ABB HESG216877K HESG441635R1
ABB HESG216877K HESG441635R1
ABB HESG216877K HESG441635R1
ABB HESG216877K HESG441635R1
ABB HESG216877K HESG441635R1

ABB HESG216877K HESG441635R1 | Industrial DCS Redundant Communication Module

  • Brand: ABB
  • Model: HESG216877K HESG441635R1
  • Product Type: Communication Processor Module
  • Series: HESG Series (ABB Procontic DCS Communication Family)
  • Core Function: Manages redundant data exchange between Procontic DCS controllers and distributed I/O modules; supports multi-protocol communication (Profibus DP, Modbus TCP) and system diagnostics for industrial automation networks.
  • Key Specs: PowerPC 440 processor, 512MB RAM, dual-redundant architecture (≤50ms failover), -40°C to +70°C operating temperature, SIL 2 certified (IEC 61508).
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Part number: ABB HESG216877K HESG441635R1
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Description

HESG216877K HESG441635R1: Product Overview
The HESG216877K HESG441635R1 is a communication processor module within ABB’s HESG series, designed for integration into Procontic distributed control systems (DCS) to serve as the central data highway for controller-to-I/O communication. Its role is to ensure deterministic, high-availability data exchange between Procontic C-series controllers and distributed I/O modules (e.g., S800 series), transmitting control commands (setpoints, interlocks) and process data (sensor readings, device status) across large-scale industrial architectures. For continuous process industries—such as oil refining, chemical manufacturing, and power generation—it mitigates communication bottlenecks and single-point failures, critical for maintaining process stability and safety.
Functionally, the module implements a dual-redundant active/standby architecture with automatic failover, processing cyclic data (up to 1,024 bytes per I/O station) and acyclