.1.8 Foreign Device Interface Network....................................................................1-5
1.1.9 HPC800 Redundancy ......................................................................................1-6
1.2 Features ...............................................................................................................1-6
1.2.1 Composer Compatibility...................................................................................1-7
1.3 Intended User ......................................................................................................1-7
1.4 User Manual Content ..........................................................................................1-7
1.5 Using this Manual................................................................................................1-8
1.6 Glossary of Terms and Abbreviations...............................................................1-8
1.7 Document Conventions ......................................................................................1-9
1.8 Reference Documents.........................................................................................1-9
1.8.1 Downloading Reference Documents from SolutionsBank .............................1-10
1.9 Related Nomenclature ......................................................................................1-10
1.10 Specifications .................................................................................................... 1-11
1.11 Design Standards ..............................................................................................1-12

2. Description ..................................................................................................... 2-1

2.1 Introduction .........................................................................................................2-1
2.2 HC800 Controller .................................................................................................2-2
2.2.1 Circuitry............................................................................................................2-3
2.3 CP800 Communication Processor.....................................................................2-5
2.3.1 Block Diagram..................................................................................................2-5
2.3.2 Microprocessor ................................................................................................2-5
2.3.3 PN800 ..............................................................................................................2-6
2.3.4 Memory ............................................................................................................2-6

2VAA001586 C i
TABLE OF CONTENTS

2.3.5 NVRAM ............................................................................................................2-6

2.3.6 Stop/Reset .......................................................................................................2-6
2.3.7 Switches and LEDs..........................................................................................2-6
2.4 CP800 Operation .................................................................................................2-6
2.4.1 Exception Reports............................................................................................2-6
2.4.2 Messages.........................................................................................................2-7
2.4.3 Data Integrity....................................................................................................2-8
2.4.4 Power System Status.......................................................................................2-8
2.4.5 CW800 .............................................................................................................2-8
2.4.6 Redundancy Link .............................................................................................2-8
2.4.7 Machine Fault Timer ........................................................................................2-9
2.4.8 Stop/Reset .......................................................................................................2-9
2.4.9 Switches and LEDs..........................................................................................2-9
2.5 Redundancy Failover ..........................................................................................2-9
2.5.1 Redundancy Operation ....................................................................................2-9
2.6 Power System Status ........................................................................................2-10

3. Installation ...................................................................................................... 3-1

3.1 Introduction .........................................................................................................3-1
3.2 Special Handling .................................................................................................3-1
3.3 Unpacking and Inspection..................................................................................3-1
3.4 Power Supply.......................................................................................................3-1
3.5 Installation and Connection Sequence .............................................................3-2
3.6 Mounting Instructions.........................................................................................3-2
3.6.1 MB810 Base Mounting.....................................................................................3-2
3.6.2 Vibration Hardening and Mounting ..................................................................3-4
3.6.3 HC800 and CP800 Module Insertion/Removal ................................................3-4

4. Operation........................................................................................................ 4-1
4.1 Introduction .........................................................................................................4-1
4.2 CP800 Module......................................................................................................4-1
4.2.1 Fault Status LED ..............................................................................................4-2
4.2.2 Stop/Reset .......................................................................................................4-4
4.2.3 Operating Modes .............................................................................................4-4
4.2.4 Module Integrity ...............................................................................................4-4
4.3 HC800 Module......................................................................................................4-5
4.3.1 HC800 Top Cover LEDs...................................................................................4-6
4.3.2 Stop/Reset Switch............................................................................................4-7
4.3.3 HC800 Startup .................................................................................................4-7
4.3.4 Modes of Operation .........................................................................................4-8

ii 2VAA001586 C
 TABLE OF CONTENTS

5. Troubleshooting............................................................................................. 5-1
5.1 Introduction .........................................................................................................5-1
5.2 Troubleshooting Procedures .............................................................................5-1
5.3 Flowcharts............................................................................................................5-1
5.4 Error Codes..........................................................................................................5-2
5.4.1 HC800 Error Codes .........................................................................................5-2
5.4.2 CP800 Error Codes..........................................................................................5-5
5.5 Status Summary ..................................................................................................5-5
5.5.1 HC800 Status Summary ..................................................................................5-5
5.5.2 CP800 Status Summary.................................................................................5-10
5.6 Diagnostic Tests ................................................................................................5-12
5.6.1 HC800 Diagnostic Test Descriptions..............................................................5-12
5.6.2 Running HC800 Offline Diagnostic Tests.......................................................5-15
5.6.3 HC800 Diagnostic Test Procedure.................................................................5-15
5.6.4 HC800 Diagnostic Mode LED Display ...........................................................5-16
5.6.5 CP800 Diagnostic Tests.................................................................................5-16
5.6.6 CP800 Diagnostic Test Descriptions..............................................................5-17
5.6.7 Running CP800 Offline Diagnostics...............................................................5-20
5.6.8 Display Mode .................................................................................................5-21
5.6.9 Halt On Error..................................................................................................5-22
5.7 CP800 Duplicate IP Address Detection Procedure ........................................5-22

6. Maintenance ................................................................................................... 6-1

6.1 General .................................................................................................................6-1

7. Replacement and Spare Parts ...................................................................... 7-1

7.1 Parts......................................................................................................................7-1

8. Module Repair and Replacement ................................................................. 8-1

8.1 Introduction .........................................................................................................8-1
8.2 Procedure.............................................................................................................8-1

9. HC800 Setup................................................................................................... 9-1

9.1 HC800 Module Configuration .............................................................................9-1
9.2 HC800 Jumper Setting ........................................................................................9-2
9.2.1 Battery Enable Jumper ....................................................................................9-2
9.3 HC800 Switch Settings .......................................................................................9-2
9.3.1 HC800 Dipswitch Settings ...............................................................................9-2
9.3.2 Virtualization of Dipswitches ............................................................................9-3
9.3.3 HC800 Physical Dipswitch SW1 ......................................................................9-4
9.3.4 HC800 Virtual Dipswitch SW1 .........................................................................9-4

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TABLE OF CONTENTS

9.3.5 HC800 Virtual Dipswitch SW2 .........................................................................9-5

9.3.6 HC800 Virtual Dipswitch SW3 .........................................................................9-7
9.3.7 HC800 Virtual Dipswitch SW4 .........................................................................9-7
9.3.8 HC800 Virtual Dipswitch SW5 .........................................................................9-7
9.3.9 HC800 Virtual Dipswitch SW6 - Loop Number ................................................9-8
9.4 SOE Time Synchronization IP Addressing for HC800 .....................................9-8
9.4.1 Changing SOE Time Synchronization IP Address for HC800 .........................9-9
9.5 Setting ModbusTCP Address for HC800 .........................................................9-10

10. CP800 Setup................................................................................................. 10-1

10.1 Module Configuration .......................................................................................10-1
10.1.1 IP Addressing.................................................................................................10-1
10.1.2 CP800 Switch Settings ..................................................................................10-4
10.2 CP800 Jumper Settings ....................................................................................10-6
10.2.1 Battery Enable Jumper ..................................................................................10-6

11. CP800 and HC800 Firmware Update ...........................................................11-1

11.1 Introduction ....................................................................................................... 11-1
11.2 CP800 Firmware Update Procedure................................................................. 11-2
11.3 HC800 Firmware Update Procedure ................................................................ 11-3
11.3.1 Firmware Update Procedure from A_1 to A_2............................................... 11-3
11.3.2 Firmware Update Procedure (from A_2 or higher)......................................... 11-4

A. Online Configuration ..................................................................................... A-1

A.1 Introduction to Online Configuration ............................................................... A-1
A.2 Setup ................................................................................................................... A-1
A.2.1 Redundant Cycle ............................................................................................ A-2
A.2.2 Primary Cycle.................................................................................................. A-4

B. Propagation Time Settings ........................................................................... B-1

B.1 Description.......................................................................................................... B-1
B.2 RFO810 Bus Architecture.................................................................................. B-2
B.3 Additional HN800 and CW800 Bus Architecture Examples ........................... B-5
B.4 Setting Propagation Time for Distance Greater than 1200 Meters ................ B-8

iv 2VAA001586 C
 LIST OF TABLES

LIST OF TABLES

Table 1-1: Glossary of Terms and Abbreviations .......................................................1-8

Table 1-2: Reference Documents ...............................................................................1-9
Table 1-3: Related Nomenclature .............................................................................1-10
Table 1-4: Specifications for HC800 .........................................................................1-11
Table 1-5: Specifications for CP800 .........................................................................1-12
Table 1-6: HPC800 Design Standards .....................................................................1-12
Table 4-1: LED States (CP800) ..................................................................................4-2
Table 4-2: CP800 CPU run codes ..............................................................................4-2
Table 4-3: CP800 Error Codes ...................................................................................4-3
Table 4-4: LED States (HC800) ..................................................................................4-6
Table 4-5: HC800 CPU run codes ..............................................................................4-7
Table 5-1: HC800 Error Codes ...................................................................................5-2
Table 5-2: HC800 Fault Status LED and Other Conditions ........................................5-5
Table 5-3: Byte and Bit description for HC800 ...........................................................5-6
Table 5-4: Byte Description - HC800 ..........................................................................5-6
Table 5-5: CP800 Status Byte Description ...............................................................5-10
Table 5-6: CP800 Status Bit Descriptions ................................................................5-11
Table 5-7: HC800 Diagnostic Tests ..........................................................................5-13
Table 5-8: HC800 Diagnostic Dipswitch Settings .....................................................5-15
Table 5-9: CP800 Diagnostic Tests ..........................................................................5-17
Table 5-10: CP800 Switch SW2 - Diagnostic Options ..............................................5-20
Table 5-11: CP800 Switch SW2 - Hardware Diagnostic Mode .................................5-20
Table 7-1: Module and Base Nomenclature ...............................................................7-1
Table 7-2: Cable Nomenclatures ...............................................................................7-1
Table 7-3: Miscellaneous Parts ..................................................................................7-2
Table 9-1: Physical Dipswitch SW1- Normal Run Settings .........................................9-4
Table 9-2: Physical Dipswitch SW1- Special Operation Settings ...............................9-4
Table 9-3: Physical Dipswitch SW1- Diagnostic Mode Settings .................................9-4
Table 9-4: HC800 Virtual Switch SW2 settings during normal operation ...................9-5
Table 9-5: HC800 Physical SW1 / Virtual SW2 Settings (Special Operations) ..........9-6
Table 9-6: HC800 Virtual Switch SW3 ........................................................................9-7
Table 9-7: HC800 Virtual Switch SW4 ........................................................................9-7
Table 9-8: HC800 Virtual Switch SW5 ........................................................................9-7
Table 10-1: CP800 Switch SW1 ................................................................................10-4
Table 10-2: CP800 Switch SW2 settings during normal operation ...........................10-5
Table 10-3: CP800 Switch SW2 settings during diagnostic mode operation ............10-6
Table 10-4: CP800 Switch SW4 ................................................................................10-6
Table A-1: Legend of Symbols ................................................................................... A-1
Table A-2: Redundant Cycle ...................................................................................... A-2
Table A-3: Primary Cycle ........................................................................................... A-4
Table B-1: Propagation Time Special Operations ...................................................... B-8

2VAA001586 C v
LIST OF TABLES

vi 2VAA001586 C
 LIST OF FIGURES

LIST OF FIGURES

Figure 1-1: HPC800K01 Components........................................................................ 1-1

Figure 1-2: PN800 and CW800 Peer-to-Peer communications in Symphony Plus
Systems ................................................................................................... 1-4
Figure 1-3: HN800 Bus Terminators .......................................................................... 1-5
Figure 1-4: Redundant HPC800 controller ................................................................. 1-6
Figure 2-1: HPC800 Controller with Communication Termination Units .................... 2-1
Figure 2-2: HPC800 Connector, DIP switch and LED locations................................. 2-2
Figure 2-3: Functional Block Diagram ........................................................................ 2-3
Figure 2-4: CP800 Block Diagram.............................................................................. 2-5
Figure 2-5: SD I/O Power Wiring.............................................................................. 2-10
Figure 3-1: Recommended Power Supply Concept ................................................... 3-2
Figure 3-2: Three position locking screw on DIN-rail locking device .......................... 3-3
Figure 3-3: Mounting of MB810 base to DIN-rail........................................................ 3-3
Figure 3-4: MB810 Vibration Mounting Lugs.............................................................. 3-4
Figure 4-1: CP800 Top Cover .................................................................................... 4-1
Figure 4-2: HC800 Top Cover .................................................................................... 4-5
Figure 5-1: HC800 Troubleshooting Flowchart - Fault Status LED ............................ 5-1
Figure 5-2: LEDs - Pass/Fail .................................................................................... 5-16
Figure 5-3: CP800 Diagnostic LEDs ........................................................................ 5-17
Figure 5-4: CP800 Diagnostic Menu Revision Information ...................................... 5-22
Figure 5-5: CP800 Diagnostic Menu Print Flag sub-menu....................................... 5-23
Figure 5-6: CP800 Diagnostic Menu; Duplicate IP Address Not Detected............... 5-23
Figure 5-7: CP800 Diagnostic Menu with Option ‘Y’ Displayed - Duplicate IP
Address Detected .................................................................................. 5-23
Figure 5-8: CP800 Diagnostic Menu showing MAC address of module with
duplicate IP Address .............................................................................. 5-24
Figure 9-1: HC800 Switch and Jumper Locations ...................................................... 9-2
Figure 9-2: Virtual Switch menu ................................................................................. 9-3
Figure 10-1: CP800 Switch and Jumper Locations................................................... 10-4
Figure A-1: Redundant Cycle ..................................................................................... A-4
Figure A-2: Primary Cycle........................................................................................... A-5
Figure B-1: HN800 extended with Multiple RFO810 Optical Links ............................. B-1
Figure B-2: CW800 Extended with an RFO810 Optical Links .................................... B-2
Figure B-3: HN800 with RFO810 Star Architecture .................................................... B-3
Figure B-4: CW800 with RFO810 Architecture........................................................... B-3
Figure B-5: Symphony Plus I/O devices on the HN800 bus (local and remote) ......... B-4
Figure B-6: Remote Peer-to-Peer communications over CW800 ............................... B-5
Figure B-7: Multiple HPC800 Controllers around a central CW800 hub..................... B-6
Figure B-8: Communications in a large, distributed site ............................................. B-7

2VAA001586 C vii
LIST OF FIGURES

viii 2VAA001586 C
Safety Summary

The following table categorizes the various safety precautions to be followed when using the HPC800 module:

Safety Precaution Description

Electrostatic Sensitive Device

Devices labeled with this symbol require special handling precautions as described in section
3- Installation of this user manual.

GENERAL WARNINGS Equipment Environment:

All components, whether in transportation, operation or storage, must be in a noncorrosive
environment.

Electrical Shock Hazard During Maintenance:

Disconnect power or take precautions to insure that contact with energized parts is avoided when
servicing.

2VAA001586 C 1
 Safety Precaution Description (Continued)
SPECIFIC WARNINGS Verify the main power, field power, and power entry panel circuit breakers/switches are turned off
before starting installation, retrofit, upgrade, or wiring procedures. Failure to do so could result in severe
or fatal shock or equipment damage. Do not turn the power on until the installation, retrofit, upgrade, or
wiring procedures are complete. Refer to sub-section 3.5- Installation and Connection Sequence of this
user manual, where this Specific Warning statement is applicable.

A module or base should not be inserted or removed with power applied when located in a Class I,
Division 2 hazardous location unless the area is known to be nonhazardous. Refer to sub-section
3.5- Installation and Connection Sequence of this user manual, where this Specific Warning statement
is applicable.

All redundant and non-redundant HPC800 controllers connected together on a common CW800 bus
must share the same 24vdc common power input. Refer to sub-section 1.1.9- HPC800 Redundancy of
this user manual, where this Specific Warning statement is applicable.

Do not attempt to change the keying of the MB810 base, HC800, CP800, or any other Symphony Plus
module. Insertion of a module into the wrong base or incorrect position of a base may result in
permanent damage to the module or base. Refer to sub-section 2.3- CP800 Communication Processor
of this user manual, where this Specific Warning statement is applicable.

Before you remove the HC800 module from its base, make sure you press the Stop/Reset button once
to halt the module. If you fail to halt the module before removing it from its base, then it could result in
unpredictable I/O communications. Refer to sub-section 3.6.3- HC800 and CP800 Module
Insertion/Removal of this user manual for procedure details. This Specific Warning statement is
applicable to sub-sections: 2.2.1.9- Stop/Reset and 2.3.6- Stop/Reset of this user manual.

Do not connect the MB810 mounting base to another mounting base while it is powered. Do not
connect the MB810 mounting base (powered or unpowered) to another mounting base that is powered.
Refer to sub-section 3.6.1- MB810 Base Mounting of this user manual, where this Specific Warning
statement is applicable.

The keying of each module and base is pre-set at the factory and must not be changed. Keying for the
HC800 module is 1=E and 2=E. Keying for the CP800 modules is 1=C and 2=C. Keying on the MB810
mounting base is A1=E, A2=E, B1-C and B2=C. Refer to sub-section 3.6.3.1- Insertion of this user
manual, where this Specific Warning statement is applicable.

Do not tilt the module at an angle during removal. It is recommended to extract the module straight out
of the base. Refer to sub-section 3.6.3.2- Removal of this user manual, where this Specific Warning
statement is applicable.

Do not remove an operational controller under power unless the stop/reset switch has been depressed
once and the controller has halted (status LED is red a). This procedure must be followed when
removing a controller from a redundant configuration. An operational controller must halt operation
before control passes to the redundant controller. Refer to sub-section 4.3.2- Stop/Reset Switch of this
user manual, where this Specific Warning statement is applicable.

Firmware revision levels must be the same in both primary and redundant controllers. If the firmware
revision levels are different and a failover occurs, the redundant controllers may operate erratically.
Refer to sub-section 4.3.2- Stop/Reset Switch of this user manual, where this Specific Warning
statement is applicable.

Do not reset a controller before the LEDs or controller status byte indicate that the controller is
available. Resetting a controller prematurely could result in unpredictable operation, loss of output data,
or loss of control. Refer to appendix A.2- Setup of this user manual, where this Specific Warning
statement is applicable.

Symphony Plus modules may be located up to 3 kilometers from the central CW800/HN800 bus hub.
The total cable length between any two ends off of the central hub may not be more than 3 kilometers.
The total cable length includes the length of all. Refer to appendix B.4- Setting Propagation Time for
Distance Greater than 1200 Meters of this user manual, where this Specific Warning statement is
applicable.

2 2VAA001586 C
 Safety Precaution Description (Continued)
SPECIFIC CAUTION To prevent damage to the pins, make sure the baseplate plugs and sockets are fully aligned, as the
units interconnect. Under no circumstances use excessive force. Refer to sub-section 3.6.1.1-
Mounting Procedure of this user manual, where this Specific Caution statement is applicable.

For installations in ATEX classified areas:

• Turn off power to the I/O segment before you remove or install modules in the MB810 mounting
base.
• Turn off power before you remove or install CTB810, CTB811, HBX01L, HBX01R bus
extenders.
• Turn off power before you remove or insert TER800 terminators or SPK01-0x cables.

Refer to sub-section 3.6- Mounting Instructions of this user manual, where this Specific Caution
statement is applicable

2VAA001586 C 3
4 2VAA001586 C
About This Book

About This Book

Document Conventions
Microsoft Windows conventions are normally used for the standard presentation of material when entering text, key
sequences, prompts, messages, menu items, screen elements, etc.

Document Icons
This user manual uses the following document icons with a corresponding statement, wherever applicable, to point out
important information or useful hints to the user:

Electrical Warning icon: It indicates the presence of a hazard that could result in
electrical shock.

Warning icon: It indicates the presence of a hazard that could result in a plant shutdown
or personal injury.

Caution icon: It indicates the presence of a hazard that could result in corruption of
software or damage to equipment/property.

Information icon: It alerts the user to pertinent facts and conditions

Tip icon: It indicates advice on, for example, how to design your project or how to use a
certain function.

NOTE The Note statement highlights important information pertaining to a particular descriptive text (for
example: 'Module description', 'Installation', 'Configuration', or 'Operational procedure', etc.) in the
document.
Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property
damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in
degraded process performance leading to personal injury or death. Therefore, fully comply with all Warning and Caution
notices.

2VAA001586 C 5
 About This Book

6 2VAA001586 C
Introduction Overview

1. Introduction
1.1 Overview
The Harmony Process Controller, HPC800K01, consists of a control processor (HC800), a communication processor
(CP800), a dual module mounting base (MB810), network terminators (TER800) and communication termination units
(CTB810 and CTB811). The HPC800K01 is used for non-redundant applications, HPC800K02 is used for redundant
applications. The HPC800K02 contains two HC800 modules, two CP800 modules, two MB810 mounting bases,
communication bus terminators (TER800), and communication termination units (CTB810 and CTB811). The HPC800K01
is shown in Figure 1-1.
The HC800 control processor can handle specific control and information processing applications in addition to multiple-
loop analog, sequential, and batch control. It has the power to execute demanding process control applications that are
data intensive, program intensive or both. The HC800 supports multiple control languages such as C, function codes (FC),
and Batch 90™.
The CP800 module provides a HPC800 controller with access to the Symphony Plus Plant Network (PN800).
The HC800 and CP800 processors are inserted into a MB810 mounting base. The MB810 provides 24 VDC power input,
Ethernet and serial communication connection ports. The MB810 is designed to be din rail mounted to provide quick and
easy installation.

Figure 1-1: HPC800K01 Components

2VAA001586 C 1-1
HPC800 Overview Introduction

1.1.1 HPC800 Overview

HPC800 is a high-performance, high-capacity process controller that is used to support the plant’s total control
requirements, from discrete and continuous, to batch and advanced control applications.
The HPC800 controller environment executes demanding process control applications that are both data and program
intensive. Redundancy options are available at all levels of control, I/O and communication, resulting in maximum flexibility
and availability.
Along with a range of I/O options, the HPC800 delivers powerful, versatile and scalable automation solutions for plant
applications of all sizes.
Simultaneously, the HPC800 connects to DIN style I/O modules and traditional Rack I/O modules. Intelligent I/O devices
such as smart transmitters, actuators, intelligent electronic devices (IEDs), and third-party PLCs are easily integrated
through industry-standard fieldbuses and networks. Each device’s resident information can be used in control strategies
and higher-level applications in order to produce tighter and more reliable process control solutions.
The HPC800 controller uses ABB extensive set of field-proven standard function code algorithms and S+ Engineering’s
graphical design tools to develop its control strategies. Programming and control language support also includes C
programming, Batch 90, and UDF (user-defined function) control configurations. By using the same function code
algorithms as previous generations of Symphony and INFI 90 controllers, the HPC800 supports the easy and risk-free
porting of installed control execution environments.
The controller industrial grade embedded system architecture allows the HPC800 to execute closed loop control of more
than 5,000 I/O in less than 250 msec. Low power consumption allows for installation in sealed enclosures without requiring
fans, louvers, air filters or other forced cooling techniques. This eliminates many potential trouble factors and contributes to
the controller’s high reliability and availability. All in all, the HPC800 provides users with the benefits of fast, accurate and
uninterrupted control of their process.
S+ Operations, S+ Engineering and other applications communicate with HPC800 controllers over the system’s high-
speed, high-throughput and high-security 100 Mbps Fast Ethernet-based redundant communication Plant Network
(PN800). The network-centric architecture allows for integration of field devices, process and electrical system areas, and
business enterprise systems in a simple, scalable, seamless and secure manner.

1.1.2 Harmony Process Controller

The HPC800 module is the fundamental control node of the Symphony Plus system. The HC800 performs the actual
process control and configuration management. CP800 performs the communication processing to the PN800 network.
Connection to the PN800 network enables the HPC800 to:
• Communicate field input values and states for process monitoring and control.
• Receive control instructions from plant personnel through human system interfaces to adjust process field outputs.
• Provide feedback to plant personnel of actual output changes through human system interfaces.
• Download controller function block configuration information and parameters from S+ Engineering:
Composer.Harmony tool These configurations parameters determine the operation of functions such as process
control, data acquisition, alarming, trending, and logging.
• Generate a report status.
• Download firmware updates.
The communication components of the Symphony Plus system include the Symphony Plus Plant Network (PN800), the
CW800 peer-to-peer communication bus (CW800), SOE Time Synchronization Network, and the Harmony communication
bus (HN800). Each component performs specific functions within the system.

1.1.3 PN800 Network

The Symphony Plus Plant Network (PN800) is a bidirectional, high speed Ethernet data network that operates at a
communication rate of 100-Mbaud. Multiple HPC800s may be connected to the PN800 network.
The PN800 network supports IEC 62439 Parallel Redundancy Protocol, 2010 version (PRP-0 or PRP) for increased
Ethernet network reliability. The benefits of PRP include network redundancy and seamless failover caused by single point
of failure.
Two independent LANs are used to provide this redundancy and seamless failover. The CP800 sends a copy of each
outgoing message to the destination nodes simultaneously over each independent LAN. The destination node accepts the
first message received and discards the duplicate message. This architecture ensures that, as long as one LAN is working,
the destination always receives the message.

1-2 2VAA001586 C
Introduction CW800 Communication Bus

HC800 Peer to peer communications are supported on the PN800 network.

On the PN800 network, a node can either be an HPC800 controller, a PNI800 network interface, a bridge to an INFI-NET
loop, or a PC running human system interface software, for e.g. Symphony Plus Operations Server or Symphony Plus
Engineering Station.

NOTE: All Symphony Plus software applications require the PNI800 to be connected to the same PN800 network
segment. Some applications may require exclusive use of the PNI800.

Symphony Plus Composer™ engineering tools, Harmony OPC Server, and other ABB software applications interface to the
PN800 networking using a secure application interface called HarmonyAPI (HAPI). Third-party applications are not directly
connected to the PN800 network because of network security. Harmony OPC Server software provides a standard OPC
interface for third-party applications to access data on the PN800 network.

1.1.4 CW800 Communication Bus

The CW800 bus is a high speed communication bus. CW800 is used for peer-to-peer communications between HPC800
controllers. Multiple HPC800 controllers on the same CW800 bus are identified by combination of Loop Number, Node
Number and the HC800 module address. These controllers can have the same HC800 module address (recommend to use
default of ‘2’), since all HPC800 controllers always have unique Loop Number and Node Number combination in a
Symphony Plus system.
The CW800 bus can extend to remote location by the RFO810 fiber-optic repeaters. You must use the optical link provided
by the RFO810s when you need to extend CW800 communication outside a local enclosure. The CW800 bus supports one
RFO810 link per bus. This link can support multiple controllers on each side of the link and can be extended up to 3 km.
Refer to Appendix B: Propagation Time Settings of this user manual for more details on remote optical link.
Each electrical CW800 bus is capable of supporting up to 32 single HPC800 controllers or 16 redundant pairs of HPC800
controllers. When using RFO810 optical link, electrical CW800 bus on each side supports up to 30 single HPC800
controllers or 15 redundant pairs of HPC800 controllers.
A CW800 bus segment starts at a CTB810 communication termination base. A TER800 terminator is installed into the
CW800 connector on the CTB810.The bus then runs through the adjacent MB810 where makes connection with the CP800
and HC800 modules. The bus continues to the adjacent CTB811 communication termination base where it is either
terminated or extended using a SPK800-?? cable to another CTB810 or CTB811. Each end of the CW800 bus must be
terminated using a TER800.
When using RFO810 optical link for CW800, you can use either RMU811 base, which has bus connectors on the base, or
RMU810 base with HBX01L and HBX01R bus terminal boards. Do not use HN810 or HN811 bus terminal board for
RFO810 optical link. TER800 terminator must be Rev E or later revisions for RFO810 optical link.

2VAA001586 C 1-3
PN800 and CW800 Peer-to-Peer Communications Introduction

1.1.5 PN800 and CW800 Peer-to-Peer Communications

HPC800 to HPC800 peer-to-peer communications can occur over both the PN800 network and the CW800 communication
bus. The following figure (Figure 1-2) shows the differences between these two communication paths.

Figure 1-2: PN800 and CW800 Peer-to-Peer communications in Symphony Plus

Systems

NOTE: The PN800 “loop signals” are asynchronous / exception report based, whereas CW800 signals are synchronous
and periodic “bus signal” communications. This communication architecture optimizes data flow for superior
performance.

1.1.6 HN800 Communication Bus

The HN800 communication bus is high speed link used within a cabinet to connect the HC800 controller to its associated
I/O devices such as a PDP800 (PROFIBUS master module), a HAI805 (HART Analog input module), or other Symphony
Plus IO modules. The HN800 bus enables Net90, INFI90, Symphony, other Symphony Plus, or S800 I/O systems to
connect to Symphony Plus controllers. The Symphony/Harmony SPK800-PBA1-0x (where: the value of ‘x’ can either be ‘1’,
‘2’,’3’, or ‘4’, whichever is applicable) cables are used to connect to Net90, INFI90, Symphony, or Symphony Plus Rack I/O
systems. The PDP800 module or the IOR810 Gateway module is used to connect to the S800 I/O system.
The HN800 bus can extend to remote locations using the RFO810 fiber-optic repeaters. You must use the optical link
provided by the RFO810s when you need to extend HN800 communication outside a local enclosure. The HN800 bus
supports a 'Star Architecture' with RFO810s. With the controller located in the center of the 'Star', the local HN800 bus can
support up to 8 RFO810 optical links. Each RFO810 optical link can be up to 3 km long. Refer to Appendix B: Propagation
Time Settings of this user manual for more details on remote optical link.
Each electrical HN800 bus is capable of supporting up to 64 HN800 devices. As a special rule, one RFO810, either single
or redundant, is counted as 4 HN800 devices.
Typically, a HN00 bus segment starts at a CTB810 communication termination base. A TER800 terminator is installed into
the HN800 connector on the CTB810 base. The bus then runs through the side edge connector to the adjacent MB810
where it connects with the HPC800 controller modules. Signals from the controller are sent through the bus, as it connects
to the adjacent CTB811 communication termination base where it is either terminated or extended using a SPK800-xx cable
to a HBX01L or HN810 bus terminal board. The HN800 bus then routes through all connected IO bases (PTU810, MB805,
HBS01-xxx, etc.) until the HN800 bus is terminated at a HBX01R or HN811 terminal board with an installed TER800
terminator. Other HN800 bus configurations are possible when each end of the HN800 bus is terminated using a TER800
terminator.

1-4 2VAA001586 C
Introduction SOE Time Synchronization Network

When there is any RFO810 on a HN800 bus, then all bus terminal boards on this HN800 bus must use HBX01L and
HBX01R. All TER800 terminators on this HN800 bus must be Rev E or later revisions. HN810 or HN811 bus terminal board,
and TER800 with older revision can only be used on isolated electrical HN800 without any RFO810 optical link.

NOTE: A simple rule to follow is that each HN800 connector on a HBX01L or HBX01R board must be populated with
either a cable connection or a terminator. This rule also applies to CW800, HN810 and HN811 boards, CTB810 and
CTB811 boards, and RMU811 base.

The following figure (Figure 1-3) shows two HPC800 controllers communicating with each other over the CW800 bus. In
addition, each controller also communicates to the Symphony Plus I/O modules using their own HN800 bus. The location of
TER800 terminators are shown in Figure 1-3.
NOTE: An HN800 bus must not be associated with more than a single pair of CTB810/810 termination bases. i.e. a
single non-redundant or redundant controller pair.

Figure 1-3: HN800 Bus Terminators

1.1.7 SOE Time Synchronization Network

The HPC800 controller utilizes a dedicated Ethernet network for SOE time synchronization. The SOE Time Synchronization
Network Ethernet port is located on the MB810 mounting base labeled EN1 A. If an HPC800 controller does not use the
SOE function, then the SOE Time Synchronization port does not need to be connected or configured for IP address.

1.1.8 Foreign Device Interface Network

The HPC800 controller employs a dedicated Ethernet network for the interfacing of foreign devices directly to the HPC800
controller. The Foreign Device Interface Network Ethernet port is located on the MB810 mounting base labeled EN1 B.
Harmony Gateway Software (HGS) is used to provide a ModbusTCP interface capable of supporting up to 8 servers and
128 clients.

2VAA001586 C 1-5
HPC800 Redundancy Introduction

1.1.9 HPC800 Redundancy

The HPC800 controller supports hardware redundancy for the HC800, and CP800 (refer to Figure 1-4) processor modules.
Two HC800 modules and two CP800 modules are required for redundancy.
Each MB810 mounting base has its own power input allowing each HPC800 to be powered independently.

All redundant and non-redundant HPC800 controllers connected together on a common CW800 bus must
share the same 24vdc common power input.

Each backup HC800 or CP800 module continuously monitors its primary using dedicated redundancy communication links
(CP800-to-CP800 and HC800-to-HC800). A failover to the backup occurs when the backup detects a primary module
failure. When this happens, the backup assumes responsibility and the primary is taken offline.

NOTE: The failover of a processor module (HC800 or CP800) within an HPC800 controller does not cause the other
processor module in that HPC800 controller to failover. It continues to function as the primary processor (HC800 or
CP800) for the HPC800 module.

NOTE: The HC800 module must be configured for redundancy. Refer to FC 90 S3 details in the
S+ Engineering for Harmony Function Code Application Manual for detailed procedure on how to configure HC800 for
redundancy.

The HPC800 module supports line redundancy for the PN800 network and the CW800 and HN800 communication buses.
Refer to sub-section 2.5- Redundancy Failover of this user manual for more information.

Figure 1-4: Redundant HPC800 controller

1.2 Features
The HPC800 interface has the following features:
• PROFIBUS and HART intelligent device integration.
• PN800 Ethernet network provides a plant-wide communication network.
• Dedicated SOE Time Synchronization Network provides time synchronization across the control system plant wide.
• HPC800 controller interface modules provide localized startup and shutdown on power failure without operator
intervention.
• Fast response time. The 100-Mbaud communication rate gives timely information exchange.
• The HPC800 controller processes TCP and UDP messages supporting broadcast, multicast, and time
synchronization messages.
• All messages contain checksums, encrypted keys, and cyclical redundancy checks (crc) to insure data integrity.

1-6 2VAA001586 C
Introduction Composer Compatibility

1.2.1 Composer Compatibility

Composer support for the HC800, CP800, and PNI800 modules is provided starting with S+ Engineering: Composer
Harmony version 6.0. Earlier versions of Composer does not recognize the HPC800 or PNI800.

1.3 Intended User

Personnel installing, operating, or maintaining any component of the HPC800 controller should read this user manual
before performing any installation, operation, or maintenance procedures. Installation requires an engineer or technician
with experience in handling electronic circuitry and familiarity with communication networks.

1.4 User Manual Content

The user manual consists of ten sections and two appendices:
• Introduction:
This section provides an overview of the HPC800 controller interface. It also contains features and specifications.

• Description:
This section provides a functional block diagram level description of the HPC800 controller interface modules and
explains module operating theory.

• Installation:
This section details the handling guidelines and describes the HPC800 controller interface installation and
connection sequence.

• Operation:
This section provides information about normal module operation.

• Troubleshooting:
This section explains how to troubleshoot the modules using error codes and lists corrective actions.

• Maintenance:
This section explains the maintenance schedule for the HPC800 controller.

• Replacement and Spare Parts:

This section provides a list of part numbers and nomenclature.

• Module Repair and Replacement:

This section describes the procedure to replace the HC800 or CP800 modules.

• HC800 Setup:
This section describes the steps required to set up the HC800 module of the HPC800 controller.

• CP800 Setup:
This section explains the steps required to set up the CP800 module of the HPC800 controller.

• CP800 and HC800 Firmware Update:

This section describes the steps to update the CP800 and HC800 firmware.

2VAA001586 C 1-7
Using this Manual Introduction

• Appendix A: Online Configuration:

This appendix explains how to make configuration changes without affecting the primary controller or interrupting
the control process.

• Appendix B: Propagation Time Settings:

This appendix explains the procedure to set the propagation time for the HPC800 controller.

1.5 Using this Manual

Make sure to read this user manual in sequence. It is important to become familiar with the entire contents of this user
manual before using the modules.
This user manual is organized to enable quick information retrieval:
1. Read the Introduction, Description and Operation sections to gain an understanding of the HPC800 controller
and its functionality.
2. Perform all steps in the Installation section. This section provides an installation flowchart.
3. Read the Operation section before applying power to the HPC800.
4. Refer to the Troubleshooting section, if a problem occurs. This section helps to diagnose and correct common
problems.
5. Refer to the Maintenance section for scheduled maintenance requirements.
6. Refer to the Replacement and Spare Parts section for HPC800 replacement procedures. The section provides
a replacement flowchart.

1.6 Glossary of Terms and Abbreviations

The following table (Table 1-1) contains those terms and abbreviations that are unique to ABB or have a definition that is
different from standard industry usage.

Table 1-1: Glossary of Terms and Abbreviations

Term Definition

BOOTP BOOTP is a network protocol used by a network client to obtain an IP address

from a configuration server. On initial power-up, the CP800 attempts to obtain
the first two octet values using BootP. If BootP fails, then the value is set using
the procedure detailed in sub-section 10.1.1- IP Addressing of this user
manual.

PN800 Symphony Plus system advanced Ethernet data communication highway.

CW800 High speed, redundant, peer-to-peer communication link. Used to transfer

information between intelligent modules within a Harmony control unit.

Exception report Information update generated when the status or value of a point changes by
more than a specified significant amount or after a specified period of time.

HN800 Redundant communication bus between the Harmony HC800 control

processor and Symphony Plus I/O modules.

PC Personal Computer. A generic termed used for desktop or laptop computers.

HGS Harmony Gateway Software is a ModbusTCP interface used to connect

foreign devices to the HC800 controller.

ModbusTCP A TCP transport protocol that embeds a Modbus frame into a TCP frame,

S800 I/O Comprehensive, distributed and modular process I/O system that
communicates over industry standard field buses.

MFT Machine fault timer. Reset by the processor during normal operation. If not
reset regularly, then the MFT times out and the controller stops

1-8 2VAA001586 C
Introduction Document Conventions

Table 1-1: Glossary of Terms and Abbreviations (Continued)

Term Definition

FC Function code. An algorithm which manipulates specific functions. These

functions are linked together to form the control strategy.

Composer S+ Engineering suite of tools used to configure S+ Control controllers and IO

IP Address The four bytes of an IP address. In dotted-decimal notation, an IP address

appears as follows -
[ octet]. [ octet]. [ octet]. [ octet]
like 192.165.7.2
Definition: An octet represents any eight-bit quantity. By definition, octets range
in mathematical value from 0 (zero) to 255.

PRP Parallel Redundancy Protocol (PRP) is a data communication network

standardized by the International Electrotechnical Commission as IEC 62439-3
Clause 4. It allows systems to overcome any single network failure without
affecting the data transmission.
It can be applied to most Industrial Ethernet applications since it is independent
of the protocols and provides seamless failover.
Under PRP, each network node has two Ethernet ports attached to two
different local area networks of arbitrary, but similar topology.

SOE Sequence of Events.

VDC Volts direct current.

MMU Module Mounting Unit.

Logic Power Power needed to run the module’s logic circuits.

Field Power (or IO) Power needed for field signals.

1.7 Document Conventions

A term ‘x’ in a nomenclature or a part number indicates a variable for that position (e.g., HPC800K0x).

1.8 Reference Documents

The following table (Table 1-2) lists the documents that provide additional information for related hardware and software.
Refer to these documents when required.

Table 1-2: Reference Documents

Document ID Document Title

2VAA000811 S+ Engineering for Harmony Introduction and Installation Manual.

2VAA000812 S+ Engineering for Harmony Primary Interface Manual.

2VAA000813 S+ Engineering for Harmony Automation Architect Manual.

2VAA002581 S+ Engineering for Harmony Gateway Software User Manual.

2VAA000844 S+ Engineering for Harmony: Function Code Application Manual.

2VAA001588 S+ I/O: SPRIO22 Remote I/O Module User Manual.

2VAA001714 S+ I/O: HAI805 and HAO805 HART Analog Input/Output Modules User
Manual.

2VAA001586 C 1-9
Downloading Reference Documents from SolutionsBank Introduction

Table 1-2: Reference Documents (Continued)

Document ID Document Title

2VAA001446 S+ I/O: PDP800 PROFIBUS Master Module Hardware and Operation User
Manual.

2VAA001719 S+ I/O: PNI800 Harmony Plant Network (PN800) Interface User

Manual.

2VAA002993 Technical Description - Symphony Plus Ethernet Networking.

1.8.1 Downloading Reference Documents from SolutionsBank

Follow the given steps to download appropriate document referenced in the user manual:
1. Click on the following hyperlink- ‘SolutionsBank' to open the SolutionsBank Search web page.

NOTE: If you are unable to open the SolutionsBank hyperlink, then call ABB Sales Service representative for
SolutionsBank subscription access rights.

2. Click on the Advanced Search button in the SolutionsBank Search web page.
3. Enter appropriate document ID number followed by an asterisk mark (*) in the Doc ID: field.

For Example: Enter 2VAA000844* in the Doc ID: field to view/download appropriate versions of the
S+ Engineering for Harmony Function Code Application Manual.
4. Click on the Search button to view appropriate versions of the user manual.
5. Click on appropriate user manual title (for e.g: ‘S+ Engineering for Harmony Function Code Application Manual’)
to download it to the system.

1.9 Related Nomenclature

The following table (Table 1-3) lists the nomenclature related to the HPC800 controller:

Table 1-3: Related Nomenclature

Nomenclature Description

HC800 Control processor module of the HPC800 controller.

CP800 Communication processor module of the HPC800

controller.

MB810 S+ Control mounting base. Mounts 1 HC800 and 1

CP800 module. A component of the HPC800 controller.

CTB810 and S+ Control communication terminal board.

CTB811

HBX01L and HN800/CW800 bus extender terminal board.

HBX01R

HN810 and HN800 bus terminal board.

HN811
NOTE: It does not support usage of RFO810 optical
link.

TER800 S+ Control communication bus terminator. A terminator is

required at each end of the CW800 and HN800
communication bus.

PNI800 S+ Control Plant Network Interface module.

1-10 2VAA001586 C
Introduction Specifications

1.10 Specifications
The following tables (Table 1-4 and Table 1-5) lists the specifications for the HC800 and CP800 modules:

Table 1-4: Specifications for HC800

Property Characteristic/Value

Power requirements2 +24 VDC at 200 mA; 5 W

Overvoltage category I for power
(IEC 61010-1)

Microprocessor 32-bit processor running at 256 MHz

Memory 4 Mbytes ROM, 64 Mbytes RAM, 2 Mbytes MRAM

All memory has 32-bit data path

DRAM NVRAM Flash ROM

Total Available Total Available Total
8 Mbytes 7.56 Mbytes 2 Mbytes 1.90 Mbytes 2 Mbytes

Communication rates 4 Mbps (CW800 and HN800)

10/100 Mbps (Time-sync and Foreign Device Interface)

Mounting Keyed to MB810 mounting base which is then mounted to DIN-rail. Key
positions the HC800 are 1 = E, 2 = E

Ambient temperature1 0° to 55°C (32° to 131°F)

Relative humidity1 20% to 95% up to 55°C (131°F) non-condensing

20% to 45% from 55°C (131°F) to 70°C (158°F) non-condensing

Atmospheric pressure1 3048.0m (10,000.0 ft.)

Air quality ISA S71.04 G1

Certification
Canadian Standards Certified for use as process control equipment in an ordinary
Association (CSA) (nonhazardous) location
(pending)
CE mark EMC directive
CE (pending)
NOTES:
1. These product specifications exceed the testing limits specified in CSA standard 601010-1-12
(altitude up to 2000m, maximum relative humidity of 80%, and operating temperature range of 5C to
40C). ABB has tested and certified this product to the values given here.

2. To be supplied by a Class 2 or Limited Energy source (reference 61010-1 3rd edition for
requirements of an Energy Limited power source).

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

2VAA001586 C 1-11
Design Standards Introduction

Table 1-5: Specifications for CP800

Property Characteristic/Value

Power requirements2 +24 VDC at 200 mA; 5 W

Overvoltage category I for power
(IEC 61010-1)

System capability
PN800 3937 addressable nodes in the system. Any combination of PN800
node types (HPC800, PNI800, etc.) are supported.

Microprocessor 32-bit processor running at 256 MHz

Memory 4 Mbytes ROM, 64 Mbytes RAM

Communication rates 10/100 Mbps (PN800)

4 Mbps (CW800)

Mounting Keyed to MB810 mounting base which is then mounted to DIN-rail. Key
positions the HC800 are 1 = C, 2 = C

Ambient temperature1 0° to 55°C (32° to 131°F)

Relative humidity1 20% to 95% up to 55°C (131°F) noncondensing

20% to 45% from 55°C (131°F) to 70°C (158°F) noncondensing

Atmospheric pressure1 Sea level to 3048.0m (10,000.0 ft.)

Air quality ISA S71.04 G1

Certification
Canadian Standards Certified for use as process control equipment in an ordinary
Association (CSA) (nonhazardous) location
(pending)
CE CE mark EMC directive
(pending)
NOTES:
1. These product specifications exceed the testing limits specified in CSA standard 601010-1-12
(altitude up to 2000m, maximum relative humidity of 80%, and operating temperature range of 5C to
40C). ABB has tested and certified this product to the values given here.

2. To be supplied by a Class 2 or Limited Energy source (reference 61010-1 3rd edition for
requirements of an Energy Limited power source).

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

1.11 Design Standards

The following table (Table 1-6) lists the design standards for the HPC800 module:

Table 1-6: HPC800 Design Standards

Category Standard Description

Safety CSA C22.2 No. 142 Safety standards for process control
equipment
ANSI/ISA S82.01-1994

EN 61010-1 Safety standards for process control

equipment
CSA C22.2 No. 1010.1

1-12 2VAA001586 C
Introduction Design Standards

Table 1-6: HPC800 Design Standards (Continued)

Category Standard Description

Environmental EN 60068-2-1 Operating temperature

EN 60068-2-2

EN 6000682-14

EN 60068-2-78 Operating relative humidity

ISA S71.04 (level 1 liquids, Air quality

EN60068-78, solids, gases)

MIL-STD-810G, 501.5, 502.5 Storage and Transport Temperature

Test

MIL-STD-810G, 500.5 Low Air Pressure (Operational)

MIL-STD-810G, 500.5 Storage and Transport Altitude Test

Vibration MIL-STD-810G, 514.6 Storage/transportation vibration

Category 1, basic transportation

EN 60068-2-27 Shock
EN 610068-2-31 Drop

EN 61298-3

EN 60068-2-6 Operating vibration (sinusoidal)

EN 61298-3

EMI, RFI, and EN 61000-4-2 (level 3) ESD

electrical surge
EN 61000-4-3 (level 3) EMI susceptibility

EN 61000-4-4 (level 3) Electrical fast transient

EN 61000-4-5 (level 3) Electrical surges

EN 61000-4-6 (level 3) Conducted immunity

EN 61000-4-8 (level 3) Magnetic fields

CISPR-11 & CISPR 16-1-1 Radiated emissions

EN 61000-4-11 Voltage Fluctuation Immunity Test

EN 61000-4-11 Voltage Deviation Immunity Test

EN 61000-6-2

CSPR 11 Conducted Emissions Test

CISP16-1-1

Flammable CSA C22.2 No. 213 Nonincendive equipment

atmospheres
ISA S12.12 Nonincendive equipment

FM Class 3611 Division 2 equipment

Flammability of IEEE 383 Intercabinet cables

product components
UL rating VW-1 Intracabinet cables

UL 94 V-0, V-1, V-2, or V5 Flammability of plastic materials

CE Mark directives 2006/95/EC Low voltage directive

2004/108/EC EMC directive

Certifications CSA1 Canadian Standards Association

safety standard

2VAA001586 C 1-13
Design Standards Introduction

Table 1-6: HPC800 Design Standards (Continued)

Category Standard Description

ATEX Certification2 Equipment and protective systems
(Ex II 3 G Ex nA IIC T5 Gc), intended for use in potentially
explosive atmospheres.
NOTES:
1. This product is certified to CSA standard CSA 61010-1-12 3rd edition.

2. The HC800, CP800, MB810, CTB810, CTB811, HBX01L, HBX01R, TER800, and SPK800-0x
products have been ATEX certified for use in explosive atmosphere Equipment group II,
Equipment category 3, gaseous environment (G), Explosion protection type Ex, Protection type
nA, Gas group IIC, and Equipment protection level Gc (II 3 G Ex nA IIC T5 Gc) provided the
equipement is installed under the following conditions:

• Operating temperature: 0-55°C.

• Relative Humidity: 20-95% non-condensing.
• The equipment must be installed in enclosures with a minimum International Protection Rating
equal to IP54.
• All equipment in the system is powered by a non-sparking fuse with a maximum current rating of
0.7A.
• Fuse holders to be certified to meet or exceed Ex IIG requirements.
• All neutral line connections of the power supply system are connected to ground.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

1-14 2VAA001586 C
Description Introduction

2. Description
2.1 Introduction
This section explains the functionality of the HPC800 interface. The following figure (Figure 2-1) displays the Harmony
components that make up the interface.

Figure 2-1: HPC800 Controller with Communication Termination Units

2VAA001586 C 2-1
HC800 Controller Description

The following figure (Figure 2-2) displays a more detailed view of the various HPC800 connectors, switches, and LEDs.

Figure 2-2: HPC800 Connector, DIP switch and LED locations

2.2 HC800 Controller

The HC800 controller incorporates the power of a 32-bit microprocessor operating at 256 megahertz. This is coupled with
32-bit wide double data rate memory design with an optimized interface. The microprocessor supplies superior
performance capable of supplanting the need for external mainframes or minicomputers.
In some processes, the effects of a control failure in the system can create dangerous situations or cause economic loss. To
reduce the possibility of these problems occurring, redundant controllers provide increased availability. Redundant
controllers link directly to each other via the MB810 mounting base connectors. No cabling is required. Each controller uses
a redundant high speed communication link to accomplish this function. If the primary controller fails, the redundant
controller is waiting in standby mode and immediately takes over. The redundant controller has the same control strategy
loaded in its memory as the primary controller and is ready to assume control. The redundant communication channel
ensures that single point failures does not prevent the redundant controller from being in a state of readiness to take over.
While the controller is directing a process, it also executes diagnostic routines. It is constantly checking the integrity of its
hardware and firmware during normal operation. If the diagnostic routines discover a controller hardware or software
problem, it makes that information available to the operator. The operator has access to this information through fault status
LEDs on the controller top cover and through reports received on the human system interface (HSI) in controller status
bytes.
The HC800 module occupies the left position of the MB810 module base. The HC800 is mechanically keyed to fit only into
the left most position on the MB810 mounting base. A single module locking screw secures the HC800 to the MB810. There
are 8 LEDs on the cover that display event or error counts and error codes. There is also one fault status LED that indicates
the operation status of the module. A stop/reset button is also provided. A mini-USB connector on the cover is used for
diagnostic purposes (firmware downloads, etc.).

2-2 2VAA001586 C
Description Circuitry

2.2.1 Circuitry
The controller has all the needed circuitry to operate as a stand-alone controller. The following figure (Figure 2-3) displays a
block diagram of the controller circuitry.

Figure 2-3: Functional Block Diagram

2.2.1.1 Clock

The clock section provides the clock signals to drive the microprocessor and associated peripheral devices. The clock/timer
section also includes a real-time clock.

2.2.1.2 Microprocessor

The microprocessor operating system instructions and the FC library reside in the read only memory (flash ROM). The
microprocessor carries out all control responsibilities as it executes the control strategy set up in its function block
configuration. The microprocessor constantly updates the machine fault timer (MFT) circuit. If the microprocessor or
software fails, the MFT circuit times out, issues a board wide halt, and the fault status LED turns red. This condition is a fatal
controller error.

2.2.1.3 Memory

The memory is made up of the following:

• 4 megabytes of flash ROM
• 128 megabytes of DRAM
• 2 megabytes of NVRAM
The flash ROM memory holds the operating system instructions for the microprocessor. The DRAM memory provides
temporary storage and a copy of the system configuration. The NVRAM memory holds the system configuration (control
strategy designed with FCs) and files for Batch 90, C and UDF applications. NVRAM memory retains stored information
even when it the HC800 module loses power.

2.2.1.4 NVRAM

The HC800 uses an onboard battery to safely preserve data kept in NVRAM.

2VAA001586 C 2-3
Circuitry Description

2.2.1.5 Redundant Controllers

Redundancy is accomplished through internal circuitry of the MB810 mount base connecting from side connector of
adjacent bases.
As the primary controller executes, the redundant controller waits in standby mode and receives a copy of block outputs
over this link. If for any reason the primary controller fails, the redundant controller takes over without any process
interruption. Refer to sub-section 2.5- Redundancy Failover of this user manual for more information.

2.2.1.6 HN800 Communication

An HN800 interface enables communication with Symphony Plus IO modules. HN800 is a 16-bit interface that operates
through control registers in the I/O section of controller memory and a one-megabyte memory space for shared DRAM.
Each electrical HN800 bus is capable of supporting up to 64 HN800 devices. As a special rule, one RFO810, either single
or redundant, is counted as 4 HN800 devices.
Physical connection from the controller to IO modules is provided by a cable connection from the CTB810/CTB 811
controller communication terminal boards to the HBX01L/HBX01R or HN810/811 bus terminal boards. When there is any
RFO810 optical link on a HN800 bus, then all bus terminal boards on this HN800 bus must use HBX01L and HBX01R, and
all TER800 terminators on this HN800 bus must be Rev E or later revisions.

2.2.1.7 I/O Section

The I/O section interface allows the microprocessor to read the switches that tell it how to operate and set the controller
address.
This section also contains latches whose outputs connect to the status and error LEDs.
This section monitors redundant controllers and outputs a signal to the controller active LED on the NTMP01.
Upon failover, this output de-energizes and the output of the redundant controller energizes its controller active LED on the
NTMP01 as it takes over.
Additionally, the I/O section monitors the Stop/Reset push button. When the push button is pressed, the I/O section insures
that the controller completes any I/O functions before it stops the controller.

2.2.1.8 Serial Channels

Two independent serial channels (one RS-485 and one USB) are available on the controller. Both serial channels are
dedicated for language support (C). Clear to send (CTS) and request to send (RTS) handshake signals are supported. A
DUART circuit on the controller supplies the serial channels with handshaking signals. Clock signals for the baud rate
generator are derived from an onboard, 7.3728-megahertz oscillator.
The USB link is located on the front cover of the HC800 controller and is used for diagnostic and firmware download
purposes. A 9-pin RS-485 connector is located on the MB810 mounting base, which is reserved for future use.

2.2.1.9 Stop/Reset

Control logic determines the Stop/Reset push button operation. The Stop/Reset push button is used to halt the module
operation and to reset the module. It is accessible through a small hole in the top cover. Pressing the Stop/Reset push
button once causes the module to perform an orderly shutdown. Pressing the Stop/Reset push button a second time resets
the module.
Before you remove the HC800 module from its base, make sure you press the Stop/Reset button once to
halt the module. If you fail to halt the module before removing it from its base, then it could result in
unpredictable I/O communications. Refer to sub-section 3.6.3- HC800 and CP800 Module
Insertion/Removal of this user manual for procedure details.

2.2.1.10 Switches and LEDs

The HC800’s CPU reads one of several internal event and error counters and writes count data to data latches to control
the LEDs. It reads switches SW1 through SW5 through data buffers to determine its operating mode and operating
addresses. A fault status LED is located near the top of the module.

2-4 2VAA001586 C
Description CP800 Communication Processor

2.3 CP800 Communication Processor

The CP800 communication processor module is the PN800 communication interface for the HPC800. The CP800 module
allows any HPC800 node to communicate with any other HCP800 node within the Symphony Plus system.
The CP800 contains microprocessor based communication circuitry that enables it to interface with the PN800 network with
other CP800 modules (and PNI800 modules).
The CP800 module is mechanically keyed to the right position of the MB810 module base. A single screw secures the
CP800 to the MB810.
Do not attempt to change the keying of the MB810 base, HC800, CP800, or any other Symphony Plus
module. Insertion of a module into the wrong base or incorrect position of a base may result in permanent
damage to the module or base.
There are 8 LEDs on the cover that display status and error codes. There is also one fault status LED that indicates the
operation status of the module. A stop/reset button is also provided. A mini-USB connector on the top cover is used to
update module firmware from an attached PC or laptop.
The CP800 module has a single card edge connector that provides signal and power connections when it is inserted into
the MB810 base.
Communication between PN800 network nodes is through Ethernet cable. Ethernet connection is made on the MB810
mounting base.

2.3.1 Block Diagram

The following figure (Figure 2-4) displays a functional block diagram of the CP800 module. The module contains a central
processing unit (CPU), memory, CW800 interface, and a PN800 interface that supports redundant PN800 networks.

Figure 2-4: CP800 Block Diagram

2.3.2 Microprocessor
The CP800 contains a 32-bit microprocessor running at 256 megahertz and associated support circuitry (i.e., control logic,
address decoder, buffer control, etc.). The microprocessor interprets and executes instructions to control communication
and run diagnostics. Since the microprocessor is responsible for overall module operation, it communicates with all the
functional blocks.

2VAA001586 C 2-5
PN800 Description

2.3.3 PN800
The CP800 module handles all PN800 communication for the HPC800 controller interface. This includes transmitting
PN800 messages originated from the node and receiving messages intended for the node. The CP800 module has the
ability to isolate itself from PN800 in the event of a component failure or to perform diagnostics.
Receive:
On the receive side, the module has two independent channels with separate memory for each channel to temporarily store
incoming messages. Messages are received on both channels simultaneously and stored. The data is automatically
checked for integrity and various data protocol errors.
Transmit:
On the transmit side the module has one transmitter but two independent transmit driver circuits. Messages originated by
the node are transmitted on both channels. Messages are first checked and formatted by the CPU before they are
transmitted. Messages are transmitted using a transmit/acknowledge sequence.

2.3.4 Memory
The CP800 module memory consists of 4 megabytes ROM memory, 128 megabytes of DRAM memory, and 2 megabytes
of NVRAM. The ROM memory holds the operating system instructions for the microprocessor (i.e., firmware). DRAM
memory provides temporary storage for the CPU. The PN800 and HN800 bus interfaces also use a portion of the DRAM
memory to store received messages and messages to be transmitted.

2.3.5 NVRAM
The CP800 uses an onboard battery to safely preserve data kept in NVRAM.

2.3.6 Stop/Reset
Control logic determines the Stop/Reset push button operation. The Stop/Reset push button is used to halt the module
operation and to reset the module. It is accessible through a small hole in the top cover. If you press the Stop/Reset push
button once, it causes the module to perform an orderly shutdown. If you press the Stop/Reset push button a second time,
it resets the module.
Before you remove the CP800 module from its base, make sure you press the Stop/Reset button once to
halt the module. If you fail to halt the module before removing it from its base, it could result in unpredictable
I/O communications. Refer to sub-section 3.6.3- HC800 and CP800 Module Insertion/Removal of this user
manual for procedure details.

2.3.7 Switches and LEDs

The CP800 reads switches SW1 through SW5 to determine its operating mode and operating addresses. A fault status LED
is located near the top of the module.

2.4 CP800 Operation

The CP800 module is the communication front end for the HPC800. This sub-section provides an overview of its operating
theory.

2.4.1 Exception Reports

Exception reported data is available to all PN800 network nodes. Once configured, Harmony nodes exception report data
on PN800 automatically. A controller, for example, generates an exception report periodically to update data, after a
process point reaches a defined alarm limit or changes state, or after a significant change in value occurs. An exception
reporting route must be established, however, for the node to begin acquiring the exception reported data. The data
typically appears as dynamic values, alarms, and state changes on displays and in reports generated by human system
interfaces and other system nodes.
Exception reports can have data values in the following formats: digital, analog, and status. Exception reports are time-
stamped to reflect their processing sequence. Few examples of information contained in exception report parameters
include:
• Alarm level.
• Alarm state.

2-6 2VAA001586 C
Description Messages

• Analog process value.

• Deviation (rate of change).
• Digital process state.
• Quality.
A function block address is included in each exception report to identify the source of the report. The full address is a loop,
node, module, and block number.
Maximum and minimum report time parameters insure that an exception report is generated for static data and limit reports
for rapidly changing data. The minimum report time parameter controls the quantity of exception reports a single rapidly
changing point generates. The maximum report time parameter generates a periodic report of data items that do not
change.
The HC800 controller is the source for exception reports. The CP800 module packages together exception reports having a
common node destination. Packing places all exception reports for a destination into one message. The CP800 module
then sends them to other PN800 network nodes. This process adjusts the message size for maximum PN800 network
efficiency.
The CP800 module holds the exception report route database records and directs the operation of the HPC800 controller
interface. It acts as a gateway between PN800 and CW800. It communicates directly with the HC800 module on the
CW800 bus. Communication with all Harmony controllers is over CW800.
The CP800 module polls the HC800 controller for exception reports. The poll rate is selected through a switch setting on the
CP800 circuit board. The module has standard poll rates of four, eight, sixteen, and thirty two polls per second.
Exception reporting for a controller is automatic. The controller generates an exception report:
• Periodically to update values.
• After a process point reaches a defined alarm limit or changes state.
• After a significant change in value occurs.
There are several alarm indicators that can be communicated in an exception report message.

NOTE: If a point goes into or out of alarm, the time parameters are ignored and the value is reported immediately.
Minimum and maximum exception report times are set through FC 82.

2.4.2 Messages
The CP800 module processes TCP and UDP messages including broadcast, time synchronization, and multicast. All
PN800 message types have Ethernet headers.
Broadcast:
A node generates a broadcast message when sending information to all system nodes. Typically, these messages
announce changes in node status. Broadcast messages include:
• Node online.
• Node offline.
• Node restart.

Time Synchronization:
The time synchronization message is a high priority broadcast type of message. The CP800 module services this message
type immediately. Time synchronization provides a common system time base to be used for sequencing exception reports,
accessing trend data, and display on a human system interface such as a workstation running S+ Operations software.
Multicast:
A message that contains data for multiple destinations is a multicast message.
Message Format:
Messages exist as frames of information. Each frame consists of a message control field that follows an information field.
The information field contains the message data. It can consist of multiple messages and vary in size to a maximum of
1,500 bytes. The control field contains time of origination, sequence number, source node address, size, message type,
destinations, and checksum.
The CP800 module uses the message type to determine how to process the message. The checksum check field verifies
data integrity.

2VAA001586 C 2-7
Data Integrity Description

2.4.3 Data Integrity

There are three methods by which the CP800 module insures data integrity:
• Retry logic
• Node status table
• Polling

• Retry Logic:
Messages collision detection and retry logic is handled by the Ethernet protocol employed on the PN800
network.
• Node Status Table:
The CP800 module maintains an internal table of system wide node status such as offline and
online. When the CP800 module periodically polls nodes, it updates this table accordingly.
• Polling:
The CP800 module uses the information in its status table for polling purposes. As it scans the status table, it
picks out destinations targeted for multicast messages that have been marked offline or busy. After polling the
destination, the CP800 module updates its table.

2.4.4 Power System Status

The communication system provides a means to monitor the status of the power system of each node. This status
information can be displayed on a human system interface. Electronics within the power entry panel monitor the power
system status. A single status output is made available to the communication system. To use this feature, wire the status
output to the terminal block on the MB810 termination base labeled SA or SB.
This power system status signal is fed through the MB810 termination base to the CP800 module. The power system status
input is a TTL-compatible signal. A high voltage level (24 VDC) on power system status indicates good status. A low voltage
level (0 VDC) indicates bad status. The CP800 module reports a bad status when no connection is made to the power
system status inputs.
The CP800 Module also acts as a gateway between the PN800 network and CW800 communication bus. The module
holds the configuration database and directs the communication process between the modules residing on CW800.

2.4.5 CW800
CW800 provides a four-megabaud, peer-to-peer communication bus between HPC800 controllers. Each electrical CW800
bus is capable of supporting up to 32 single HPC800 controllers or 16 redundant pairs of HPC800 controllers. When using
RFO810 optical link, electrical CW800 bus on each side supports up to 30 single HPC800 controllers or 15 redundant pairs
of HPC800 controllers.
There are two separate communication paths on the MB810 mounting base for CW800 communications. Data is
transmitted over both channels simultaneously and received in separate receivers where it is checked for integrity. In this
way, the CW800 bus minimizes the chances that a failure on a circuit board or the backplane will cause loss of module
communication. As point data between intelligent modules travels on the bus, the module performs a bit-by-bit comparison.

2.4.6 Redundancy Link

Redundancy is accomplished via interconnection of a second adjacent MB810 base connecting through connectors on the
side of the bases. An HC800 and a CP800 must be installed in the second base and the must be configured for redundancy.
As the primary CP800 module executes, the redundant CP800 module waits in standby mode and receives a copy of route
records over this link. If for any reason the primary CP800 module fails, then the redundant CP800 module takes over
without any process interruption. Refer to sub-section 2.5- Redundancy Failover of this user manual for more information.
The primary HC800 controller associated with the now failed CP800 module does not failover to its backup HC800, i.e.
HC800 and CP800 do not failover in pairs.

NOTES:
1.Firmware revision levels must be the same in both primary and secondary CP800 and HC800 modules. If the
firmware revision levels are different and a failover occurs, then the modules may operate erratically.

2.Installing or removing a redundant CP800 module during a firmware download at either the source or
destination end of the transfer can prevent the firmware download from completing successfully.

2-8 2VAA001586 C
Description Machine Fault Timer

2.4.7 Machine Fault Timer

The machine fault timer (MFT) is a security feature built into the CP800 module. The timer is a one-shot timer that must be
periodically reset by the CP800’s CPU to prevent it from timing out. If an error condition exists that causes the module to fail
or operate incorrectly, then the timer is not reset and causes a time-out condition. A time-out condition triggers a reset signal
to shut down the module.
The module performs a series of online diagnostics to verify circuit integrity. A detected failure may trigger a reset signal to
shut down the module. If the cause of the problem is not a hardware failure, then the module and timer can be reset by the
Stop/Reset push button accessed through the front panel.

2.4.8 Stop/Reset
Control logic determines the Stop/Reset push button (SW1) operation. The Stop/Reset push button is used to halt the
module operation and to reset the module. It is accessible through a small hole in the top cover. Pressing the Stop/Reset
push button once causes the module to perform an orderly shutdown. Pressing the Stop/Reset push button a second time
resets the module.

2.4.9 Switches and LEDs

To control the top cover LEDs, the CP800’s CPU writes data to latches connected to the operation and diagnostic LEDs and
the fault status LED. This data includes operating status and error codes. The CPU reads switches SW2 and SW5 through
data buffers to determine its operating mode, operating characteristics, and address.

2.5 Redundancy Failover

In a redundant HPC800 controller interface configuration (refer to Figure 1-4), two types of failover from primary interface to
backup interface can occur: cold failover and warm failover. The current state of the exception report route database in the
primary and backup CP800 modules determines which type of failover occurs.
Warm failover causes less interruption in exception reporting as compared to a cold failover. A cold failover requires all
exception report routes to be re-established. The time it takes to complete the cold failover depends on the number of
exception report routes that need to be reestablished. The interruption can exceed one minute for an HPC800 controller
with a large configuration. In contrast, a warm failover does not require all of the exception reporting routes to be
reestablished, but can only occur if the database in the primary CP800 module has been stable for a certain period of time.
During cold failover, all other nodes that import points from the failed HPC800 controller mark the imported points with bad
quality. They remain in bad quality until new good quality exception reports are received. During a warm failover, points
configured in the HPC800 controller that has failed are not marked as being in bad quality. Warm failover allows other nodes
to maintain good quality briefly during the failover.

2.5.1 Redundancy Operation

During power up or whenever a backup CP800 module is inserted into the MB810, the two redundant CP800 modules
arbitrate for primary and backup roles. This arbitration takes place over CW800. When the primary and backup roles are
established, the backup module requests an image of the switch settings of the primary module. This image is transferred
over the CW800.
Warm failover requires the primary CP800 module to transfer a copy of its database records to the backup module. On
warm failover, the new primary module broadcasts a warm failover node restart broadcast message on the loop and
immediately obtains new exception reports from controllers in its node. These exception reports are sent to all nodes that
have established exception report routes to the former primary module. Other nodes that recognize the warm failover restart
broadcast message, sends the new primary module updated exception reports for all points that the former primary module
requested. In this way, the new primary module transfers updated exception reports out of and into its node without taking
time to reestablish exception report routes.
The backup CP800 module must receive a copy of the primary exception report route database (not exception report data)
over the redundancy link before it is ready for warm failover. The database in the primary module must be stable for 90
seconds before it can be transferred to the backup module. After 90 seconds with no changes, the primary module transfers
(one record at a time) a complete copy of its database to the backup module. It takes about three minutes to completely
transfer a large database.
If the primary CP800 module database changes before the transfer is complete, then the transfer is aborted and restarted
after 90 seconds without database changes. Once the entire database is transferred, the backup module is ready for warm
failover.

2VAA001586 C 2-9
Power System Status Description

If the primary CP800 module database changes after the backup module is ready for warm failover, then the changes are
transferred to the backup module in one of two ways. If only a few database records have changed, then the changes are
immediately transferred to the backup module. If more than a few database record changes occur in a short time period,
then the primary module resets the backup module causing the entire database to be transferred to the backup module.
The CPU LEDs on the backup CP800 module top cover indicate the current state of readiness for warm failover. When the
backup module is initially powered up, LED seven is on. This state indicates that the backup module is not ready for warm
failover. When the backup module is ready for warm failover, LED seven goes out and LED eight turns on. If the primary
module fails before the backup module is ready for warm failover, then a cold failover takes place. A cold failover protocol
requires that all exception report routes must be re-established and points imported from the failed CP800 module must be
marked with bad quality until new good quality exception reports are received.

2.6 Power System Status

The Symphony Plus system monitors the status of the power to each node. This status information can be displayed on a
human system interface. To use this feature, wire the 24 VDC power output to the terminal block on the HBX01L bus
extender labeled SA or SB. Field power status is also monitored (applicable to SD I/O mounting bases with a field power
connection).
Power status signals are fed through the bus extender to the SPC700 module. A high voltage level (24 VDC) is interpreted
as good status. A low voltage level (0 VDC) indicates bad status.
A connection must be made to both the SA and SB terminals on the power plug of the HBX01L bus extender. If this
connection is not made, then all modules on the segment generate a bad status indication and the Fault LED (F) begins
flashing on the modules.
The following figure (Figure 2-5) is a wiring example, which shows how redundant power supplies can be connected to
Symphony Plus Controller and SD I/O segments:

Figure 2-5: SD I/O Power Wiring

2-10 2VAA001586 C
Description Power System Status

As shown in the example (refer to Figure 2-5), a connection is made from the power source to the SA and SB terminals on
the HBX01L bus extender. Other controller or I/O segments which share the same source can have the SA and SB outputs
jumpered together (refer to Figure 2-5). It is not required to run a dedicated wire to all SA and SB terminals on HBX01L bus
extenders from the same power source, if all segments use the same power source, and at least one segment has
dedicated SA and SB connections to each power source.
When using a non-redundant power source, run a jumper wire between the SA and SB terminals.

NOTE: From Symphony Plus SD I/O Firmware Revision B_0 and later, FC 221 ‘I/O Device Definition’ Specification S34
can be used to independently mask: Power Status A, Power Status B, and Field Power Status for segments containing
only SD I/O modules (refer to below Note statement). When enabled, the masking operation applies to both the I/O
module status and the Fault LED. The default (zero) for specification 34 is ‘unmasked’ and all three power status checks
are enabled. Masking the I/O module status indicates that FC 221 does not generate a problem report or error summary
status when a power status fault is present, i.e. the selected power status fault is disabled.

When S34 = 0 Power Status Fault detection is enabled. Otherwise, when the ones digit = 1, the Field Power status is
masked. When the tens digit = 1, Power Status B is masked, 2 = Power Status A is masked, 3 = Power Status A & B are
masked.
For Example: S34 = 31 results in the masking of power status alarms for power status A and B, including field power.
When power fault detection monitoring is disabled it is not required to wire the SA and SB terminals to the power source.

NOTE: Symphony Plus segments which contain controllers (SPC700, HPC800) and communication modules (PNI800,
PDP800, HAI805 and HAO805) must have a connection to power status SA and SB on the HBX01L bus extender. The
Fault LED (F) flashes when there is no power status connection to the segment.

SD I/O mounting bases with a field power connector, for e.g. HBS01-EPD, must be connected to a power source (or have
power fault detection disabled) to prevent automatic generation of problem reports and error summary status bits.

2VAA001586 C 2-11
Power System Status Description

2-12 2VAA001586 C
Installation Introduction

3. Installation
3.1 Introduction
This section explains the steps necessary to install a HPC800 controller. This user manual only describes HPC800
controller installation requirements. The user manual does not provide any planning information, and assumes all
components have already been purchased and are ready to be installed.

3.2 Special Handling

Observe these steps when handling electronic circuitry:
1. Use Static Shielding Bag: Keep an assembly in its static shielding bag until ready to install it in the system.
Save the bag for future use.
2. Ground Bags before Opening: Before opening a bag containing an assembly with static sensitive devices,
touch it to the equipment housing or ground to equalize charges.
3. Avoid Touching Circuitry: Handle assemblies by the edges; avoid touching the circuitry.
4. Avoid Partial Connection of Semiconductors: Verify that all devices connected to the module are properly
grounded before using them.
5. Ground Test Equipment.
6. Use an Antistatic Field Service Vacuum: Remove dust from assemblies if necessary.
7. Use a Grounded Wrist Strap: Use ABB Automation field static kit (part number 1948385?1 - consisting of two
wrist straps, ground cord assembly, alligator clip, and static dissipative work surface) when working with
modules. The kit grounds a technician and the static dissipative work surface to the same ground point to
prevent damage to the circuitry by electrostatic discharge. Connect the wrist strap to the appropriate grounding
plug on the power entry panel. The grounding plug must be effectively connected to the earth grounding
electrode system through the AC safety ground.
8. Do Not Use Lead Pencils to Set Switches: To avoid contamination of switch contacts that can result in
unnecessary circuit board malfunction, do not use a lead pencil to set a switch.

3.3 Unpacking and Inspection

Follow the given steps to unpack and install the module:
1. Examine the hardware immediately to verify that it has not been damaged in transit.
2. Notify the nearest ABB sales office of any damage.
3. File a claim for any damage with the transportation company that handled the shipment.
4. Use the original packing material and container to store the hardware.
5. Store the hardware in an environment of good air quality, free from temperature and moisture extremes and
corrosives.

3.4 Power Supply

It is recommended to use different power supplies to power ABB Symphony Plus module system components and field
equipment.
Logic Power is used to provide power supply to the module system components and Field (I/O) Power is used to provide
power supply to the field equipment.
Examples of system components include the Symphony Plus Controller (HPC800 or SPC700), Communication Interface
(PNI800) and SD IO modules.
Examples of field equipment include transmitters, meters, etc.
The power supplies can also be configured in a redundant configuration using independent voting units.

2VAA001586 C 3-1
Installation and Connection Sequence Installation

The following figure (Figure 3-1) shows a recommended power supply concept:

Figure 3-1: Recommended Power Supply Concept

3.5 Installation and Connection Sequence

The HC800 and CP800 modules use an onboard battery to safely preserve data kept in NVRAM. To extend the shelf life of
this battery, it is shipped but disconnected from the modules internal circuitry. Before using these modules the battery must
be enabled using the Battery Enable jumper feature. Refer to sub-sections: 9.2- HC800 Jumper Setting and
10.2- CP800 Jumper Settings of this user manual for instructions on how to use the Battery Enable Jumper feature.
Verify the main power, field power, and power entry panel circuit breakers/switches are turned off before
starting installation, retrofit, upgrade, or wiring procedures. Failure to do so could result in severe or fatal
shock or equipment damage. Do not turn the power on until the installation, retrofit, upgrade, or wiring
procedures are complete.

A module or base should not be inserted or removed with power applied when located in a Class I, Division
2 hazardous location unless the area is known to be nonhazardous.
NOTE: Always follow the instructions given in sub-section 3.2- Special Handling of this user manual when handling the
modules.

3.6 Mounting Instructions

For installations in ATEX classified areas:
• Turn off power to the I/O segment before you remove or install modules in the MB810 mounting
base.
• Turn off power before you remove or install CTB810, CTB811, HBX01L, HBX01R bus extenders.
• Turn off power before you remove or insert TER800 terminators or SPK01-0x cables.

3.6.1 MB810 Base Mounting

All Symphony Plus module bases mount to standard 35mm wide DIN-rail. The DIN-rail must be mounted horizontally within
the cabinet. ABB offers pre-formed panels that may be used to mount DIN-rail into cabinets with EIA standard 19 inch rails.
Refer to section 7- Replacement and Spare Parts of this user manual for information on applicable part numbers.

3-2 2VAA001586 C
Installation MB810 Base Mounting

DIN-rail must be mounted to rigid panels and the panels and DIN-rail must electrically grounded. The DIN-rail should be
attached to the panel with screws every 100 mm (4 in) to ensure good mechanical stability and a good chassis ground
connection.
Do not connect the MB810 mounting base to another mounting base while it is powered.

Do not connect the MB810 mounting base (powered or un-powered) to another mounting base that is
powered.
Mounting the units onto the DIN-rail requires a blade screwdriver that fits securely into the three position mounting base
locking screw (1 mm slot).

Figure 3-2: Three position locking screw on DIN-rail locking device

3.6.1.1 Mounting Procedure

Follow the given steps to mount the module or communication termination base:
1. Rotate the locking device to the OPEN position.
2. Hook the upper hook at the rear of the unit baseplate securely over the upper edge of the DIN-rail
3. Snap the baseplate fully into the mounting position (refer to Figure 3-3).

Figure 3-3: Mounting of MB810 base to DIN-rail

2VAA001586 C 3-3
Vibration Hardening and Mounting Installation

4. Rotate the locking device to the SLIDE position,

5. Slide the unit along the DIN-rail to the required mounting position
6. Attach the unit to the adjacent unit baseplate using the connector plugs and sockets.

To prevent damage to the pins, be sure the baseplate plugs and sockets are fully aligned as the
units interconnect. Under no circumstances use excessive force!

7. Rotate the locking device clockwise to the LOCKED position when interconnection is complete.

The baseplate is now fully locked into position and is grounded to the DIN-rail.

3.6.2 Vibration Hardening and Mounting

To reduce the potential for vibration induced failures it is recommended that floor mounted enclosures/cabinets stand on a
structurally sound and level surface. Wall mounted enclosures/cabinets should be mounted on structurally sound vertical
walls.
When installing Symphony Plus equipment in an area adjacent to large machinery such as shakers, turbines or other
equipment which produces vibration, shock absorbers or isolation pads may be required to protect system equipment. All
Symphony Plus mounting bases have vibration mounting lugs that may be used to provide additional support when
vibration is likely to occur. The following figure (Figure 3-4) displays the location and size of the mounting lugs for the
MB810 base. These lugs can also be used when no vibration is present to provide an additional measure of support.

Figure 3-4: MB810 Vibration Mounting Lugs

It is not practical to project mechanical shock and vibration tolerances for all possible conditions at various installation sites.
If expecting excessive levels of vibration, then perform a site survey to decide, if installation locations or equipment need
vibration dampening.

3.6.3 HC800 and CP800 Module Insertion/Removal

For installations in ATEX classified areas:

• Turn off power to the I/O segment before you remove or install modules in the MB810 mounting
base.
• Turn off power before you remove or install CTB810, CTB811, HBX01L, HBX01R bus extenders.
• Turn off power before you remove or insert TER800 terminators or SPK01-0x cables.

3-4 2VAA001586 C
Installation HC800 and CP800 Module Insertion/Removal

3.6.3.1 Insertion

Symphony Plus modules and bases are keyed to prevent insertion of a module into the wrong base.
The keying of each module and base is pre-set at the factory and must not be changed. Keying for the
HC800 module is 1=E and 2=E. Keying for the CP800 modules is 1=C and 2=C. Keying on the MB810
mounting base is A1=E, A2=E, B1-C and B2=C.
Follow the given steps to mount a module into a base.
1. Verify whether the base is securely mounted to the DIN-rail and whether the DIN-rail is securely mounted to a
conductive metal panel.
2. Align the module directly over the base and push the module straight down into the base.

NOTE: Do not insert the module at an angle and do not use excessive force.

3. Tighten the module locking screw.

3.6.3.2 Removal

Follow the given steps to remove the HC800 and CP800 modules:
1. Press the STOP/RESET push button once on the module using a thin non-metallic rod to halt it.

Once you halt the module, it results in the Fault LED turning red.
2. Loosen the locking screw on the halted module using a flat-blade screwdriver, until the spring-loaded screw
head pops above the plastic recess.
3. Firmly grasp the module and pull the module away from the base, to remove it from the base.

Do not tilt the module at an angle during removal. It is recommended to extract the module straight
out of the base.

2VAA001586 C 3-5
HC800 and CP800 Module Insertion/Removal Installation

3-6 2VAA001586 C
Operation Introduction

4. Operation
4.1 Introduction
This section describes the LEDs on the HC800 and CP800 modules. It also provides important product operation
instructions and warnings for the HC800 and CP800 modules.

4.2 CP800 Module

The following figure (Figure 4-1) displays the CP800 module’s top cover.

Figure 4-1: CP800 Top Cover

2VAA001586 C 4-1
Fault Status LED Operation

4.2.1 Fault Status LED

The following table (Table 4-1) lists the meaning of the 12 LEDs shown in Figure 4-2.

Table 4-1: LED States (CP800)

LED Label State Description Corrective Action

F Red ON Fault. CP800 is stopped Steps:

1. Check the controller status.

2. Reset the CP800 module.

Green ON Run. No fault condition Action not required

Green flashing No Ethernet connection Steps:

detected.
1. Validate that the CP800’s IP
address is valid and non-null.
OR
2. Connect Ethernet cable.
Duplicate IP address
detected. 3. Check Ethernet network is up
and running.
OR 4. Change CP800 IP address to
a unique address (refer to sub-
IP address is invalid (one section 5.7- CP800 Duplicate IP
of the last two octets is Address Detection Procedure of
zero). this user manual for more
details).

R + 3rd + 1 or more flashing Network Activity LEDs Action not required

4th LEDs show a binary count of
All Off messages transmitted to Check network connections
the network

1-6 Off Action not required

1-6 On Error code Refer to Table 4-3 for error code

7- 8 On and fault LED CP800 CPU run codes Refer to Table 4-2 for details
is steady green

Table 4-2: CP800 CPU run codes

LED
Code Description
87

0x40 01 Backup module - cold failover ready

0x80 10 Backup module - hot failover ready

0xC0 11 Primary module - Normal run

NOTES: 0 = LED off, 1 = LED on.

1. Codes are displayed only when the CP800 module is running and the Fault (F) LED
is green

If errors occur while the CP800 module is operating, then the fault LED turns on red and the operation and diagnostic LEDs
on the module top cover display error codes.
The following table (Table 4-3) lists the CP800 module error codes and associated corrective actions. The module displays
error codes only when it is halted, i.e. fault LED is red.

4-2 2VAA001586 C
Operation Fault Status LED

A code that is not on the list may appear if a machine fault time-out occurs. Reset the CP800 module if this happens. The
module has failed if the fault LED remains red. Replace the module in this case.

Table 4-3: CP800 Error Codes

LEDs
Code Condition Corrective Action
87654321

0A 0 0 0 0 1 0 1 0 Software programming error Internal error. If error recurs, then call

ABB field service.

0E 0 0 0 0 1 1 1 0 CW800 address set the same on Steps:

redundant CP800 modules
1. Change the CW800 address set with
switch SW3 on a CP800 module; refer
to Table 10-4.
2. CP800 modules use address 0 or 1;
check for another module with a
duplicate CW800 address.

10 00010000 00010000 Primary failed, redundant cannot take

over, data not check pointed

11 00010001 00010001 Error during write to nonvolatile memory

13 0 0 0 1 0 0 1 1 ROM checksum error Steps:

1. Reset CP800 module.
2. Replace the CP800 module, if error
persists.

21 00100001 Software programming error Internal error. If error recurs, then call
ABB field service.

31 0 0 1 1 0 0 0 1 Memory or CPU fault Replace CP800 module.

32 0 0 1 1 0 0 1 0 Address or bus error Steps:

33 0 0 1 1 0 0 1 1 Illegal instruction 1. Reset CP800 module.

2. Replace the CP800 module, if error
34 0 0 1 1 0 1 0 0 Trace/privilege violation
persists.
35 0 0 1 1 0 1 0 1 Spurious/unassigned exception

36 0 0 1 1 0 1 1 0 Divide by zero/checksum/format
error

38 0 0 1 1 1 0 0 0 Switch settings different between Steps:

primary and backup CP800 mod-
1. Check switch settings.
ules or hardware failure.
2. Replace hardware.

39 0 0 1 1 1 0 0 1 Duplicate node number on loop Steps:

1. Change CP800 module loop address
(switch SW2) or node address (switch
SW1).
2. Check primary and backup CP800
configuration.

3D 0 0 1 1 1 1 0 1 Incompatible CP800 firmware CP800 module requires CP800

firmware update.

2VAA001586 C 4-3
Stop/Reset Operation

Table 4-3: CP800 Error Codes (Continued)

LEDs
Code Condition Corrective Action
87654321

3F 0 0 1 1 1 1 1 1 Module halted; stop button Reset CP800 module.

pressed
NOTES: 0 = LED off, 1 = LED on.
1.Codes are displayed only when the CP800 module is halted and the Fault (F) LED is red.

4.2.2 Stop/Reset
Push the Stop/Reset push button once and wait for the fault status LED to turn red before removing an CP800 module from
the MMU. Pressing the Stop/Reset push button again causes the restoration of the CP800 module to power up values after
a halt. It is also used to recover from an operator-initiated stop or a module time-out.

4.2.3 Operating Modes

The CP800 module has two modes of operation:
• Execute
• Error

• Execute:
Execute mode is the normal mode of operation. The CP800 module can request exception reports, collect
exception reports, allow the operator to adjust tunable module specifications, and configure modules within a node
residing on PN800.
• Error:
The CP800 module enters error mode, if the internal system diagnostic routines detect a hardware or
execution error. If the module detects an error, then the module halts and displays an error code on the operation
and diagnostic LEDs. Refer to section 5- Troubleshooting of this user manual for corrective actions.

4.2.4 Module Integrity

All communication modules have normal Symphony system security functions that insure module integrity. The CP800
module performs both hardware and software security checks to insure module integrity.

4.2.4.1 Hardware Checks

The CP800 module performs the following hardware checks:

• Illegal Address Detection
• Machine Fault Timer

• Illegal Address Detection:

Detecting an illegal address generates a bus error and the module halts operation. It
also displays an error code on the CP800 LEDs.
• Machine Fault Timer:
The microprocessor updates the machine fault timer. If the microprocessor fails to reset the
MFT timer, then it expires. When a time-out occurs, the module stops and the fault status LED turns red.

4-4 2VAA001586 C
Operation HC800 Module

4.2.4.2 Software Checks

The CP800 module performs the following software checks:

• Module Diagnostics
• ROM Checksum

• Module Diagnostics:
The module diagnostic routines execute automatically on system power up. If the diagnostic
tests fail, then the CP800 LEDs display error conditions, the fault status LED turns on red and the module operation
halts.
• ROM Checksum:
The ROM checksum test verifies checksums of the ROM memory. Discrepancies cause the fault
status LED to turn red and the module operation halts.

4.3 HC800 Module

The following figure (Figure 4-2) displays the HC800 module’s top cover.

Figure 4-2: HC800 Top Cover

2VAA001586 C 4-5
HC800 Top Cover LEDs Operation

4.3.1 HC800 Top Cover LEDs

The following table (Table 4-4) lists the meaning of the 12 LEDs displayed in Figure 4-2.

Table 4-4: LED States (HC800)

LED Label State Description Corrective Action

F Red ON The controller diagnostics Steps:

have detected a hardware
1. Check the controller status.
failure, configuration
problem, etc., and stopped 2. Reset the HC800 module.
the controller.
3. Re-seat the module in the
May also indicate that the base.
module has been stopped
by the Stop/Reset 4. Replace the controller.
push button.

Green ON The controller is in Action not required.

execute mode. No fault
condition

Green Flashing The controller is in

execute mode but there is
an NVRAM checksum
error, or the controller is in
the configure or error
mode.

Off No power to the controller, Steps:

or the controller is
1. Check power connections
powered.
2. Reset the HC800 module.
LED momentarily goes off
when the microprocessor 3. Re-seat the module in the
initializes on startup base.

R + 3rd + 1 or more flashing In diagnostic mode, shows Refer to the diagnostic test
4th LEDs Green the pass count of section.
diagnostic tests.

1 or more flashing In diagnostic mode, shows Refer to the diagnostic test

Red the fail count of diagnostic section.
tests.

All Off Normally off during Action not required.

Execute mode

1-6 Off Normally off during Action not required.

Execute mode

On Diagnostic test number Refer to Table 4-3 for error

code.

7 Not used when in

diagnostic mode

8 On - when in Indicates a test failure Refer to the diagnostic test

diagnostic mode section.

Off - when in Normally off during Action not required.

diagnostic mode Execute mode

7- 8 On and fault LED HC800 CPU run codes Refer to Table 4-5 for details.
is steady green

4-6 2VAA001586 C
Operation Stop/Reset Switch

Table 4-5: HC800 CPU run codes

LED
Code Description
87

0x40 01 Backup module - cold failover ready.

0x80 10 Backup module - hot failover ready.

0xC0 11 Primary module - Normal run.

NOTES:
1. 0 = LED off, 1 = LED on.
2. Codes are displayed only when the HC800 module is running and the Fault (F) LED is green.

4.3.2 Stop/Reset Switch

Do not remove an operational controller under power unless the stop/reset switch has been depressed
once and the controller has halted (status LED is red a). This procedure must be followed when removing
a controller from a redundant configuration. An operational controller must halt operation before control
passes to the redundant controller.

Firmware revision levels must be the same in both primary and redundant controllers. If the firmware
revision levels are different and a failover occurs, the redundant controllers may operate erratically.

The Stop/Reset switch is a two-hit switch. It stops the controller in an orderly manner, preventing glitches on the bus. The
switch is accessible through the opening on the top cover (refer to Figure 4-2). Since the opening is small, pressing the
switch requires a thin round object. Pressing the switch once stops operation. Always stop the controller before removing it
from the mounting base. Stopping the controller this way causes it to:
• Save and lock the controller configuration.
• Complete any nonvolatile memory write operations in progress.
• Deactivate all communication links.
• Transfer control from the primary controller to the redundant controller in redundant configurations.
• Change the status LED color to red.

Once the controller is stopped, pressing the switch again resets the controller. Use the reset mode to:
• Reset the default values to the power-up values.
• Recover from a controller time-out or operator-initiated stop.

NOTE: Pressing and holding the Stop/Reset switch provides no additional functionality over pressing and releasing the
switch, it only stops the controller. To stop the controller, press and release the stop/reset switch. To reset the controller,
press the Stop/Reset switch a second time. If the controller halts due to an error (causing the status LED to turn red), a
single push of the Stop/Reset switch resets the controller.

4.3.3 HC800 Startup

When power is applied to the controller, it does an internal check, checks its configuration, and builds the necessary
databases.
During startup of the primary controller, the front panel LEDs go through the following sequence:
1. All LEDs illuminates.
2. The fault status LED changes from red to green.
3. LEDs one through eight goes out.

During startup of the redundant controller, the LEDs go through the following sequence:
1. All LEDs illuminates.
2. The fault status LED changes from red to green.
3. All LEDs goes out.

2VAA001586 C 4-7
Modes of Operation Operation

4. LED seven illuminates red and then goes out.

5. LED eight illuminates red.

If the appropriate LEDs do not illuminate, then refer to sub-section 5.4.1- HC800 Error Codes of this user manual for more
information.

4.3.4 Modes of Operation

The controller has three operating modes:
• Execute
• Configure
• Error

• Execute:
The execute mode is the normal mode of operation. In this mode, the controller communicates with I/O
modules and other control modules. It executes control configurations, reads inputs, and updates outputs. The
controller also processes exception reports, and configuration and control messages.

• Configure:
Use the configure mode to enter or modify control strategies. The controller receives configuration
commands over CW800 and changes the data in the NVRAM memory.

NOTE: The process of configuring the controller requires information from at least two documents. Refer to the
S+ Engineering for Harmony Function Code Application Manual, which contains all of the information needed to
design a control strategy. The instruction for the particular configuration tool being used (Composer) explains the
steps required to download control strategies into controller memory.

• Error:
The controller goes into error mode whenever the built-in system diagnostics detect a hardware or
configuration error. If a hardware error is detected, the controller halts and displays the error code using group
LEDs one through eight.
If a configuration error is detected, then the controller resets and enters error mode and displays the error code
using LEDs 1-8. Additional information about the configuration error is available in bytes 3, 4, and 5 of the module
status. Refer to Table 5-6 and Table 5-7 in sub-section 5.5- Status Summary of this user manual for more
information.
If an NVRAM error is detected, then the fault status LED flashes, but the controller continues to operate. This is
possible because a copy of the configuration is held in DRAM and executed from there. The next time the controller
is reset it does not start up, but fails with an NVRAM error.

4-8 2VAA001586 C
Troubleshooting Introduction

5. Troubleshooting
5.1 Introduction
This section provides troubleshooting information necessary to isolate HPC800 controller errors. It is not meant to be all
inclusive. If a problem exists that cannot be corrected using the information provided in this user manual, then contact local
ABB service office for assistance.

5.2 Troubleshooting Procedures

Troubleshooting the HPC800 controller is limited to deciphering module LED error codes and viewing the contents of the
error counters and the module status report from any human system interface (HSI). Refer to the instruction for the specific
HSI workstation being used for information on module status reports.

5.3 Flowcharts
The flowchart given in Figure 5-1 provides a quick look at hardware related problems that may occur during controller
installation and startup. You can use this flowchart to troubleshoot problems that may occur due to improper hardware
installation.

Figure 5-1: HC800 Troubleshooting Flowchart - Fault Status LED

2VAA001586 C 5-1
Error Codes Troubleshooting

5.4 Error Codes

All Symphony Plus modules have LEDs that serve as error code displays.

5.4.1 HC800 Error Codes

HC800 control processor error codes are listed in the following table (Table 5-1). The controller displays error codes on
LEDs 1-8.

Table 5-1: HC800 Error Codes

LED
Code1 Condition Corrective Action
87654321

01 00000001 NVRAM checksum error Initialize NVRAM. If error recurs, then call
ABB field service.

02 00000010 Analog input calibration Check I/O controller error.

03 00000011 I/O controller status bad Check controller status and I/O
controllers.

04 00000100 Checkpoint buffer allocation Steps:

error
1. Reduce function block configuration
size.

2. Reset controller module.

3. Replace controller module.

05 00000101 Configuration error Check controller status (undefined block).

(undefined block)

06 00000110 Configuration error (data type Check controller status (data type)
mismatch) controllers.

08 00001000 Trip block activated Check controller status.

09 00001001 Segment violation Verify that priority is uniquely set in each

FC 82 segment and that not more than
eight segments are defined.

0A 00001010 Software programming error Internal error. If error recurs, then call ABB
field service.

0B 00001011 NVRAM initialized If NVRAM is not to be initialized, then

make sure the appropriate switch is set to
closed (refer to SW2). Otherwise, confirm
that NVRAM is initialized and action is not
required.

0C 00001100 NVRAM opened for write Initialize NVRAM. If error recurs, then call
ABB field service.

0D 00001101 Intercontroller link error Check the cable connection between

primary and redundant controllers.

0E 00001110 Redundancy IDs the same Put position 8 of SW2 in the opposite
position of the primary controller SW2
position 8.

0F 00001111 Primary failed, redundant Check configuration. Correct any faulty

cannot take over, configura- values. Execute the configuration.
tion not current

5-2 2VAA001586 C
Troubleshooting HC800 Error Codes

Table 5-1: HC800 Error Codes (Continued)

LED
Code1 Condition Corrective Action
87654321

10 00010000 Primary failed, redundant Check configuration. Correct any faulty

cannot take over, data not values. Execute the configuration.
check pointed

11 00010001 Error during write to Initialize NVRAM. If error recurs, then

nonvolatile memory contact ABB field service personnel.

12 00010010 Redundant and primary con- Set addresses the same.

troller addresses are different

13 00010011 ROM checksum error Contact ABB field service.

14 00010100 Controller set for INFI-NET- Reformat controller.

Superloop but in a Plant
Loop environment

16 00010110 Type code mismatch Set proper propagation delay setting to

match measured setting.

00010110 Nomenclature conflict on Replace backup with nomenclature that

backup (backup does not matches nomenclature of primary.
match primary)

17 00010111 Duplicate Controlway Set address to unique value between

address detected 2 - 31 in PCU. Set mode to Controlway.

19 00011001 Firmware download in prog- Wait for download to complete.

ress

1C 00011100 Firmware revision conflict Remote BRC firmware revision must be

(remote I/O controller only) updated to match local BRC.

1D 00011101 Hnet failure Check Hnet cabling and connections to

PBA, terminations, and Harmony block
I/Os. Replace the controller, if Hnet
cabling and connections check out.

1E 00011110 Duplicate device label Duplicate device label in FC 221 or FC

227 detected. Use unique labels.

20 00100000 C program format error Repeat configuration download.

21 00100001 File system error Check file directory, replace bad file.

22 00100010 Invoke C error Check C program and invoke C blocks,

correct and rerun.

23 00100011 User write violation Check C, UDF, and Batch 90 programs.

Correct and rerun.

24 00100100 C program stack overflow Check C program. Correct and re-run.

28 00101000 UDF block number Check configuration. Fix block

reference invalid configuration. Fix block reference.

29 00101001 UDF block cannot read Check configuration. Fix UDF block file.
program

2A 00101010 Not enough memory for UDF Resize configuration to fit controller.

2B 00101011 Missing UDF declaration Add FC 190 to configuration.

2C 00101100 Wrong UDF type Put correct UDF type in configuration.

2VAA001586 C 5-3
HC800 Error Codes Troubleshooting

Table 5-1: HC800 Error Codes (Continued)

LED
Code1 Condition Corrective Action
87654321

2D 00101101 Missing UDF auxiliary Put FC 198 in block configuration.

2E 00101110 UDF compiler and firmware Check firmware revision level. Verify
incompatible whether it supports UDF.

30 00110000 Primary active during failover Replace primary and/or redundant to

attempt determine faulty controller.

31 00110001 Memory or CPU fault Replace controller. If error recurs, then call
ABB field service. Check C program is
compiled for the controller.

32 00110010 Address or bus error Reset controller. If error recurs, then

replace controller. Check C program is
33 00110011 Illegal instruction compiled for the controller.

34 00110100 Internal error -

trace/privilege violation

35 00110101 Internal error - Reset controller. If error recurs, then

spurious/unassigned replace the controller. Check C program is
exception compiled for the controller.

36 00110110 Internal error - divide by 0 or

check instruction

37 00110111 Internal error - undefined trap Restart controller. If error recurs, then
replace controller.

38 00111000 Board level hardware error Contact ABB field service.

3E 00111110 mft fault Contact ABB field service.

3F 00111111 Normal stop None.

40 01000000 Redundant - configuration

current.

80 10000000 Redundant - hot takeover

ready - dynamic data check-
pointed.

C0 11000000 Primary - operating

XX 2 — Unknown Contact ABB field service.

NOTES:
1. Code numbers are hexadecimal digits.
2. This symbol represents any LED combination not specifically addressed in this table.

5-4 2VAA001586 C
Troubleshooting CP800 Error Codes

The following table (Table 5-2) lists the fault status LED states and other conditions that are indicated by the other LEDs:

Table 5-2: HC800 Fault Status LED and Other Conditions

LED Condition Corrective Action

Status Off Check power.

Check controller seating.

Check jumper J1. Remove if installed.

If power and seating are acceptable, then remove the controller and
replace with identically configured controller.

Red Press Stop/Reset button. If LED remains red, then remove the controller
and replace with identically configured controller.

Green None - normal.

Flashing Green Weak battery detected when HC800 primary module is in Execute
mode.

NOTE: LED 1 displays in red when weak battery is detected in

HC800 primary or backup module in all other modes, for e.g. during
module startup.

Orange Check jumper J1. Remove, if installed.

7/8 Off Check power.

Check controller seating.

If power and seating are acceptable, then remove the controller and
replace with identically configured controller.

Red None - indicates primary controller.

8 Off Check power.

Check controller seating.

If power and seating are acceptable, then remove the controller and
replace with identically configured controller.

Red None - indicates redundant controller in redundant configuration.

5.4.2 CP800 Error Codes

If a critical error occurs while the CP800 module is operating, then the fault status LED turns red and the module halts
operation. operation and diagnostic LEDs on the module display error codes. Refer to Table 4-3 for a list of error codes and
associated corrective actions. A code that is not listed may appear if a machine fault time-out occurs. Reset the module if
this happens. The module has failed if the fault status LED remains red. Replace the module in this case.

5.5 Status Summary

5.5.1 HC800 Status Summary

The HC800 has a 16-byte module status record. The status report provides summary flags for error conditions, module
type, and firmware revision level.
The status report can be viewed from a human system interface.
To interpret the status bytes, convert each hexadecimal byte to its binary equivalent. For example (PN800 mode):

Byte 1 0x75 = 01110101

Refer to Table 5-3 and Table 5-4 for an explanation of each byte and data bit.

2VAA001586 C 5-5
HC800 Status Summary Troubleshooting

5.5.1.1 Module Status Information - HC800

Table 5-3 and Table 5-4 explains the Symphony Plus HC800 controller status bytes.

Table 5-3: Byte and Bit description for HC800

Bit
Byte
7 6 5 4 3 2 1 0

1 ES MODE TYPE

2 FTX BAC RIO LIO CFG NVF NVI DSS

3 Error code

4 Error code descriptor (1)

5 Error code descriptor (2)

6 ETYPE

7 R1F R2F Reserve Reserved HN800A HN800B

d

8 Reserved

9 CW800A CW800B BATLOW Reserved RIOID ETHER EP1 EP2

10 PRI CFC Reserved CHK RID RDEXP OCE RDDET

11 PSA PSB Reserved Reserved RNO Reserved Reserved Reserved

12-13 Reserved

14 Module nomenclature

15 Revision letter (ASCII)

16 Revision number (ASCII)

Table 5-4: Byte Description - HC800

Field Size
Byte Field Description
or Value

12 ES 80 Error summary: 0 = good, 1 = errors

MODE 60 Module mode: 00 = configure, 10 = error, 11 =

execute

TYPE 1F Module type code: (15)16 = Enhanced status

2 FTX 80 First time in execute: 0 = no, 1 = yes

BAC 40 Backup status: 0 = good, 1 = bad

RIO 20 Summary remote input status: 0 = good, 1 = bad

LIO 10 Summary local input status: 0 = good, 1 = bad

CFG 08 Online configuration changes being made

NVF 04 Summary NVRAM failure status: 0 = good, 1 = fail

NVI 02 Summary NVRAM initialized state: 0 = no, 1 = yes

DSS 01 Digital station status: 0 = good, 1 = bad

5-6 2VAA001586 C
Troubleshooting HC800 Status Summary

Table 5-4: Byte Description - HC800 (Continued)

Field Size
Byte Field Description
or Value

3-5 Error 3 4 5
Note 1 Code
NVRAM error:
01 01 — Write failure
02 — Checksum failure
03 — Bad data
FF — Reset during write

02 (1) (2) Analog input reference error:

(1), (2) = block number of control interface I/O
module block

03 (1) (2) Missing I/O module or expander board:

(1), (2) = block number of I/O module or station

05 (1) (2) Configuration error – undefined block:

(1), (2) = block number making reference

06 (1) (2) Configuration error – input data type is incorrect:

(1), (2) = block number making reference

08 (1) (2) Trip block activated:

(1), (2) = block number of trip block

09 — — Segment violation.

0F — — Primary module has failed and the redundant

module configuration is not current

10 — — Primary module has failed and the dynamic RAM

data in the redundant module is not current

09 — — Segment violation - priority set the same in two

segments or more than eight segments defined.

11 — — NVRAM write failure error

1E (1) (2) Duplicate device definition label – multiple

FC 221 function blocks contain the same device
label.
(1), (2) = block number making reference.

2VAA001586 C 5-7
HC800 Status Summary Troubleshooting

Table 5-4: Byte Description - HC800 (Continued)

Field Size
Byte Field Description
or Value

3-5 Error 2A (1) (2) Not enough memory for UDF:

(cont) Code (1), (2) = block number making reference

20 — — Program format error - inconsistent format table

File system error:

21 00 00 Backup cannot take over due to un-initialized
FF FE file system.
FF FF Directory has not been configured.
(1) (2) List of file system free memory is corrupted.
(1), (2) = Number of files with errors.

22 (1) (2) Invoke C error:

(1), (2) = block number making reference

24 (1) (2) C program stack overflow:

(1), (2) = block number making reference

28 (1) (2) User defined function (UDF) reference is invalid:

(1), (2) = block number making reference

29 (1) (2) UDF block cannot read program file:

(1), (2) = block number making reference

2B (1) (2) Missing UDF declaration:

(1), (2) = block number making reference

2C (1) (2) Wrong UDF type:

(1), (2) = block number making reference

2D (1) (2) Missing UDF auxiliary block:

(1), (2) = block number making reference

2E (1) (2) UDF compiler and firmware are incompatible:

(1), (2) = block number making reference

62 ETYPE 1F Enhanced module type = (24)16

7 — — Unused.

— — Unused.

R1F 20 Redundancy link channel 1 failure: 0 = good, 1 =

fail

R2F 10 Redundancy link channel 2 failure: 0 = good, 1 =

fail

HN800A 02 HN800 channel A failure: 0 = good, 1 = fail

HN800B 01 HN800 channel B failure: 0 = good, 1 = fail

8 — — Unused.

5-8 2VAA001586 C
Troubleshooting HC800 Status Summary

Table 5-4: Byte Description - HC800 (Continued)

Field Size
Byte Field Description
or Value

9 CW800A 80 CW800 Bus A failure: 0 = good, 1 = fail

CW800B 40 CW800 Bus B failure: 0 = good, 1 = fail

BATLOW 20 NVRAM Battery low: 0 = good, 1 = replace battery

RIOID 08 Remote I/O Controller: 0 = no, 1 = yes

ETHER 04 Ethernet Installed: 0 = no, 1 = yes

EP1 02 The SOE Time Synchronization Ethernet Port

(labeled EN1 A on the MB810 base):
failure: 0 = good, 1 = fail

EP2 01 The Foreign Device Interface Ethernet Port

(labeled EN1 B on the MB810 base):
0 = good, 1 = fail

10 PRI 80 Module is primary versus backup; set to 1 in the

primary module.

CFC 40 Configuration current (latched until backup is

reset). Set when LED 7 is enabled (1 = on or
blinking) on the backup module.

CHK 10 Backup has completed checkpointing (latched

until backup is reset). Always set to 0 on the
primary module. Follows LED 8 (1 = on or blink-
ing) on the backup module.

RID 08 Redundancy ID. Follows setting of redundancy ID

pole on the dipswitch.

RDEXP 04 Redundancy expected. Always set to 1 on the

backup module. Follows state of FC 90,
specification S3, ones digit on the primary
module.

OCE 02 Online configuration is enabled. Follows setting of

online configuration enable pole on dipswitch.

RDDET 01 Redundancy detected (latched until module is

reset or it changes from backup to primary or
primary to backup). Set to 1 when a properly
configured redundant module is detected.

11 PSA 80 Power Status A: 0 = OK, 1 = failed/bad

PSB 40 Power Status B: 0 = OK, 1 = failed/bad

RNO 08 Redundancy NVM overrun (latched indication).

Set to 1 in primary module if NVM checkpoint
overruns have occurred. NVM checkpoint
overruns cause the primary module to reset the
backup module.

12-13 — 00 Reserved.

142 — FF Module nomenclature number (0A)16 =10 for the

HC800.

152 — FF Revision letter (in ASCII code).

For Example: (41)16 = A

2VAA001586 C 5-9
CP800 Status Summary Troubleshooting

Table 5-4: Byte Description - HC800 (Continued)

Field Size
Byte Field Description
or Value

162 — FF Revision number (in ASCII code).

For Example: (30)16 = 0
NOTES:
1. Byte 3 is displayed on the front panel LEDs when the module is in ERROR mode.
2. (x)16 denotes a hexidecimal number. The equivalent decimal or ASCII character
is to be used. Hex to ASCII Code conversion charts are readily available on the
Internet.

5.5.2 CP800 Status Summary

The CP800 has a 16-byte module status record. The status report provides summary flags for error conditions, module
type, and firmware revision level.
The status report can be viewed from a human system interface.
To interpret the status bytes, convert each hexadecimal byte to its binary equivalent. For example (PN800 mode):

Byte 1 0x75 = 01110101

Refer to Table 5-5 and Table 5-6 for an explanation of each byte and data bit.

Bit 7 0 = no errors.
Bit 6/5 11 = execute mode.
Bit 4-0 10101 = enhanced node type;
reference byte 6 (ETYPE) for actual
type.

The following table (Table 5-5) lists the fields that make up the CP800 module status report:

Table 5-5: CP800 Status Byte Description

Bit
Byte
7 6 5 4 3 2 1 0

1 ES MODE TYPE

2 Reserved

3 CSP MOV BKCFG BKSTS PSI

5 Reserved

6 ETYPE (0x25)

7 Reserved Reserved R1F R2F HN800A HN800B

9 CW800A CW800B BAT NET NET MISMATCH NET NET

LOW SWAP IDLE1 IDLE2

10 Reserved

11 PSA PSB

12 - 13 Reserved

14 Module nomenclature (0x1E for CP800)

5-10 2VAA001586 C
Troubleshooting CP800 Status Summary

Table 5-5: CP800 Status Byte Description (Continued)

Bit
Byte
7 6 5 4 3 2 1 0

15 Revision letter (ASCII)

16 Revision number (ASCII)

The following table (Table 5-6) describes each field within the module status record:

Table 5-6: CP800 Status Bit Descriptions

Byte Field Field Size or Value Description

1 ES 80 Error summary: 0 = good, 1 = errors

MODE 60 Module mode: 10 = error, 11 = execute

TYPE 1F Module type: 0x15 = enhanced status (ETYPE)

2 — 00 Reserved

3 CSP 80 Communication status problem: 0 = no, 1 = yes

MOV 40 Memory overflow: 0 = good, 1 = bad

BKCFG 10 Redundant configuration: 0 = no, 1 = yes

BKSTS 08 Backup failed: 0 = no, 1 = yes

PSI 00 Primary/backup indicator: 0 = primary, 1 = backup

4&5 — 00 Reserved

6 ETYPE 20 Enhanced module type: 0x25 = CP800

7 - - Reserved

- - Reserved

R1F 20 Redundancy Link channel 1 failure: 0 = good, 1 = fail

R2F 10 Redundancy Link channel 2 failure: 0 = good, 1 = fail

HN800A 02 HN800 channel A failure: 0 = good, 1 = fail

HN800B 01 HN800 channel B failure: 0 = good, 1 = fail

8 — 00 Reserved

2VAA001586 C 5-11
Diagnostic Tests Troubleshooting

Table 5-6: CP800 Status Bit Descriptions (Continued)

Byte Field Field Size or Value Description

9 CW800A 80 CW800 Bus A failure: 0 = good, 1 = fail

CW800B 40 CW800 Bus B failure: 0 = good, 1 = fail

BAT LOW 20 NVRAM Battery low: 0 = good, 1 = replace battery

NET SWAP 08 Network LAN A/B Swapped: 0 = no, 1 = yes

If this bit is a '1' / YES, then CP800 detects one or more
nodes on the Network having their (PN800) LAN A/B
Ethernet connections swapped (i.e. LAN A is connected
to LAN B, LAN B is connected to LAN A).

NET 04 Network LAN A/B Mismatch: 0 = no, 1 = yes

MISMATCH
If this bit is a '1' / YES, then CP800 detects that its
(PN800) LAN A/B Ethernet connections are operating in
different modes (i.e. A= 10 MHZ, B= 100 MHZ, or
A= Full Duplex, B= Half Duplex).

NET IDLE 1 02 Error on PN800 LAN 'A'. No connection on RJ45 for

PN800 LAN A (labeled EN2 A on the MB810 base).

NET IDLE 2 01 Error on PN800 LAN 'B'. No connection on RJ45 for

PN800 LAN B (labeled EN2 B on the MB810 base).

10 — — Reserved

11 PSA 80 Power Status A: 0 = OK, 1 = failed/bad

PSB 40 Power Status B: 0 = OK, 1 = failed/bad

12-13 Reserved

14 — FF Module nomenclature: 0x1E = CP800

15 — FF Revision letter (in ASCII code). For example, 0x41 = A

16 — FF Revision number (in ASCII code). For example, 0x30 = 0

5.6 Diagnostic Tests

5.6.1 HC800 Diagnostic Test Descriptions

The controller firmware contains diagnostic routines that can be invoked during controller power up. These routines verify
the proper operation of the controller components and circuitry. Putting the controller in the diagnostic mode allows the
controller to perform a variety of diagnostic tests but suspends normal operation.
Therefore, use it during installation to check controller integrity, when the system is down, or transfer system control to a slot
away from any communications bus associated with live I/O to check a currently operating controller. Refer to sub-section
5.6.3- HC800 Diagnostic Test Procedure of this user manual for information on how to use the diagnostic routines.

The following table (Table 5-7) lists each test routine and gives a brief description:

Table 5-7: HC800 Diagnostic Tests

Test Name Test-ID Description

Switches and LEDs 00 Byte value of all dipswitches are exclusive ORed together. Results
are displayed on LEDs. fault status LED is off for even or on for
odd total.

CPU 01 Verifies CPU instruction set is operational.

5-12 2VAA001586 C
Troubleshooting HC800 Diagnostic Test Descriptions

Table 5-7: HC800 Diagnostic Tests (Continued)

Test Name Test-ID Description

ROM 02 Calculates checksum of ROM and compares it to value stored in

ROM during programming.

RAM 03 Performs walking one test. Clears, verifies, sets and verifies all
RAM. Test includes byte, word and long word accesses.

NVRAM 04 Verifies read and write function of NVRAM.

Timer 05 Initializes DUART timer for 1-msec interrupts and then waits for it
to time-out.

Real-time clock 06 Verifies real-time clock is functioning.

I/O expander bus 07 Sets a latch enabling a level seven interrupt to occur.
stall

Dispatcher IRQ2 09 Issues software dispatcher request and waits for interrupt to occur.

DUART 0 0A Tests (in local loopback mode) both serial channels of DUART
circuitry that supports the RS-232-C/RS-485 serial ports.

DUART 1 0B Tests (in local loopback mode) both serial channels of DUART
circuitry that supports debug port.

CW800 0C Test CW800 interface in local loop back mode. Checks CW800
(local loop back) operation including both channel A and B, shared RAM, timers,
time-sync, registers, etc.

HN800 0D Test HN800 interface in local loop back mode. Checks HN800
(local loop back) operation including both channel A and B, shared RAM, timers,
time-sync, registers, etc.

ID ROM 0E Reads CRC code from ID-ROM.

Ethernet 0F Test Ethernet hardware in local loop back mode.

Group test 1 10 Executes tests 01 through 0F.

Unused 11 —

Unused 12 —

Redundancy link 14/24 Tests communications between redundant controllers. Checks the
primary/redundant ability to perform direct memory accessed data transfers across
both redundancy link channels. Requires two controllers
(redundant) and the appropriate redundancy cabling. Set one
controller to test 14 (primary); the other to test 24 (redundant). The
primary controller provides pass/fail indication; the redundant
controller displays data received and transmitted.

HN800 16/21 Tests HN800 communication between a controller acting as a

master and another controller acting as an I/O device. Checks the
ability to both transmit and receive HN800 messages. Requires
two controllers (redundant or primary) and the appropriate HN800
cabling, and termination hardware. Set one controller to test 16
(master); the other to test 21. Both controllers provide pass/fail
indication.
NOTE: A HAI805/HAO805/PDP800 set at test 21 can also serve
as the I/O device. This is the recommended setup for testing
HN800.

2VAA001586 C 5-13
HC800 Diagnostic Test Descriptions Troubleshooting

Table 5-7: HC800 Diagnostic Tests (Continued)

Test Name Test-ID Description

Hnet repeater 17 Tests Hnet communication when an RFO Fiber Optic Repeater is
between a master and a controller acting as an I/O device. Checks
the ability to both transmit and receive Hnet messages. Requires
two controllers (redundant or primary) and the appropriate PBA,
Hnet cabling, and termination hardware. Set one controller to test
16 (master); the other to test 21. Both controllers provide pass/fail
indication.
NOTE: A HAI805/HAO805/PDP800 set at test 21 can also serve
as the I/O device. This is the recommended setup for testing
HN800.

CW800 18/21 Tests CW800 communication between a controller acting as a

master and another controller acting as an I/O device. Checks the
ability to both transmit and receive CW800 messages. Requires
two controllers (redundant or primary) and the appropriate CW800
cabling, and termination hardware. Set one controller to test 16
(master); the other to test 21. Both controllers provide pass/fail
indication.
NOTE: A HAI805/HAO805/PDP800 set at test 21 can also serve
as the I/O device. This is the recommended setup for testing
CW800.

Unused 19 —

Group test 2 20 Executes tests 01 through 1F.

Redundancy link / 22 Displays running count of bytes received by redundant controller

redundant when primary controller is executing test 20. Provides the common
functionality of test 24.

I/O expander bus 25 Arms the fault timer and allows the I/O expander bus clock to stall.
fault time halt 1 This checks the controller ability to disengage from the I/O
expander bus in the event it can no longer drive the expander bus
clock. This test passes if controller halts with a 0x55 pattern
displayed on the LEDs 1-8. Fails if controller continues to operate
with any other pattern displayed on the LEDs.

NVRAM retention - 26 Stores a known data pattern in NVRAM for testing by the NVRAM
data storage 1 retention - data check test 27. Halts with LED pattern 0x55 if test
has completed writing data.

NOTE: Remove power from controller prior to running the

NVRAM retention - data check test. If practical leave controller
unpowered for one hour prior to running the data check test.

NVRAM retention - 27 Verifies NVRAM holds data pattern stored in test 26. Provides
data check normal pass/fail indication.

Redundancy link 28 Tests redundancy links ability to generate and detect a break in the
break transmission. An intentionally generated break is sent. The
receiver detects the break and in response sends a break back.
Requires two controllers (redundant) and the appropriate
redundancy cabling. Set both controllers to test 28.

Stop/Reset push 29 Verifies proper push button operation. Passes, if after pressing the
button 1 Stop/Reset push button once, LED display changes from 0x29 to
0x55 with the red/green LED red.

5-14 2VAA001586 C
Troubleshooting Running HC800 Offline Diagnostic Tests

Table 5-7: HC800 Diagnostic Tests (Continued)

Test Name Test-ID Description

Memory 2A Verifies the ability of the memory management unit hardware to

management unit 1 detect legal and illegal accesses to the controller memory address
space. Passes if the controller halts with LED pattern 0x23 (user
write violation halt code). Fails if the controller continues to operate
or halts with any other LED pattern.

Reserved 2C-2D Reserved for internal use by ABB engineering. Do not use.
NOTES:
1. Test is not continuous. The controller halts and displays a non-standard pass/fail indication.

5.6.2 Running HC800 Offline Diagnostic Tests

Use the HC800 controller dipswitches to select the required diagnostic routine. Diagnostic test results display on the
controller front panel LEDs. Both group and individual tests can be executed. The typical procedure is to select a diagnostic
routine to execute, set the controller dipswitches accordingly, reset the controller, and observe the results on the faceplate
LEDs. If the halt on error feature is disabled, the selected test runs repeatedly until the controller is reset and another test is
selected.

If ‘Halt on Error’ feature is enabled, then the test stops and the LEDs display the failure.

5.6.3 HC800 Diagnostic Test Procedure

Pole one of physical dipswitch SW1 must be set to the open (off) position to put the controller into the diagnostic mode.
Poles three through eight of physical dipswitch SW1 select the diagnostic test. Pole eight is the least significant bit (binary
weight one), while pole three is the most significant bit (binary weight 32). Refer to Table 5-7 for test ID values.
Pole two of physical dipswitch SW1 selects the diagnostic option. When the diagnostic option is enabled, the controller
halts test execution whenever the selected test detects an error. The number of the failing test is displayed on LEDs 1-8
(refer to Figure 5-2). The R and next two unmarked LEDs display the pass/fail count. These LEDs are green for tests that
are passed and red for failed tests. Refer to Table 5-7 for a description of each diagnostic test.
The following table (Table 5-8) defines the function of each pole of physical dipswitch SW1:

Table 5-8: HC800 Diagnostic Dipswitch Settings

Dipswitch Pole Setting Function

Physical 1 1 Diagnostics mode. Test selected with

SW1 poles 3 to 8.

2 0 Continue on failure

1 Halt on failure.

3-8 0 - 2B Test number (ID). Refer to Table 5-7.

(hex)
NOTE: 0 = closed or on, 1 = open or off.

2VAA001586 C 5-15
HC800 Diagnostic Mode LED Display Troubleshooting

Figure 5-2: LEDs - Pass/Fail

5.6.4 HC800 Diagnostic Mode LED Display

LEDs (refer to Figure 5-2) are used during diagnostic mode operation to display test results.
On controller reset, all LEDs turn on. Next, the controller reads the dipswitches, executes the selected test, and displays the
result on the LEDs. The LEDs display the test number on LEDs one through six. If LED eight is on, the test failed. The
display is latched on for 14-second for viewing ease, then the LEDs blank out for about 18-second, and the test is repeated.
The LED labeled R and the next two unlabeled LEDs display a running tally of successes and failures. Green for success,
red for failure.
If a test fails with the Halt On Failure selected (dipswitch SW1, pole two off), then the fault status LED turns red. The test
number that failed is displayed on LEDs 1-8.
For group tests (10, 20), each test is run in numerical order. On a failure, LED eight flashes and LEDs one through six
display the test number that failed. When all tests in the group are done, the error count is incremented and displayed on
the LED labeled R and the next two unlabeled LEDs.

5.6.5 CP800 Diagnostic Tests

The firmware of the CP800 module contains various diagnostic routines used to verify proper operation of components and
circuitry. Some are run automatically during startup and normal operation (online), and others can be invoked manually
(offline). If any of the online checks detect a hardware problem, then the module provides error status code indications (if
possible) and halts. Refer to Table 5-5 to decipher the status codes.
Offline tests can be run to verify operation of suspect CP800 modules or to check module integrity before putting it into
operation. Offline diagnostics should only be run during installation or when a system is down. Putting the CP800 module
into diagnostic mode allows it to perform a variety of diagnostic tests but suspends normal operation.

5-16 2VAA001586 C
Troubleshooting CP800 Diagnostic Test Descriptions

This procedure gives the steps necessary to run offline diagnostics. The diagnostics run in the CP800 module. While in
Diagnostic mode the CP800 LEDs operate differently than during normal operation.
The following figure (Figure 5-3) displays the LED locations on the CP800:

Figure 5-3: CP800 Diagnostic LEDs

5.6.6 CP800 Diagnostic Test Descriptions

The following table (Table 5-9) describes the diagnostic tests:

Table 5-9: CP800 Diagnostic Tests

Test Name Test-ID Description

Switches and LEDs 00 Byte value of all dipswitches are exclusive ORed together. Results
are displayed on LEDs. fault status LED is off for even or on for
odd total.

CPU 01 Verifies CPU instruction set is operational.

ROM 02 Calculates checksum of ROM and compares it to value stored in

ROM during programming.

RAM 03 Performs walking one test. Clears, verifies, sets and verifies all
RAM. Test includes byte, word and long word accesses.

NVRAM 04 Verifies read and write function of NVRAM.

Timer 05 Initializes DUART timer for 1-msec interrupts and then waits for it
to time-out.

Real-time clock 06 Verifies real-time clock is functioning.

2VAA001586 C 5-17
CP800 Diagnostic Test Descriptions Troubleshooting

Table 5-9: CP800 Diagnostic Tests (Continued)

Test Name Test-ID Description

I/O expander bus 07 Sets a latch enabling a level seven interrupt to occur.
stall

Dispatcher IRQ2 09 Issues software dispatcher request and waits for interrupt to occur.

DUART 0 0A Tests (in local loopback mode) both serial channels of DUART
circuitry that supports the RS-232-C/RS-485 serial ports.

DUART 1 0B Tests (in local loopback mode) both serial channels of DUART
circuitry that supports debug port.

CW800 0C Test CW800 interface in local loop back mode. Checks CW800
(local loop back) operation including both channel A and B, shared RAM, timers,
time-sync, registers, etc.

HN800 0D Test HN800 interface in local loop back mode. Checks HN800
(local loop back) operation including both channel A and B, shared RAM, timers,
time-sync, registers, etc.

ID ROM 0E Reads CRC code from ID-ROM.

Ethernet 0F Test Ethernet hardware in local loop back mode.

Group test 1 10 Executes tests 01 through 0F.

Unused 11 —

Unused 12 —

Redundancy link 14/24 Tests communications between redundant controllers. Checks the
primary/redundant ability to perform direct memory accessed data transfers across
both redundancy link channels. Requires two controllers
(redundant) and the appropriate redundancy cabling. Set one
controller to test 14 (primary); the other to test 24 (redundant). The
primary controller provides pass/fail indication; the redundant
controller displays data received and transmitted.

HN800 16/21 Tests HN800 communication between a controller acting as a mas-

ter and another controller acting as an I/O device. Checks the abil-
ity to both transmit and receive HN800 messages. Requires two
controllers (redundant or primary) and the appropriate HN800
cabling, and termination hardware. Set one controller to test 16
(master); the other to test 21. Both controllers provide pass/fail
indication.
NOTE: A HAI805/HAO805/PDP800 set at test 21 can also serve
as the I/O device. This is the recommended setup for testing
HN800.

Hnet repeater 17 Tests Hnet communication when an RFO Fiber Optic Repeater is
between a master and a controller acting as an I/O device. Checks
the ability to both transmit and receive Hnet messages. Requires
two controllers (redundant or primary) and the appropriate PBA,
Hnet cabling, and termination hardware. Set one controller to test
16 (master); the other to test 21. Both controllers provide pass/fail
indication.
NOTE: A HAI805/HAO805/PDP800 set at test 21 can also serve
as the I/O device. This is the recommended setup for testing
HN800.

5-18 2VAA001586 C
Troubleshooting CP800 Diagnostic Test Descriptions

Table 5-9: CP800 Diagnostic Tests (Continued)

Test Name Test-ID Description

CW800 18/21 Tests CW800 communication between a controller acting as a

master and another controller acting as an I/O device. Checks the
ability to both transmit and receive CW800 messages. Requires
two controllers (redundant or primary) and the appropriate CW800
cabling, and termination hardware. Set one controller to test 16
(master); the other to test 21. Both controllers provide pass/fail
indication.
NOTE: A HAI805/HAO805/PDP800 set at test 21 can also serve
as the I/O device. This is the recommended setup for testing
CW800.

Unused 19 —

Group test 2 20 Executes tests 01 through 1F.

Redundancy link / 22 Displays running count of bytes received by redundant controller

redundant when primary controller is executing test 20. Provides the common
functionality of test 24.

I/O expander bus 25 Arms the fault timer and allows the I/O expander bus clock to stall.
fault time halt 1 This checks the controller ability to disengage from the I/O
expander bus in the event it can no longer drive the expander bus
clock. This test passes if controller halts with a 0x55 pattern
displayed on the LEDs 1-8. Fails if controller continues to operate
with any other pattern displayed on the LEDs.

NVRAM retention - 26 Stores a known data pattern in NVRAM for testing by the NVRAM
data storage 1 retention - data check test 27. Halts with LED pattern 0x55 if test
has completed writing data.

NOTE: Remove power from controller prior to running the

NVRAM retention - data check test. If practical leave controller
unpowered for one hour prior to running the data check test.

NVRAM retention - 27 Verifies NVRAM holds data pattern stored in test 26. Provides
data check normal pass/fail indication.

Redundancy link 28 Tests redundancy links ability to generate and detect a break in the
break transmission. An intentionally generated break is sent. The
receiver detects the break and in response sends a break back.
Requires two controllers (redundant) and the appropriate
redundancy cabling. Set both controllers to test 28.

Stop/Reset push 29 Verifies proper push button operation. Passes if after pressing the
button 1 Stop/Reset push button once, LED display changes from 0x29 to
0x55 with the red/green LED red.

Memory 2A Verifies the ability of the memory management unit hardware to

management unit 1 detect legal and illegal accesses to the controller memory address
space. Passes, if the controller halts with LED pattern 0x23 (user
write violation halt code). Fails if the controller continues to operate
or halts with any other LED pattern.

Reserved 2C-2D Reserved for internal use by ABB engineering. Do not use.
NOTES:
1.Test is not continuous. The controller halts and displays a nonstandard pass/fail indication.

2VAA001586 C 5-19
Running CP800 Offline Diagnostics Troubleshooting

5.6.7 Running CP800 Offline Diagnostics

Steps:
1. Run the diagnostics with the CP800 module in a test enclosure or verify whether the system is offline.
2. Set switch SW1 poll 1 to enable diagnostic mode.
3. Put the CP800 module into diagnostic mode.

This allows the module to perform a variety of diagnostic tests but suspends normal operation.
4. Select the test options with poles one of switch SW2 as shown in the following table (Table 5-10).

Table 5-10: CP800 Switch SW2 - Diagnostic Options

Pole Setting Option Description

1 0 Halt on error: no Refer to sub-section 5.6.9- Halt On Error

of this user manual for more details.
1 Halt on error: yes
NOTE: 1 = off or open; 0 = on or closed.

5. Select the required test by setting switch SW2 as shown in the following table (Table 5-11).

Table 5-11: CP800 Switch SW2 - Hardware Diagnostic Mode

Pole
Test ID Test
3 4 5 6 7 8

00 0 0 0 0 0 0 LEDs and switches1

01 0 0 0 0 0 1 CPU

02 0 0 0 0 1 0 ROM

03 0 0 0 0 1 1 RAM

04 0 0 0 1 0 0 NVM

05 0 0 0 1 0 1 TIMER - 5307 system TIC

06 0 0 0 1 1 0 Real Time Clock

07 0 0 0 1 1 1 XBus Stall

08 0 0 1 0 0 0 Module BUS

09 0 0 1 0 0 1 Dispatcher

0A 0 0 1 0 1 0 RS-232 (local loopback)

0B 0 0 1 0 1 1 Debug & DCS link local

0C 0 0 1 1 0 0 PNET DBUS

0D 0 0 1 1 0 1 DBUS (local loopback)

0E 0 0 1 1 1 0 IDROM

10 0 1 0 0 0 0 Group 1 test - 01 to 0E

5-20 2VAA001586 C
Troubleshooting Display Mode

Table 5-11: CP800 Switch SW2 - Hardware Diagnostic Mode (Continued)

Pole
Test ID Test
3 4 5 6 7 8

12 0 1 0 0 1 0 Exbus CP800

14 0 1 0 1 0 0 Redundancy

16 0 1 0 1 1 0 HNET DBUS MASTER

20 1 0 0 0 0 0 Group 2 test - 01 to 16

21 1 0 0 0 0 1 DBUS SLAVE (for MASTER)

22 1 0 0 0 1 0 DCS & Redundancy (Backup)

23 1 0 0 0 1 1 DCS (Backup role)

24 1 0 0 1 0 0 Redundancy (Backup role)

25 1 0 0 1 0 1 XBus Assassin

26 1 0 0 1 1 0 NVM retention, data store

27 1 0 0 1 1 1 NVM retention, data check

28 1 0 1 0 0 0 Redundancy break

29 1 0 1 0 0 1 STOP push button

2A 1 0 1 0 1 0 MMU

2C 1 0 1 1 0 0 Copy image to ROM

2D 1 0 1 0 1 1 LOAD image from RS-232 port to

ROM
NOTES: 1 = off or open; 0 = on or closed.
1. Test is not continuous.

6. Insert the module into the base.

Refer to sub-section 3.6.3- HC800 and CP800 Module Insertion/Removal of this user manual, if required.
7. Observe the Test Failure Indicator LED to determine, if the test passed or failed (refer to Figure 5-3).

NOTE: Solid red indicates a failure. In general if a diagnostic test fails, replace the module. Table 5-9
describes each test.

5.6.8 Display Mode

Following are the display modes available on the CP800:
• Test Number
• Pass/Fail Count

• Test Number:
The test number display mode uses LEDs 1 - 6 to display the diagnostic test number and LED eight to
display whether the test passed or failed (refer to Figure 5-3). If a diagnostic test is successful, Fault LEDs displays
green and the diagnostic test number LEDS (1-6) and LED eight remains off.
If a diagnostic test is not successful, then Fault LED goes solid red if pole 1 of Dip Switch 2 is set to 1, or flashes
red if set to 0. LEDs 1-6 display the diagnostic test number and LED eight turns solid red. LED seven is not used in
test number display mode.

2VAA001586 C 5-21
Halt On Error Troubleshooting

• Pass/Fail Count:
The Pass/Fail Count LEDs display a combination of incrementing pass and fail counters
(refer to Figure 5-3). LEDs “R” and the next two unlabeled LEDs display a binary count of the number of passed
tests and LEDs five through eight display the number of failed tests.

5.6.9 Halt On Error

Following are the Halt On Error options available on the CP800:
• Disabled
• Enabled

• Disabled:
If Halt on Error option is disabled, then the selected test runs repeatedly until the module is removed. The
Fault LEDs turns red when pole 1 of SW2 is set to halt on failure (1). Otherwise it flashes green.
• Enabled:
If Halt on Error is enabled, then the test stops, if an error is encountered. LEDs 1-6 display the test
number and LEDs “R” and the next two unlabeled LEDs display the pass count and failure count. The test
continues to run, however, if no error is detected.

5.7 CP800 Duplicate IP Address Detection Procedure

If the CP800 module is started without an Ethernet cable physically plugged in to either of its ports, then the fault light blinks
and TCP/IP functionality does not begin. The CP800 module then waits until a cable is attached. Once a cable is attached,
it issues a special ARP message to determine, if its IP address is unique. If the CP800's IP is unique, then the CP800
module starts up as usual. If the CP800's IP is not unique, then the fault light again blinks and TCP/IP functionality is
disabled.
If the CP800’s IP address is found to be a duplicate of an IP address already on the network, then the MAC address of the
conflicting device can be viewed through the CP800’s Diagnostic menu. This information can then be used to locate the
module with the conflicting IP address and resolve the issue.
Follow the given steps to retrieve the MAC address:
1. Connect to the CP800’s USB diagnostic port. (Refer to the S+ Control: HPC800 Harmony Process Controller
User Manual for connection procedures and settings.)
2. Press any key to view the CP800’s revision information and to verify the connection, once the module is
connected to the USB diagnostic port.

Figure 5-4: CP800 Diagnostic Menu Revision Information

3. Press ‘p’ to up the prompt to change the print flag of the CP800’s Diagnostic menu.

5-22 2VAA001586 C
Troubleshooting CP800 Duplicate IP Address Detection Procedure

4. Enter ‘f’ as the print flag and press the Enter key, as shown in the following figure (Figure 5-5):

Figure 5-5: CP800 Diagnostic Menu Print Flag sub-menu

5. Press the Enter key to display additional menu options as shown in the following figure (Figure 5-6):

Figure 5-6: CP800 Diagnostic Menu; Duplicate IP Address Not Detected

If the IP address of the CP800 is not unique, then a new option ‘Y’ appears on the Diagnostic menu, as shown in the
following figure (Figure 5-7):

Figure 5-7: CP800 Diagnostic Menu with Option ‘Y’ Displayed - Duplicate IP Address Detected

2VAA001586 C 5-23
CP800 Duplicate IP Address Detection Procedure Troubleshooting

When you press ‘Y’, it prints the MAC address of the module with the conflicting IP address to the terminal display screen,
as shown in the following figure (Figure 5-8).

Figure 5-8: CP800 Diagnostic Menu showing MAC address of module with duplicate IP Address

All IP address conflicts must be resolved to enable the CP800 TCP/IP functionality. Once you resolve the IP address conflict
and restart the module, the menu option ‘Y’ no longer appears in this menu. If the menu option still appears, then another IP
address conflict exits, which needs to be resolved.

5-24 2VAA001586 C
Maintenance General

6. Maintenance
6.1 General
There are some basic procedures for keeping all the components of the HPC800 system in good working order.
• The operating environment must be clean and free of corrosive and conductive contaminants.
• The ventilation slots in the module housings should be kept clean and unclogged by dust to ensure proper cooling.

NOTE: Use a soft bristle brush to clean the slots when needed.

• For general cleaning, use a lint-free cloth and a mild, all-purpose, non-flammable, commercial spray cleaner to
remove dirt, fingerprints, and grease from the equipment.

NOTE: Spray the cleaner on the cloth and not directly on the equipment.

• Proper grounding procedures should be followed for electrostatic discharge (ESD) protection.

2VAA001586 C 6-1
General Maintenance

6-2 2VAA001586 C
Replacement and Spare Parts Parts

7. Replacement and Spare Parts

7.1 Parts
Order parts without commercial descriptions from the nearest ABB sales office. Contact ABB Automation for help
determining the quantity of spare parts to keep on hand for your particular system.
The following tables (Table 7-1, Table 7-2, and Table 7-3) lists the HPC800 controller related parts.:

Table 7-1: Module and Base Nomenclature

1 2 3 4 5 6 Description

C P 8 0 0 Communication Processor Module

H C 8 0 0 Harmony Processor Module

M B 8 1 0 HC/CP Mounting Base, Double Wide

C T B 8 1 0 Communication Termination Base, Left Side

C T B 8 1 1 Communication Termination Base, Right Side

P N I 8 0 0 Plant Network Interface Module

M B 8 0 5 PNI800 Mounting Base, Single Wide

T E R 8 0 0 Terminator for CW800 and HN800 communication

bus

Table 7-2: Cable Nomenclatures (1)

1 2 3 4 5 6 7 8 9 Description

S P K 8 0 0 - 0 A CW800/HN800 0.5 meter cable

S P K 8 0 0 - 0 1 CW800/HN800 1 meter cable

S P K 8 0 0 - 0 2 CW800/HN800 2 meter cable

S P K 8 0 0 - 0 3 CW800/HN800 3 meter cable

S P K 8 0 0 - 0 4 CW800/HN800 4 meter cable

S P K 8 0 0 - P B A 1 - 0 1 Symphony Plus cable connects rack modules

(through PBA800) to HPC800 controller. The cable
has a connector for TER800, terminator; 1 meter long

S P K 8 0 0 - P B A 1 - 0 2 Symphony Plus cable connects rack modules

(through PBA800) to HPC800 controller. The cable
has a connector for TER800, terminator; 2 meter long

S P K 8 0 0 - P B A 1 - 0 3 Symphony Plus cable connects rack modules

(through PBA800) to HPC800 controller. The cable
has a connector for TER800, terminator; 3 meter long

S P K 8 0 0 - P B A 1 - 0 4 Symphony Plus cable connects rack modules

(through PBA800) to HPC800 controller. The cable
has a connector for TER800, terminator; 4 meter long
(1) Cable lengths are approximate

2VAA001586 C 7-1
Parts Replacement and Spare Parts

Table 7-3: Miscellaneous Parts

Part Number Description

19469849 Battery enable Jumper

7-2 2VAA001586 C
Module Repair and Replacement Introduction

8. Module Repair and Replacement

8.1 Introduction
This section explains the replacement procedure for the HPC800 module. There are no special tools required to replace the
module.

8.2 Procedure
If the module is faulty, then replace it with a new module.

For installations in ATEX classified areas:

• Turn off power to the I/O segment before you remove or install modules in the MB810 mounting
base.
• Turn off power before you remove or install CTB810, CTB811, HBX01L, HBX01R bus extenders.
• Turn off power before you remove or insert TER800 terminators or SPK01-0x cables.

NOTE: Do not try to repair the module. If you replace the components of the module, then it affects the performance and
warranty of the module. In non-hazardous areas, the module can be removed from the mounting base while power is
supplied to the mounting base.

Follow the given steps to replace a module:

1. Remove the module per instructions given in sub-section 3.6.3.2- Removal of this user manual.
2. Configure the replacement module per instructions given in section 9- HC800 Setup for the HC800 module or
section 10- CP800 Setup for the CP800 module.

NOTE: Refer to section 11- CP800 and HC800 Firmware Update of this user manual for firmware update, if
required.

NOTE: Make sure the switch settings are set per the original replaced module.

3. Insert the module in the same MB810 mounting base used for the original module per instructions given in sub-
section 3.6.3.1- Insertion of this user manual.
4. Return to normal operation.

2VAA001586 C 8-1
Procedure Module Repair and Replacement

8-2 2VAA001586 C
HC800 Setup HC800 Module Configuration

9. HC800 Setup
Perform the following activities before an HC800 module can be put into service:
1. Unpack the module per instructions given in sub-sections: 3.2- Special Handling and 3.3- Unpacking and
Inspection of this user manual.
2. Perform a visual inspection of the module.
3. Set the battery enable jumper per instructions given in sub-section 9.2.1- Battery Enable Jumper of this user
manual.
4. Set HC800 switches per instructions given in sub-sections: 9.3- HC800 Switch Settings, 9.4- SOE Time
Synchronization IP Addressing for HC800 and 9.5- Setting ModbusTCP Address for HC800 of this user manual.

NOTE: Sub-sections: 9.4- SOE Time Synchronization IP Addressing for HC800 and 9.5- Setting ModbusTCP
Address for HC800 of this user manual are optional for setting HC800 switches.

5. Update HC800 module firmware to match firmware revision of other HC800 controllers in the system.
Redundant HC800 pairs must be at the same firmware revision. ABB recommends to use
the latest firmware available for HC800 controller modules. Refer to section11- CP800 and
HC800 Firmware Update of this user manual for firmware update instructions.
6. Format the HC800 module.
7. Load the controller configuration.

9.1 HC800 Module Configuration

This section describes the steps required to set up the HC800 module of the HPC800 controller (refer to Figure 9-1).
Switches must be set and jumper setting verified before putting the module into operation.

2VAA001586 C 9-1
HC800 Jumper Setting HC800 Setup

Figure 9-1: HC800 Switch and Jumper Locations

9.2 HC800 Jumper Setting

9.2.1 Battery Enable Jumper

Follow the given steps before you use the HC800 module:
1. Position the Battery Enable jumper located on the side of the module (refer to Figure 9-1) to the enabled
position.
2. Move the jumper from the default shipping and storage position to the Battery Enabled position.

9.3 HC800 Switch Settings

9.3.1 HC800 Dipswitch Settings

The HC800 module has one physical dipswitch (SW1) and six virtual dipswitches (saved in NVM) that require user selection
based on required module operating characteristics. The dipswitches select module operation options, serial port
communication characteristics, and baud rate. Refer to Figure 9-1 for dipswitch locations.

9-2 2VAA001586 C
HC800 Setup Virtualization of Dipswitches

9.3.2 Virtualization of Dipswitches

From HC800 firmware revison A_2 onwards, the physical dipswitches have been virtualized. Only SW1 on the PCB is used
to configure the HC800. Dipswitches - SW2 to SW5 are no longer used and their functions have been moved to virtual
switches available in the debug utility.
The following figure (Figure 9-2) shows the new virtual switch menu that is used to configure the module:

Figure 9-2: Virtual Switch menu

In this virtual switch menu, there are six virtual switches that are used by the HPC800 controller.

NOTE: To use the virtual switches, HC800 firmware A_2 or later must be installed.

9.3.2.1 Procedure

Follow the given steps to use the virtual switches:

NOTE: In the following procedure- steps 1 to 8 are only required when putting a new module in operation for the first
time, or after changing Battery Enable jumper setting, or after firmware upgrade from A_1 to A_2 or later. When you
format the module by Special Operation mode, it does not affect the virtual dipswitches settings saved in NVM.

1. Set physical SW1 to perform ‘STOP Pushbutton’ diagnostic 0X29, SW1 = 0XA9 = 10101001 (sets virtual NVM
dipswitches to default values).
2. Insert the module into its base.
3. Push the STOP button and wait for the module to display red light.
4. Set physical SW1 to perform ‘FORMAT NVM’+ Special Operation 0X02, SW1=0X22= 00100010.
5. Reset the module and wait for Special Operation to complete (module red lights with 0x3F on LEDs).
6. Set physical SW1 to perform ‘NORMAL RUN’ 0x00, SW1=0x00=00000000
7. Reset the module
8. Wait for LEDs 7 and 8 and flashing green status LED to appear.
9. Connect computer to USB port.
10. Enter the following text, 'S+' (uppercase letter ‘S’ followed by ‘plus’ sign) using hyperterminal emulation software
to startup the S+ General Operations menu.
11. Select a DIP Switch edit operation, where:
• A = Edit Module address.
• B= Hardware Special Operations - to format the HC800 configuration NVM.
• C = Detailed DIP Switch Edit Display - manipulates all six virtual DIP switches in NVM (does not set virtual
NVM dipswitches to default values).

NOTE: Most users need to only select option ‘A’.

12. Enter ESC to return to the General Operations menu.

13. Reset the module using the Stop/Reset button to install the NVM DIP Switch changes into the run time RAM
images.

2VAA001586 C 9-3
HC800 Physical Dipswitch SW1 HC800 Setup

14. Wait for the module to reset.

15. Close the hyperterminal session.
16. Disconnect the cable from the USB port.

9.3.3 HC800 Physical Dipswitch SW1

Physical dipswitch SW1 determines the operation modes (normal operation, diagnostic mode, special operations) of the
HC800 module.
The following table (Table 9-1) lists the physical dipswitch SW1 Normal Run settings:

Table 9-1: Physical Dipswitch SW1- Normal Run Settings

Pole Setting Function

1 0 Normal Run

2 0 Normal Run

3 0 Normal Run Mode

4 0 Normal Operation

5-8 0 Unused

NOTE: 0 = closed or on, 1 = open or off.

The following table (Table 9-2) lists the physical dipswitch SW1 Special Operation settings:

Table 9-2: Physical Dipswitch SW1- Special Operation Settings

Pole Setting Function

1 0 Normal Run

2 0 Normal Run

3 1 Special Operations Mode

4-8 0 Special Operation Number to be run (0 to 31).

NOTE: Refer to sub-section 9.3.5.1- HC800 Special Operations

(Physical SW1 or Virtual SW2) and Table 9-5 of this user manual for
more details.

NOTE: 0 = closed or on, 1 = open or off.

The following table (Table 9-3) lists the physical dipswitch SW1 Diagnostic Mode settings:

Table 9-3: Physical Dipswitch SW1- Diagnostic Mode Settings

Pole Setting Function

1 1 Diagnostics mode. Test selected with

poles 3 to 8.

2 0 Continue on failure

1 Halt on failure.

3-8 0 - 2B Test number (ID). Refer to Table 5-7.

(hex)

NOTE: 0 = closed or on, 1 = open or off.

9.3.4 HC800 Virtual Dipswitch SW1

Virtual dipswitch SW1 is used to set the HC800's module address. Valid values are from 2-31. The default value is 2.

9-4 2VAA001586 C
HC800 Setup HC800 Virtual Dipswitch SW2

9.3.5 HC800 Virtual Dipswitch SW2

Virtual dipswitch SW2 is used to set controller options that are available when the controller is in normal operation and in
special operation.

NOTE: Refer to Table 9-4 for option settings during normal operation when dipswitch SW2 pole one is set to closed (on).

Virtual dipswitch SW2 is also used to set special operations. Special operations can be performed when diagnostic mode is
disabled and virtual dipswitch SW2 pole one is set to 1. Refer to sub-section 9.3.5.1- HC800 Special Operations (Physical
SW1 or Virtual SW2) of this user manual for more details.

Table 9-4: HC800 Virtual Switch SW2 settings during normal operation

Pole Setting1 Function

1 1 Enable special operations

0 Normal operation

2 1 Enable Online configuration

0 Disable Online configuration

3 1 Disable NVRAM checksum

0 Normal operation

4 1 Disable Flash ROM checksum

0 Normal operation

5 0 Reserved for future

6 0 Reserved for future

7 0 Normal Operation

1 Initialize - This operation destroys (erases) the controller

function block configuration. To initialize NVRAM (erase
configuration): leave pole open; insert controller into
powered MB810 base.

When group A LEDs 1, 2 and 4 are on, remove the

controller, put the pole in the closed position, and insert the
controller. The controller is now ready to be configured.

Use special operation two to format and initialize all

NVRAM.

NOTE: This pole must remain closed for normal operation.

8 0 Reserved for future

NOTES:
1. Recommended settings are in bold boxes.

9.3.5.1 HC800 Special Operations (Physical SW1 or Virtual SW2)

The special operations feature provides a means to configure the controller to perform a one-time special operation rather
than entering its normal mode of operation. Setting physical dipswitch SW1 pole three to open (off) or Virtual SW2 pole one
to 1 enables the special operation mode. Poles three through eight select the special operation. Table 9-5 shows the
dipswitch settings and explains each special operation.
The S+ debug menu selection ‘B’, Hardware Special Operations provides a simpler and automated process for
performing typical Special Operations.

NOTE: You can use the S+ debug menu selection ‘C’, Detailed DIP Switch Edit Display to perform detailed selections
using Virtual dipswitch SW2.

2VAA001586 C 9-5
HC800 Virtual Dipswitch SW2 HC800 Setup

Follow the given steps to use physical dipswitch SW1 to set the controller for special operations and reset it for normal
operation:

NOTE: When you are using virtual dipswitch SW2, the procedure steps are similar, but you need to use the S+ debug
menu to change switch poles settings and reset controller without removing the module from the mounting base.

1. Set HC800 physical dipswitch SW1 per Table 9-5.

Table 9-5: HC800 Physical SW1 / Virtual SW2 Settings (Special Operations)

Physical dipswitch SW1

Special (or Virtual dipswitch SW2)
Pole settings Description
Operation
12345678

0 00100000 Force the controller into configure mode.

(10000000)

2 00100010 Initialize and format all NVRAM configuration space

(10000010) HC800.

5 00100101 Permit segment modification (allows change to

(10000101) segment scheme configured with FC 82, specification
S1).

6 00100110 Enable time-stamping. This operation instructs the

(10000110) controller to generate time information with point data.

16 00110000 Set Propagation Delay Time for distance of 1200m

(10010000) fiber-optic bus (default as set by Special operation 2)
for HN800 and CW800.

172 00110001 Set Propagation Delay Time for distance of 1200m

(10010001) fiber-optic bus for HN800 and 30m electrical bus for
CW800.

18 2 00110010 Set Propagation Delay Time for distance of 3000m

(10010010) fiber-optic bus for HN800 and 30m electrical bus for
CW800.

19 2 00110011 Set Propagation Delay Time for distance of 300m

(10010011) fiber-optic bus for HN800 and 30m electrical bus for
CW800.

20 00110100 Set Propagation Delay Time for distance of 300m

(10010100) fiber-optic bus for HN800 and 3000m fiber-optic bus
for CW800.

21 00110101 Set Propagation Delay Time for distance of 1200m

(10010101) fiber-optic bus for HN800 and 3000m fiber-optic bus
for CW800.

22 00110110 Set Propagation Delay Time for distance of 3000m

(10010110) fiber-optic bus for HN800 and CW800.

NOTES:
1. 0 = closed or on, 1 = open or off.
2. It cannot be used with RFO810 when set for 30m electrical bus.

2. Insert the HC800 module in its position in the MB810 mounting base. (Refer to sub-section
3.6.3- HC800 and CP800 Module Insertion/Removal of this user manual for more details.)

When the special operation is complete, the fault LED turns red and LEDs one through six illuminate.
3. Remove the HC800 module.
4. Repeat Step 1 through Step 3 for any other special operation, if required.

Perform special operation two as the first step of the controller installation.

9-6 2VAA001586 C
HC800 Setup HC800 Virtual Dipswitch SW3

5. Reset all poles on physical dipswitch SW1 to the closed (on) position, when all special operations are complete.

When you are using virtual dipswitch SW2, set poles two through eight of SW2 (controller options) for the
required controller operation per Table 9-4.
6. Insert the HC800 module in its mounting base; it begins normal operation

9.3.6 HC800 Virtual Dipswitch SW3

Virtual dipswitch SW3 is used to select certain operating options and enables diagnostics that are meaningful to qualified
ABB service personnel.
The following table (Table 9-6) dipswitch SW3 settings:

Table 9-6: HC800 Virtual Switch SW3

Pole Setting Function

1 0 Required for Normal Operation.

2-8 0 Reserved for future.

NOTES:
1. Unless otherwise noted, required settings are in bold boxes.

9.3.7 HC800 Virtual Dipswitch SW4

Virtual dipswitch SW4 sets additional advanced module options that are meaningful to qualified ABB service personnel.
The following table (Table 9-7) details the dipswitch SW4 settings.

Table 9-7: HC800 Virtual Switch SW4

Pole Setting Function

1-4 0 Reserved for future.

5 0 Required for normal operation.

6-8 1 Required for normal operation.

NOTES:
1. Unless otherwise noted, required settings are in bold boxes.

9.3.8 HC800 Virtual Dipswitch SW5

Virtual dipswitch SW5 is used to set the node number of the HC800. The backup module uses assigned node number +
(plus) ‘1’ automatically while operating as a backup. Initially, all primary modules must have even node numbers.

NOTE: Both components of an HPC800 controller (HC800 + CP800) must have the same node number. The node
number of CP800 is set by the fourth octet of its IP address. Refer to section 10- CP800 Setup of this user manual for
CP800 IP address setting details. Make sure an even number is used for node number.

Table 9-8: HC800 Virtual Switch SW5

Pole Function Setting Description

1-7 Node Number Set an even value from 2 HC800 uses the node number to
to 254 distinguish itself from other nodes on the
PN800 network.The backup module uses
assigned node number + (plus) ‘1’
automatically while operating as a backup.

8 Reserved 0 Pole #8 shall always be read as “0” in

order to enforce even node numbers only

2VAA001586 C 9-7
HC800 Virtual Dipswitch SW6 - Loop Number HC800 Setup

Virtual Switch SW5 Pole

Address (Binary Value)
Example
1 2 3 4 5 6 7 8
(128) (64) (32) (16) (8) (4) (2) (1)

2 0 0 0 0 0 0 1 0

64 0 1 0 0 0 0 0 0

250 1 1 1 1 1 0 1 0

User setting

9.3.9 HC800 Virtual Dipswitch SW6 - Loop Number

Virtual dipswitch SW6 is used to set the loop number for the HC800. A value from 1 to 250 can be selected.

NOTE: Both components of an HPC800 controller (HC800 + CP800) must have the same loop number. The loop
number of CP800 is set by the third octet of its IP address. Refer to section 10- CP800 Setup of this user manual for
CP800 IP address setting details.

Virtual Switch SW6 Pole

Address (Binary Value)
Example
1 2 3 4 5 6 7 8
(128) (64) (32) (16) (8) (4) (2) (1)

1 0 0 0 0 0 0 0 1

64 0 1 0 0 0 0 0 0

250 1 1 1 1 1 0 1 0

User setting

9.4 SOE Time Synchronization IP Addressing for HC800

The HC800 module must be configured to periodically acquire the current time from an SNTP server when its configuration
contains function blocks, which utilize the Sequence Of Events sub-system. The HC800's SOE Time Sync Port (EN1-A)
uses Ethernet to communicate with an SNTP server. If an HPC800 controller does not use the SOE function, then the SOE
Time Synchronization port does not need to be connected or configured for IP address.
To establish a communication between the HC800's SOE Time Sync. Port and the SNTP server, the HC800 must have the
following valid network parameters configured:
• IP address
• IP address mask
• Default gateway address.
All IP addresses consist of 4 octets separated by a '.' (dot). Refer to sub-section 1.6- Glossary of Terms and Abbreviations
of this user manual for the definition of an IP address.
These network parameters are configured using the HC800's diagnostic port. When first powered up (new module out of
the box), the HC800 module initializes these parameters to default values of:
IP Address: 0.0.0.0
IP mask: 255.255.255.0
Default Gateway Address: 0.0.0.0
You must manually change these initial values to suit the target network. Network parameters are changed using the
diagnostic port as described in sub-section 9.4.1- Changing SOE Time Synchronization IP Address for HC800 of this user
manual.
When the HC800 module is used in a redundant controller configuration:

9-8 2VAA001586 C
HC800 Setup Changing SOE Time Synchronization IP Address for HC800

• The HC800 module, which occupies the left-side position of the MB810 base uses the IP address entered through
the diagnostic port.
• The HC800 module, which occupies the right-side position of the MB810 base uses the IP address of the HPC800
module placed on the left-side position of the MB810 base + (plus) ‘1’ added to the fourth octet of the IP address.
For Example:
MB810 - Left-side HC800 - IP Address: 10.127.1.30
MB810 - Right-side HC800 - IP Address: 10.127.1.31

9.4.1 Changing SOE Time Synchronization IP Address for HC800

The network parameters for the HC800's SOE Time Synchronization port are set using the mini-USB port on the top cover
of the module. A USB to mini-USB cable and a computer running terminal emulator software that supports Xmodem
protocol (e.g. TeraTerm) is required.

NOTE: If the IP mask for both networks is set to 255.255.255.0, then the first three octets (for e.g. 10.127.1.xxx) of the
HC800's SOE Time Synchronization network and the ModbusTCP Foreign Device Interface network address
cannot be the same for proper operation.

For Example: If the SOE Time Synchronization IP address begins with 10.127.1, then the ModbusTCP Foreign Device
Interface address cannot begin with 10.127.1. Ensure that these IP address octets are unique for each network.

Follow the given procedure steps to define the HC800's SOE Time Synchronization IP address, IP Address Mask, and
Default Gateway settings:
1. Configure the terminal emulation software to communicate to the COM port with these settings: 115K baud, no
parity, 8 data bits, 1 stop bit, and no flow control.
2. Connect a USB cable to the mini-USB connector on the top cover of the HC800, with the module installed in its
base and powered up.

After connection with the HC800 module is made, the terminal emulation software displays a blank screen.
3. Enter ~ (tilde) then ! (exclamation) to access the diagnostic menu.

Following is an example of a typical configuration session:

>>>>> BLOCK I/O DEBUG <<<<<
platform: MFP
nomenclature: 10
firmware: A.2
revision out: 1002.13
MAC0 address: 00 c0 c9 01 c0 8c
MAC1 address: 00 c0 c9 81 c0 8c
ROM composite checksum: D544
ROM calculated checksum: D544
? ETHER
Ethernet Configuration
1 --> EN1 B - Foreign Device Port IP Addr/Mask
2 --> EN1 A - SOE Time Sync Port IP Addr/Mask
3 --> Network SNTP Time Server's IP Addr
X --> Exit
Select: 2
Enter the HC800's SOE Time Sync. Port network parameters:
The current IP address: 0.0.0.0
Enter an IP address:???.???.???.??? 10.127.1.100
IP address: 10.127.1.100

2VAA001586 C 9-9
Setting ModbusTCP Address for HC800 HC800 Setup

The current IP mask: 255.255.255.0

Enter an IP mask ???.???.???.???
IP mask: 255.255.255.0
The current Gateway address: 0.0.0.0
Enter a Gateway address ???.???.???.??? 10.127.1.1
Gateway address: 10.127.1.1
This module must be restarted for changes to take effect
Ethernet Configuration
1 --> EN1 B - Foreign Device Port IP Addr/Mask
2 --> EN1 A - SOE Time Sync Port IP Addr/Mask
3 --> Network SNTP Time Server's IP Addr
X --> Exit
Select: 3
Enter the SNTP Server's network IP address.
The current SNTP Time Server's IP address: 0.0.0.0
Enter an IP address ???.???.???.??? 10.127.1.200
SNTP Time Server's IP address: 10.127.1.200
This module must be restarted for changes to take effect
Ethernet Configuration
1 --> EN1 B - Foreign Device Port IP Addr/Mask
2 --> EN1 A - SOE Time Sync Port IP Addr/Mask
3 --> Network SNTP Time Server's IP Addr
X --> Exit
Select: X
4. Disconnect the USB cable from the HC800.

9.5 Setting ModbusTCP Address for HC800

The HC800 module uses the Harmony Gateway software (HGS) to send and receive information between the HC800
controller and PLC devices over ModbusTCP. To establish communications, the HC800's foreign device port must assign
valid values for the ModbusTCP IP address, ModbusTCP address mask, and ModbusTCP default gateway. FC 227 is used
to define the ModbusTCP configuration parameters. HGS provides a Composer Harmony sample control logic diagram to
create required communication configuration. Refer to the S+ Engineering for Harmony Gateway Software User Manual for
more information.

NOTE: The backup HC800 module uses the IP address of the primary module with ‘+1’ added to the fourth octet. On
failover the backup HC800 must use the IP address of the primary module. Ensure that duplicate IP addresses are not
present on the Foreign Device Network.

NOTE: If the IP mask for both networks is set to 255.255.255.0, then the first three octets (e.g. 10.127.1.xxx) of the
HC800's SOE Time Synchronization network and the ModbusTCP Foreign Device Interface network address cannot be
the same for proper operation.

For Example: If the SOE Time Synchronization IP address begins with 10.127.1, then the ModbusTCP Foreign Device
Interface address cannot begin with 10.127.1. Ensure that these IP address octets are unique for each network.

The ModbusTCP address can also be set using the mini-USB port on the top cover of the module or through the C program
implementation of Harmony Gateway software. Refer to the procedure given in sub-section 9.4.1- Changing SOE Time
Synchronization IP Address for HC800 of this user manual, and substitute EN1 B for EN1 A in the procedure, to set the
address using the mini-USB port.
On module startup, the 3 methods of assigning a ModbusTCP address are executed in the following sequence by the
HC800 module:
1. Using the mini-USB port procedure.

9-10 2VAA001586 C
HC800 Setup Setting ModbusTCP Address for HC800

2. Through FC 227.
3. Through the C program implementation of Harmony Gateway software.

This indicates that an address set using the mini-USB port procedure is overwritten by settings defined in FC 227 (if FC 227
is present in the configuration), and the settings of FC 227 are overwritten by the Harmony Gateway software address
settings.

NOTE: Only one method of setting the ModbusTCP address must be used to avoid overwriting values by mistake.

2VAA001586 C 9-11
Setting ModbusTCP Address for HC800 HC800 Setup

9-12 2VAA001586 C
CP800 Setup Module Configuration

10. CP800 Setup

Perform the following activities before a CP800 module can be put into service:
1. Unpack the module per instructions given in sub-sections: 3.2- Special Handling and 3.3- Unpacking and
Inspection of this user manual.
2. Perform a visual inspection of the module.
3. Set the battery enable jumper per instructions given in sub-section 10.2.1- Battery Enable Jumper of this user
manual.
4. Set CP800 switches per instructions given in sub-section 10.1- Module Configuration of this user manual.
5. Update CP800 module firmware to match firmware revision of other CP800 controllers in the system.
Redundant CP800 pairs must be at the same firmware revision. ABB recommends to use
the latest firmware available for CP800 controller modules. Refer to section 11- CP800 and
HC800 Firmware Update of this user manual for firmware update instructions.

10.1 Module Configuration

This sub-section describes the steps required to set up the CP800 module of the HPC800 controller (refer to Figure 10-1).
Switches must be set and jumper setting verified before putting the module into operation.

10.1.1 IP Addressing
The CP800 uses Ethernet TCP/IP to communicate with other nodes. In order to establish communications, the CP800 must
have valid values set for the IP address, address mask, and default gateway. All IP addresses consist of 4 octets separated
by a ‘.’. Refer to sub-section 1.6- Glossary of Terms and Abbreviations of this user manual for the definition of an IP
address.
Theses values are set using the diagnostic port. All four octets are set using the diagnostic port. When first powered up
(new module out of the box), the CP800 sets these values to default value of:
Default IP Address = 0.0.0.0
The following IP address example explains how loop and node numbers are integrated into the IP address of the module.
Example IP Address = 192.168.7.2
Where: the IP address: 192.168.loop#.node#

NOTE: A loop# number or node# number value of zero prevents the CP800 from operating. The CP800 flashes the top
green LED every second until the address is corrected. The node number must be an even value in the range between 2
and 254. The loop number must be in the range between 1 and 250. Both components of the HPC800 (HC800 + CP800)
must have the same loop number and node number. The virtual dipswitches are used to set the node number and loop
number for the HC800 module. Refer to section 9- HC800 Setup of this user manual for HC800 virtual dipswitches
setting details.

On initial power-up, the CP800 attempts to obtain the first two octet values using BootP. If BootP fails, then the value is set
as stated in the previous paragraph. The default IP mask is:
IP mask: 255.255.255.0
Default gateway: zzz.zzz.zzz.001 (where the first three octets are taken from the IP address described above).
The user must manually change these initial values if the value obtained above is inappropriate for the target system, or if a
previous value is set in CP800 Non Volatile Memory (NVM). The values are changed using the diagnostic port as described
in sub-section 10.1.1.1- Changing the IP Address Octets of this user manual.
The backup CP800 uses the IP address of the primary module with +1 added to the fourth octet. On failover the backup
CP800 shall use the IP address of the primary module.

10.1.1.1 Changing the IP Address Octets

The octets of the CP800’s IP address are set using the mini-USB port on the top cover of the module. A USB to mini-USB
cable and a computer running terminal emulator software that supports Xmodem protocol (e.g. TeraTerm) is required.
Follow the given procedure steps to define the CP800’s IP Address, IP Address Mask, and Default Gateway settings:

2VAA001586 C 10-1
IP Addressing CP800 Setup

1. Configure the terminal emulation software to communicate to the COM port with these settings: 115K baud, no
parity, 8 data bits, 1 stop bit, and no flow control.

NOTE: Verify the baud rate set using SW2 is set to 115K baud.

2. Connect a USB cable to the mini-USB connector on the top cover of the CP800, with the CP800 installed in its
base and powered up.
Use Windows Device Manager to create or select an existing virtual COM port for the CP800. In
may be necessary to disconnect and reconnect the COM port before proceeding.

After connection with the CP800 is made, the terminal emulation software displays a blank screen.
3. Enter P then F to display the diagnostic menu:
CP800 Revision A_0.001
3--> LOCAL MODULE UTILITIES
4--> REMOTE MODULE UTILITIES
5--> ERROR MESSAGE MONITOR
D--> BRC DIAGNOSTICS
E--> ELECTRONIC IDS
T--> SET TERMINAL TYPE
P--> PRINT FLAG (=f)
R--> RTIP UTILITIES
U--> CPU UTILIZATION
X--> EXIT DIAGNOSTICS

SELECT OPTION:

The current firmware revision of the CP800 displays at the top of the menu.

4. Press E and press enter to display the ELECTRONIC IDS sub-menu.

ELECTRONIC IDS
0--> Display MAC Address
1--> Display/Enter IP Address
X--> Exit
Enter option:
5. Press 1 and Enter to display the current IP assigned to the CP800.

NOTE: Default IP values are 0.0.0.0.

IP Address is: 0. 0. 0. 0.
IP Mask is: 0. 0. 0. 0.
IP Default Gateway is: 0. 0. 0. 0.

Change IP Address ???

Enter 'Y' to change IP Address, 'N' to exit

6. Type Y and Enter to change the IP address.

7. Enter the IP address (for example; 10.127.xxx.yyy).

This procedure requires that all four octets of the IP address are entered at this time.

8. Press Enter; the IP address is displayed on the screen.

Entered IP Address is: 10.127.1.200

Enter 'Y' to accept and use this IP address, 'N' to exit

9. Type Y and press Enter to accept the IP address; the following message is displayed:
‘IP Address Set Succeeded’

Once the IP address is set, a prompt to set the IP Address Mask is displayed:
Change IP Address Mask ???

10-2 2VAA001586 C
CP800 Setup IP Addressing

Enter 'Y' to change IP Address Mask, 'N' to exit

10. Enter IP Address Mask (for example: 255.255.255.000).

11. Press Enter to accept the IP Address Mask.

The entered value is displayed on the screen and you are prompted to confirm the value.
Entered IP Address Mask is: 255.255.255
Enter 'Y' to accept and use this mask, 'N' to exit
12. Type Y and press Enter to accept.

The following message is displayed and you are prompted to change the Default Gateway Address.
‘IP Mask Set Succeeded’
Change Default Gateway Address ???
Enter 'Y' to change Gateway Address, 'N' to exit

13. Type Y and press Enter,

14. Enter the Default Gateway Address (for example:10.127.1.1).
15. Press Enter to display the entered value.
Enter Default Gateway Address: 10.127.1.1
Entered Default Gateway Address is: 10.127.1.1
Enter 'Y' to accept and use this Gateway address, 'N' to exit

16. Type Y and press Enter to accept the value.

The following message is displayed and you return to the ELECTRONIC IDS menu.
‘IP Default Gateway Set Succeeded’
ELECTRONIC IDS
0--> Display MAC Address
1--> Display/Enter IP Address
X--> Exit
Enter option:

17. Type 1 and then press Enter to validate whether the correct IP address is entered for the CP800.
IP Address is: 10.127. 1.200.
IP Mask is: 255.255.255. 0.
IP Default Gateway is: 10.127. 1. 1.
Change IP Address ???
Enter 'Y' to change IP Address, 'N' to exit

18. Type N and press Enter to continue.

Now, the IP address is set for CP800, disconnect the USB cable from the CP800.

2VAA001586 C 10-3
CP800 Switch Settings CP800 Setup

10.1.2 CP800 Switch Settings

The following figure (Figure 10-1) displays the location of switches and jumpers on the CP800. This sub-section details the
switch settings needed for proper operation of the CP800.

NOTE: Switches SW3 and SW5 are not used and must be left in their default position (0 or closed).

Figure 10-1: CP800 Switch and Jumper Locations

10.1.2.1 CP800 Dipswitch SW1

Set switch SW1 per Table 10-1.

Table 10-1: CP800 Switch SW1

Pole Function Setting Description

1 Normal / Diagnostics 0 Normal run mode.

Mode
1 Diagnostics mode.

10-4 2VAA001586 C
CP800 Setup CP800 Switch Settings

Table 10-1: CP800 Switch SW1 (Continued)

Pole Function Setting Description

2-8 Reserved 0 Reserved for future.

NOTES:
1. 1 = open or off, 0 = closed or on.
2. Unless otherwise noted, required settings are in bold boxes.

10.1.2.2 CP800 Dipswitch SW2

Set switch SW2 per Table 10-2 when in normal running mode (SW1 pole 1=0).

Table 10-2: CP800 Switch SW2 settings during normal operation

Pole Function Setting Description

1 ROM Checksum 0 = Enabled Enables/Disables online ROM

Enable 1 = Disabled check summing

2 Time Stamp Filter 0 = On Sets exception report time-

stamps to within 5 seconds of
1 = Off CP800 module time. This should
only be set to Off when external
devices are time stamping
exception report values to a
more accurate time standard.

3 Redundancy 0 = No Redundancy Indicates whether the module is

configured or not configured for
1 = Redundancy Enabled redundancy.

4-5 Poll Rate Pole 4 Pole 5 Poll Rate Sets the number of times per
second that the CP800 polls
0 0 1/sec HC800 for exception reports.
0 1 2/sec

1 0 4/sec

1 1 8/sec

6 - 8 Diagnostic Port P6 P7 P8 Baud Rate Selects diagnostic port baud

Baud Rate Select rate.
0 0 0 1200

0 0 1 2400

0 1 0 4800

0 1 1 9600

1 0 0 19,200

1 0 1 38,400

1 1 0 57,600

1 1 1 115,200
NOTES:
1. 1 = open or off, 0 = closed or on
2. Recommended settings are in bold boxes.

2VAA001586 C 10-5
CP800 Jumper Settings CP800 Setup

Set switch SW2 per Table 10-3 when in diagnostic mode (SW1 pole 1= 1).

Table 10-3: CP800 Switch SW2 settings during diagnostic mode operation

Pole Function Setting Description

1 Halt on failure Mode 0 = Keep Running Determines what offline diagnostic tests
do when a failure occurs.
1 = Halt on Failure

2 Daughter Board 1 0 Not used.

3-8 Diagnostic Test Select Selects diagnostic test number (ID).

NOTE: 1 = open or off, 0 = closed or on.

10.1.2.3 CP800 Dipswitch SW4

Set switch SW4 per Table 10-4.

Table 10-4: CP800 Switch SW4

Pole Function Setting Description

1-5 Reserved 0 Set all to zero.

6 Burst cache disabled 0 Processor operates more quickly with

cache enabled
Burst cache enabled 1

7 Data cache disabled 0 Processor operates more quickly with

cache enabled
Data cache enabled 1

8 Instruction cache disabled. 0 Processor operates more quickly with

cache enabled
Instruction cache enabled. 1
NOTES:
1. 1 = open or off, 0= closed or on.
2. Recommended settings are in bold boxes.

10.2 CP800 Jumper Settings

10.2.1 Battery Enable Jumper

Follow the given steps before you use the CP800 module:
1. Position the Battery Enable jumper located on the side of the module (refer to Figure 10-1) to the enabled
position.
2. Move the jumper from the default shipping and storage position to the Battery Enabled position.

10-6 2VAA001586 C
CP800 and HC800 Firmware Update Introduction

11. CP800 and HC800 Firmware Update

11.1 Introduction
The firmware in the HC800 and CP800 may require updates from time to time. The HC800 firmware can be downloaded
using the S+ Engineering: Composer Harmony tool or through the USB port on its top cover. The CP800 firmware must be
loaded using the USB port. Refer to S+ Engineering for Harmony Primary Interface User Manual for detailed procedure on
how to download firmware using the S+ Engineering: Composer Harmony tool.

NOTE: You need to perform the firmware download using the Composer Harmony tool while the controller is in
Configure mode only. Do not attempt to load the firmware while the controller is in Execute mode.

NOTE: You need to perform the firmware download using the Composer Harmony tool on a single controller only. For a
redundant pair of modules, the module that is not being updated needs to be halted or removed from the DIN rail
mounting base before the firmware download. You need to load the firmware twice to each individual module in a
redundant pair to update both modules.
The following prerequisites are required to load firmware using the USB port:
• USB to mini-USB cable.
• PC with terminal emulator software installed that is capable of running Xmodem protocol (e.g. TeraTerm).
• ABB HC800 or CP800 firmware.
• USB to RS232 converter driver from Future Technology Devices International Ltd. (FTDI) FT232R.

11.2 CP800 Firmware Update Procedure

NOTE: The following procedure uses ‘TeraTerm’ as the terminal emulation software for the firmware update. The
procedure can vary depending on the type of terminal emulation software used.

NOTE: The CP800 module requires a Windows Combined Driver Model (CDM) interface driver, which can be installed
on Windows 2000, XP, VISTA or Windows 7.

In some situations, Windows Update can be used to automatically locate and download the device driver for this interface.
If Windows Update is unable to locate the correct driver, then you can download the FT232R interface driver from the
manufacturer's web site - http://www.ftdichip.com.
Currently, the driver file is named per the latest available version of CDM WHQL Certified.zip. The following application note
(from the manufacturer's web site) describes the driver installation procedure:
"Document Reference No.: FT_000160 FTDI Drivers Installation guide for Windows 7 Application Note AN_119 (latest
version)”.
Follow the given steps to update the CP800 module firmware using the USB Port:
1. Open the TeraTerm application.
2. Configure the TeraTerm serial port to ‘Baud Rate’:115200, ‘Parity’: None, ‘Data’: 8 bit, and ‘Stop’: 1 bit.
3. Halt and remove the module from the mounting base.
4. Set SW1 pole 1 to Open on the module.
5. Set SW2 poles 3, 5, 6, and 8 to Open on the module.
6. Reinstall the module into a powered base.
7. Connect a USB cable to the mini-USB connector on the top cover of the module.
8. Make a new TeraTerm connection.
9. Select File > XMODEM > Send from the TeraTerm menu.
10. Browse to locate the folder that contains the binary firmware file in the ‘Search’ dialog box.
11. Double-click on the appropriate binary firmware file and click on the Cancel button in the ‘download’ dialog box
that appears.

NOTE: When you perform steps 9 through 11, it eliminates the need to browse the firmware file during the
limited time allowed to begin the firmware download.

12. Enter the following text ‘~!’ (tilde, exclamation mark); the following message appears:

2VAA001586 C 11-1
HC800 Firmware Update Procedure CP800 and HC800 Firmware Update

“You have 15 sec to start XMODEM download of binary file”

13. Select File > Transfer > XMODEM > Send from the TeraTerm menu.

Once you select File > Transfer > XMODEM > Send; the binary firmware file that you browsed for in Step 10
appears in the ‘Search’ dialog box.
14. Double-click on the appropriate binary firmware file.

Once you double-click on the binary firmware file, a ‘download’ dialog box appears and the firmware download
operation begins.The ‘download’ dialog box displays the progress of the firmware download.

NOTE: Do not remove the module until the following message appears:

“You have 15 sec to start XMODEM download of binary file”

15. Remove the module and set switch settings on SW1 and SW2 to the normal positions.
16. Restore the TeraTerm connection to the CP800 diagnostic port (the baud rate is still 115,200 baud).
17. Press the <Enter> key; a single line that displays the firmware revision and build number appears in the
TeraTerm window.

11.3 HC800 Firmware Update Procedure

11.3.1 Firmware Update Procedure from A_1 to A_2

NOTE: In firmware revision A_1, physical switches are used to configure the HC800 module. Now, in firmware revision
A_2, physical switches are replaced with virtual switches to configure the HC800 module.

NOTE: The HC800 module requires a Windows Combined Driver Model (CDM) interface driver, which can be installed
on Windows 2000, XP, VISTA or Windows 7.

In some situations, Windows Update can be used to automatically locate and download the device driver for this interface.
If Windows Update is unable to locate the correct driver, then you can download the FT232R interface driver from the
manufacturer's web site - http://www.ftdichip.com.
Currently, the driver file is named per the latest available version of CDM WHQL Certified.zip. The following application note
(from the manufacturer's web site) describes the driver installation procedure:
"Document Reference No.: FT_000160 FTDI Drivers Installation guide for Windows 7 Application Note AN_119 (latest
version)”.
Follow the given steps to update the HC800 firmware from A_1 to A_2 using the USB Port
1. Halt and remove the module from its mount base.
2. Set SW1 and SW2 poles 1, 3, 5, 6, and 8 to Open on the HC800 module.
3. Connect a USB cable to the mini-USB connector on the top cover of the HC800 module.
4. Configure the COM port to 115, N, 8, and 1 (115K baud, no parity, 8 data bits, and 1 stop bit) using terminal
emulation software.
5. Select no flow control.
6. Insert the HC800 module in the base and wait for the following prompt message to appear:

“Hello, enter ‘~’ and “!” to start XMODEM download”

7. Select Transfer > Send using terminal emulation software.
8. Select the download file and XModem protocol.
9. Copy (CTRL+C) the file name and path.
10. Close the Send File dialog-box.
11. Enter the following text, ‘~!’ (tilde, exclamation mark); the following message appears:

“You have 15 sec to start XMODEM download of binary file”

12. Select Transfer > Send using terminal emulation software.
13. Paste (CTRL+V) the file name and path selected in Step 9 of this procedure in the Transfer File dialog box.

11-2 2VAA001586 C
CP800 and HC800 Firmware Update Firmware Update Procedure (from A_2 or higher)

14. Enter Return to start the transfer and wait for the following prompt message to appear:

“Hello, enter “~“ and “!” to start XMODEM download”

NOTE: Do not remove the HC800 module until after this message has appeared.

15. Remove the HC800 module.

16. Set SW1 to 1010 1001.
17. Insert the module into its base.
18. Push the STOP button and wait for the module to display red light.
19. Remove the HC800 module and set all poles on all switches (SW1 - SW5) to Closed.
20. Insert the HC800 module in the base.
21. Disconnect/re-connect the terminal emulation software.
22. Wait for the "*" symbol to display and then enter the tilde exclamation mark (~!).

The banner displayed on the serial port shows the firmware revision.
23. Format the HC800 module using the S+ debug menu selection 'B', Hardware Special Operations.

Alternatively, the module can be formatted using special operation 2. Refer to sub-section 9.3.5.1- HC800 Special
Operations (Physical SW1 or Virtual SW2) of this user manual for instructions on how to perform special operations.
Now, the physical switches SW2, SW3, SW4, and SW5 have been replaced by virtual switches. Refer to sub-section
9.3.2- Virtualization of Dipswitches of this user manual for procedure details on how to configure the virtual switches.

11.3.2 Firmware Update Procedure (from A_2 or higher)

NOTE: The HC800 module requires a Windows Combined Driver Model (CDM) interface driver, which can be installed
on Windows 2000, XP, VISTA or Windows 7.

In some situations, Windows Update can be used to automatically locate and download the device driver for this interface.
If Windows Update is unable to locate the correct driver, then you can download the FT232R interface driver from the
manufacturer's web site - http://www.ftdichip.com.
Currently, the driver file is named per the latest available version of CDM WHQL Certified.zip. The following application note
(from the manufacturer's web site) describes the driver installation procedure:
"Document Reference No.: FT_000160 FTDI Drivers Installation guide for Windows 7 Application Note AN_119 (latest
version)”.
Follow the given steps to update the HC800 firmware using the USB Port:
1. Halt and remove the module from its mount base.
2. Set physical SW1 poles 1, 3, 5, 6, and 8 to Open on the HC800 module.
3. Connect a USB cable to the mini-USB connector on the top cover of the HC800 module.
4. Configure the COM port to 115, N, 8, and 1 (115K baud, no parity, 8 data bits, and 1 stop bit) using terminal
emulation software.
5. Select no flow control.
6. Insert the HC800 module in the base and wait for the following prompt message to appear:

“Hello, enter “~“ and “!” to start XMODEM download”

7. Select Transfer > Send using terminal emulation software.
8. Select the download file and XModem protocol.
9. Copy (CTRL+C) the file name and path.
10. Close the Send File dialog box.
11. Enter the following text, ‘~!’ (tilde, exclamation mark); the following message appears:

“You have 15 sec to start XMODEM download of binary file”

12. Select Transfer > Send using terminal emulation software.
13. Paste (CTRL+V) the file name and path in the Transfer File dialog box.
14. Enter Return to start the transfer and wait for the following prompt message to appear:

2VAA001586 C 11-3
Firmware Update Procedure (from A_2 or higher) CP800 and HC800 Firmware Update

“Hello, enter “~“ and “!” to start XMODEM download”

NOTE: Do not remove the HC800 module until after this message has appeared.

15. Remove the HC800 module and set physical SW1 all poles to Closed.
16. Verify all poles on physical switches SW2, SW3, SW4, and SW5 are also Closed.
17. Insert the HC800 module in the base.
18. Disconnect/re-connect terminal emulation software.
19. Wait for the "*" symbol to display and then enter tilde exclamation mark (~!).

The banner displayed on the serial port shows the firmware revision.
20. Format the HC800 module using the S+ debug menu selection 'B', Hardware Special Operations.

Alternatively, the module can be formatted using special operation 2. Refer to sub-section 9.3.5.1- HC800 Special
Operations (Physical SW1 or Virtual SW2) of this user manual for instructions on how to perform special operations.

11-4 2VAA001586 C
Online Configuration Introduction to Online Configuration

A. Online Configuration
A.1 Introduction to Online Configuration
Using Online Configuration in conjunction with redundant controllers enables making configuration changes without
affecting the primary controller or interrupting the control process.

NOTE: The term ‘redundant controller’ always refers to the original redundant controller, and the term primary controller
always refers to the original primary controller. When the roles are reversed, the statuses of the controllers are carefully
noted.

S+ Engineering: Composer Harmony tool provides functions to guide the user through the online configuration process.
These functions use the enhanced status information contained in byte ten of the controller status report. Using Composer
for online configuration is the preferred method. The information in this appendix explains how to manually perform online
configuration.
In redundant controller configurations, the primary controller executes the process control logic while the redundant
controller tracks the configuration of the primary. Online configuration allows removing the redundant controller from the
tracking mode and making configuration changes, without interrupting the process control operation of the primary
controller. It also supports conventional offline changes. When the redundant controller has been reconfigured, it can
assume control with the new configuration while the original primary controller assumes the redundant role.
During startup of the new configuration in the redundant controller, it uses the current values of all process outputs in the
primary controller. This feature permits bumpless transfer of control to the new configuration.

A.2 Setup
Set pole two of virtual dipswitch (SW2) of the redundant and primary HC800 module to 1, to enable online configuration.
This provides communication access to the backup HC800 module at an address one higher than what is set by virtual
dipswitch SW1.
Online configuration of redundant controllers requires two consecutive CW800 addresses to be reserved (n and n+1; where
‘n’ is the primary address, ‘n+1’ is the redundant).
Do not reset a controller before the LEDs or controller status byte indicate that the controller is available.
Resetting a controller prematurely could result in unpredictable operation, loss of output data, or loss of
control.
In some user applications, controllers are remotely located, and the operator is unable to view the LEDs. In these
applications, the data from the redundant controller status byte must be used. This appendix shows both the state of LEDs
seven and eight as well as the contents of the redundant controller status byte (specifically bits seven, six, three and one).
For each step of the online configuration process, both the contents of the status byte as well as the state of LEDs seven
and eight (refer to Figure 4-2) are indicated in the margin.
A workstation running S+ Operations software is an example of HSI platforms that may be used to acquire controller status
reports. Refer to the instruction for the interface being used for the procedures to call up status reports.
The following table (Table A-1) details the symbols used in this appendix:

Table A-1: Legend of Symbols

Description Primary Redundant

Controller address n n+1

Redundant controller status byte Bit1 Bit1

76543210 76543210
01xx0x0x 10xx1x0x

LEDs 7 and 8. In the following tables, on

LED 7 is on top, LED 8 is on bottom. off
blinking
NOTES: x = ignore, 1 = bit set, 0 = bit not set.
bit 7 = first time in execute (most significant bit (MSB))
bit 6 = redundant controller status bad
bit 3 = online configuration changes being made
bit 1 = NVRAM default configuration

2VAA001586 C A-1
Redundant Cycle Online Configuration

A.2.1 Redundant Cycle

Table A-2 and Figure A-1 displays the redundant cycle.

Table A-2: Redundant Cycle

Primary Redundant Step

n n+1 1. Save a copy of the current configuration. This enables it to be easily

00xx0x0x 10xx0x0x restored if needed.

n n+1 2. Place the redundant controller in configure mode.

01xx0x0x 00xx0x0x
The green LED of the redundant controller blinks indicating configure
mode. The controller status also indicates configure mode. Configuration
commands to the redundant controller are sent to the address of the
primary controller plus one (n+1). The primary controller now indicates
that the redundant controller is not available for automatic failover. Bit 6
indicates this condition.
To return to Step 1 without making any changes, place the redundant
controller in execute mode and reset it after LED 8 illuminates or the
primary status indicates 00xx0x0x. Resetting a controller causes all the
LEDs on it to light momentarily before returning to normal status.
n n+1 When changes are being made to the redundant controller, LED 7 blinks
01xx0x0x 00xx1x0x and bit 3 of the redundant controller is set indicating that the
configurations of the redundant and primary controllers do not match. If
these changes to the configuration are incorrect, then return to Step 1 by
an initialize of the redundant controller NVRAM while it is in configure
mode.

n n+1 3. When an error exists in the new configuration, the redundant controller
01xx0x0x 00xx1x0x enters error mode when initiating a transfer to execute mode command.
Return to configure mode to fix the error. The green LED of the redundant
controller blinks to indicate it is in the error or configure mode. The first
byte of the controller status also indicates the mode. Redundant
controller LED 7 blinks and bit 3 of the controller status is set to indicate
that configuration differences exist between the primary and redundant.

n __ During steps 2, 3 and 4 of online configuration, the redundant controller is

01xxxx0x not capable of taking over as primary controller because of the
incomplete configuration or incomplete checkpoint data. If there is a
complete failure of the primary controller, then the online configured
redundant controller takes over as the primary controller, but is in error
mode. All Harmony block I/O and I/O expander bus controllers enter their
configured stall states.

n n+1 4. The redundant controller can now be placed in execute mode,

01xx0x0x 00xx1x0x provided no errors remain in the new configuration.
Additional configuration changes can be made by entering configure
mode (Step 2). If changes are not made, then a redundant controller
reset returns the redundant controller to the state of Step 1. If changes
are made, then the redundant controller must be put into configure mode
and initialized to get to the state of Step 1.

NOTE: The redundant cycle step transition 3 to 4 occurs automatically

after a successful Step 3 redundant controller execute. The
transaction completion time depends on the controller configuration.

A-2 2VAA001586 C
Online Configuration Redundant Cycle

Table A-2: Redundant Cycle (Continued)

Primary Redundant Step

n n+1 5. When the checkpoint data for the old configuration is received from
01xx0x0x 10xx1x0x the primary controller, the reconfigured redundant controller can assume
the role of the primary controller if a failure is detected in the old
configuration (Step 8). However, the primary controller still indicates that
no redundant controller is available when the configuration is different.
Additional configuration changes can be made by entering configure
mode (Step 2). If changes are not made, then a redundant controller
reset returns the redundant controller to the state of Step 1. If changes
are made, then the redundant controller must be put into configure mode
and initialized to get to the state of Step 1.

n n+1 6. After changes are made, press and release the Stop/Release button
01xx0x0x 00xx1x0x twice on the redundant controller to make the reconfigured redundant
controller as the primary controller. The first time stops the controller; the
second time resets the controller. The redundant controller comes up in
execute mode with the configuration marked as valid.

n n+1 7. Redundant cycle step transitions 5 to 6 to 7 to 8 occur automatically

01xx0x0x 10xx1x0x after the Step 5 redundant controller reset. The time it takes to complete
these transitions depends on controller configuration. The status
indicated in cycles 5, 6 and 7 can not be seen depending on the actual
step transition times. The important status to wait on is indicated by Step
8.
After the checkpoint data is updated, the redundant controller is ready to
take over the duties of the primary controller.

n n+1 8. The redundant controller requests the primary controller to shut down
01xx0x0x 11xx1x0x and assume the role of a hot redundant controller (n+1). The redundant
controller waits to act as the primary controller (n). A hot redundant
controller retains the old configuration and control data and is ready to
assume control, if an error is detected in the new configuration.

n+1 n 9. The primary controller has removed the bus clock (BUSCLK) and acts
01xx0x0x 01xx1x0x as a hot redundant controller (n+1). The reconfigured redundant
controller is now serving as the primary controller (n).

NOTE: In this phase of the online configuration, the backup is not

tracking tuning or other changes. This transition phase should be
concluded as quickly as feasible to return to normal hot standby
operation.

Before proceeding to the following commands, ensure that LED/controller

status is as shown in Step 8. To return to Step 4, reset the redundant con-
troller (n). This allows correcting a bad configuration.
The primary controller (n+1) must be reset at this point for the online
configuration cycle to complete. Resetting the primary controller (n+1),
currently acting as the hot redundant controller, tells it to get a copy of the
new configuration.

n+1 n 10. After the redundant controller copies the new configuration into the
10xx0x0x 00xx0x0x primary controller, the cycle is complete. The redundant controller is now
serving as the primary controller (n) while the primary handles the
redundant controller role (n+1). The LED combination and controller
status is the opposite of Step 1, indicating the role reversal.

2VAA001586 C A-3
Primary Cycle Online Configuration

Figure A-1: Redundant Cycle

A.2.2 Primary Cycle

Table A-3 and Figure A-2 displays the primary cycle. The step numbers in this cycle correspond to the states of Figure A-2.
This information is provided for status purposes. Follow the redundant cycle steps to perform online configuration.

Table A-3: Primary Cycle

Primary Redundant Step

n n+1 1. The primary controller is actively controlling the process. This

01xx0x0x 10xx1x0x represents the same juncture as Step 4 of the redundant cycle.

n+1 n 2. When the shutdown request is received from the redundant controller
01xx0x0x 11xx1x0x (Step 7 of the redundant cycle), the primary controller stops executing
and removes the bus clock (BUSCLK).

n+1 n 3. The primary controller is now acting as the hot redundant controller
01xx0x0x 01xx1x0x (n+1). All old configuration and block output information remains intact
from when it is shut down in Step 2. If the new configuration is not
operating as expected, then the primary controller, currently acting as the
hot redundant controller (n+1), can take control using the old
configuration and block output information (returns to Step 1).

n+1 n 4. Resetting the primary controller (n+1), currently acting as the hot
00xx0x0x 00xx1x0x redundant controller, directs it to get a copy of the new configuration
(Step 8 of the redundant cycle).

A-4 2VAA001586 C
Online Configuration Primary Cycle

Table A-3: Primary Cycle (Continued)

Primary Redundant Step

n+1 n 5. When the new configuration has been copied, the redundant
10xx0x0x 00xx0x0x controller has completed its cycle and is now serving as the primary
controller.

n+1 n 6. After the checkpoint data is complete, the primary controller is now
10xx0x0x 00xx0x0x serving as the redundant controller and is ready to take over the control
process with the updated configuration. The primary cycle is complete.
This represents the same juncture as Step 10 of the redundant cycle.

Figure A-2: Primary Cycle

2VAA001586 C A-5
Primary Cycle Online Configuration

A-6 2VAA001586 C
Propagation Time Settings Description

B. Propagation Time Settings

B.1 Description
The HN800 bus is a redundant control level communication system that is part of the S+ Control system. The HN800 bus
communicates process field input and output data between the I/O system and the controllers. The controllers mainly use
this bus for process control and monitoring.
Controllers use the CW800 bus for peer-to-peer communications. CW800 is also a redundant communication bus, which is
used to exchange direct point data with other controllers and for redundancy communication.
Each of these communication buses can extend to remote location. When HN800 and/or CW800 communication is required
to extend outside a local enclosure, it must use the optical link provided by the RFO810s. This link consists of two RFO810s
and a RMU810 or RMU811 on the local side and two RFO810s and a RMU810 or RMU811 at the remote side. HBX01L and
HBX01R bus terminal boards must be used for RFO810 optical link. All TER800 terminators must be Rev E or later
revisions for RFO810 optical link. HN810 or HN811 bus terminal board, and TER800 with older revision can only be used on
isolated electrical HN800 without any RFO810 optical link.
The HN800 bus supports a ‘Star Architecture’ with RFO810s. With the controller located in the center of the ‘Star’, the local
HN800 bus can support up to 8 RFO810 links. Each RFO810 segment can be up to 3 km long and have up to 64 devices on
each remote segment (refer to Figure B-1). As a special rule, one RFO810, either single or redundant, is counted as 4
HN800 devices.
The CW800 bus supports one RFO810 link per bus. This link can support multiple controllers on each side of the link and
can be extended up to 3 km (refer to Figure B-2). Electrical CW800 bus on each side supports up to 30 single HPC800
controllers or 15 redundant pairs of HPC800 controllers.
These communication buses allow S+ devices to reside locally, remotely, or both with no difference in performance or
configuration. All S+ devices are designed for redundant communications. Both channel A and channel B are active at all
times and a failure in either channel does not affect system operation.

Figure B-1: HN800 extended with Multiple RFO810 Optical Links

2VAA001586 C B-1
RFO810 Bus Architecture Propagation Time Settings

Figure B-2: CW800 Extended with an RFO810 Optical Links

B.2 RFO810 Bus Architecture

The HN800 and CW800 buses used in the Symphony Plus system can be extended up to 3 km for remote applications. The
RFO810 modules provide the fiber optic communication link required to extend these networks. Both HN800 and CW800
can use the RFO810 modules to extend their overall length but they have different limitations on their architecture. The
HN800 bus can support up to 8 RFO810 segments form a centrally located controller (refer to Figure B-3). This
configuration is referred to as a ‘Star’ and each segment can be up to 3 km long and have 64 HN800 devices connected to
it. The CW800 bus supports only one optical link (refer to Figure B-4). This link can be up to 3 km long and support multiple
controllers on each side of the link.

B-2 2VAA001586 C
Propagation Time Settings RFO810 Bus Architecture

The following figures - Figure B-3 and Figure B-4 schematically represent HN800 and CW800 bus length and architecture
limitations for Symphony Plus systems:

Figure B-3: HN800 with RFO810 Star Architecture

Figure B-4: CW800 with RFO810 Architecture

The following figure (Figure B-5) shows an example of Symphony Plus HAI805 and HAO805 HART modules physically
located up to 3 kilometers from the central HN800 bus:

NOTE: The HART I/O modules shown in Figure B-5 can be replaced with PDP800, PROFIBUS modules, or a
combination of HART and PROFIBUS modules.

2VAA001586 C B-3
RFO810 Bus Architecture Propagation Time Settings

Figure B-5: Symphony Plus I/O devices on the HN800 bus (local and remote)

NOTE: The HPC800 module can be connected to a local I/O and remotely located I/O modules.

Similarly, the CW800 communication bus can also be extended up to 3 kilometers. This allows for peer-to-peer
communications between HPC800 controllers to take place over a long distance.

B-4 2VAA001586 C
Propagation Time Settings Additional HN800 and CW800 Bus Architecture Examples

The following figure (Figure B-6) shows an example of peer-to-peer communications between HPC800 controllers
connection:

Figure B-6: Remote Peer-to-Peer communications over CW800

NOTE: The local I/O that is connected to each HPC800 controller through the HN800 bus is not shown in Figure B-6.
Symphony Plus modules can be located up to 3 kilometers from the central CW800/HN800 bus hub.

NOTE: Daisy chaining of remote links is not allowed.

B.3 Additional HN800 and CW800 Bus Architecture Examples

The flexibility provided by the Symphony Plus system allows for a variety of distributed system architectures.
The following two examples explain the powerful capabilities of Symphony Plus system.
Example 1:
The following figure (Figure B-7) shows four controllers connected to a central CW800 bus and a fifth controller remotely
located 3 kilometers from the central CW800 hub.
Peer-to-peer communications from any of the controllers can be done on the CW800 bus. Communications to the remotely
located Controller 5 behave exactly in the same way as communications between Controllers 1 and 2, i.e. the fiber optic link
is invisible to the CW800 bus. Each controller in turn has a remotely mounted I/O attached to its own HN800 bus per this
example.

NOTE: None of the remote HN800 links for Controller 5 are more than 3 km from the HN800 #5 bus.

2VAA001586 C B-5
Additional HN800 and CW800 Bus Architecture Examples Propagation Time Settings

Figure B-7: Multiple HPC800 Controllers around a central CW800 hub

Example 2:
The following figure (Figure B-8) shows peer-to-peer communications that can occur in a large, geographically distributed
plant.
In this example, three separate areas are connected over the PN800, Ethernet based plant network. Each controller uses
the PN800 network for peer-to-peer communications or to communicate with the S+ Operations HMI or S+ Engineering
Composer tools. Within each area, the CW800 buses are remotely located from a central CW800 bus hub.

NOTE: In Area #1, none of the remote CW800 buses are more than 3 kilometers from each other (refer to Figure B-3).

B-6 2VAA001586 C
Propagation Time Settings Additional HN800 and CW800 Bus Architecture Examples

Figure B-8: Communications in a large, distributed site

2VAA001586 C B-7
Setting Propagation Time for Distance Greater than 1200 Meters Propagation Time Settings

B.4 Setting Propagation Time for Distance Greater than 1200 Meters
A Harmony Repeater (RFO810) or NTRL14 is used to make the remote connection. The controller uses a default bus
length of 1200 meters after the initialize/format special operation 2. If the default bus length of 1200 meters is being used,
then additional special operation is not required after special operation 2; i.e., the Set Propagation Delay Time for 1200
meters special operation 16 is not performed since it is the default (refer to Table B-1).
A special operation is performed on the HC800 module to select one of the four propagation time (refer to Table B-1) based
on the distance of the furthest HN800/CW800 module. This additional propagation time allows remote HN800 IO modules
(HAI805, HAO805, and PDP800), and remote CW800 modules (HC800, CP800) to be located up to 3000 meters from the
local controller. All local HC800 control processors (primary and redundant) must have the same propagation time special
operation performed before startup. The local primary controller establishes the propagation time for the bus when it starts
up. During startup each local redundant controller measures the established propagation time and compares the measured
value to its configured value at startup.
A local redundant (primary or redundant) controller displays red light with LEDs 2, 3, and 5 = TYPE CODE MISMATCH error
when the selected propagation time does not match the measured proptime of the current bus master (primary controller).
The configuration download through the CW800 link contains the primary format information and stores the configured
propagation time in the redundant format information during the download. However, the startup check is completed before
the configuration download is performed. Therefore, propagation time must match before a local redundant controller can
be placed onto a bus with an active primary.
The CW800 proptime is automatically set to the value defined for the HN800 bus. It is not necessary to
perform the special operation to set propagation time for remote HC800 control processors or CP800
communication processors on the CW800 bus.
The HN800 I/O bus and CW800 Communication bus use a default bus length of 1200 meters at startup. The default
propagation time is overridden at startup, when a HPC800 controller that is already online detects a bus master (primary
controller). Then, the propagation time is set to the measured value to prevent a conflict.
On startup, the HN800 I/O modules perform a background propagation time check once a second. A sequential counter is
started when a valid measured value is different than the current selected value. The propagation time is set to the new
measured value, if the measured value remains the same for five sequential checks (five seconds).
This mode of operation permits the HN800 bus to be in a non-functional state when propagation time is changed for up to
five seconds, after the HPC800 controller has started the HN800 interface as a controller type. This is an acceptable state
because the bus had been previously stalled; i.e., a special operation on the primary controller with the redundant controller
removed. The primary controller can again change its propagation time only through a special operation and the redundant
controller must be offline before inserting the primary controller with the new propagation time. The tens digit of the FC 89
block output #31999 on the controller reports the configured bus distance.
Steps:
1. Set the HC800 dipswitch per Table B-1.
2. Follow the procedure steps given in sub-section
9.3.5.1- HC800 Special Operations (Physical SW1 or Virtual SW2) of this user manual to use propagation time
special operations.

The following table (Table B-1) details the propagation time special operations:

Table B-1: Propagation Time Special Operations

DipSwitch SW1 CW800 Fiber Distance (m) Maximum

Maximum FC 89 Output
(or Virtual (unless designated Number of I/O
Special HN800 Fiber Number of Tens Digit
dipswitch SW2) Electrical for electrical points per
Operation Distance (m) Blocks @250 (Block
Pole settings bus cable connection second
msec (HN800) #31999)
12345678 only) (CW800)

16 (default) 00110000 1200 1200 64 500 0

(1 0 0 1 0 0 0 0)

17 00110001 1200 30 (Electrical)2 64 10,000 1

(1 0 0 1 0 0 0 1)
18 00110010 3000 30 (Electrical)2 35 10,000 2
(1 0 0 1 0 0 1 0)

B-8 2VAA001586 C
Propagation Time Settings Setting Propagation Time for Distance Greater than 1200 Meters

Table B-1: Propagation Time Special Operations (Continued)

DipSwitch SW1 CW800 Fiber Distance (m) Maximum

Maximum FC 89 Output
(or Virtual (unless designated Number of I/O
Special HN800 Fiber Number of Tens Digit
dipswitch SW2) Electrical for electrical points per
Operation Distance (m) Blocks @250 (Block
Pole settings bus cable connection second
msec (HN800) #31999)
12345678 only) (CW800)
19 00110011 300 30 (Electrical)2 128 10,000 3
(1 0 0 1 0 0 1 1)

20 00110100 300 3000 128 250 4

(1 0 0 1 0 1 0 0)

21 00110101 1200 3000 64 250 5

(1 0 0 1 0 1 0 1)

22 00110110 3000 3000 35 250 6

(1 0 0 1 0 1 1 0)
NOTES: 0 = closed or on, 1 = open or off.
1. The maximum number of recommended Symphony Plus modules communicating over the HN800 bus assumes a scan rate of 250 milli-
seconds, and is the total of both local and remote modules on the bus. Proportionally, additional HN800 modules can be installed on the
bus when slower scan rates are used.

2. The usage of RFO810, Fiber Optic Repeaters is not allowed when CW800 is set for 30 (Electrical).

2VAA001586 C B-9
Setting Propagation Time for Distance Greater than 1200 Meters Propagation Time Settings

B-10 2VAA001586 C
 INDEX

INDEX

C Power system status 8

Controller Propagation Time Settings 1
Dipswitch SW2 15, 1
Dipswitch SW5 15 R
Group B LEDs 2, 1 Redundancy 6
Controlway 3, 8 Redundant
Controller error codes 2
D
Diagnostic tests 12, 13, 17 S
Diagnostics 16 SOE Time Synchronization 8
Dipswitch SOE Time Synchronization IP Addressing 8
SW2 15, 1 Special handling 1
SW5 15 Status report 10
Document Stop/Reset 4
Conventions 9
Intended user 7 T
Troubleshooting 1
E
Error codes 2 U
Exception report 6 Unpacking 1
F
Features 6
Field (I/O) Power 1
Field Power (or IO) 9
Flowcharts 1

H
Harmony control unit (HCU) 2
Harmony Repeater 8
HC800’s ModbusTCP Address 10
HCU interface 1

I
Inspection 1
Installation sequence 1

L
LEDs
Group A 16
Group B 2, 1
Logic Power 9, 1

M
Machine fault timer 9
Maintenance 1
Mounting hardware 2

N
Nomenclature 1

O
Online configuration 1
Operating procedures 1

P
Parts 1
Power Supply 1

2VAA001586 C 1
INDEX

2 2VAA001586 C
ABB Inc. NOTICE

Document Number: 2VAA001586 C

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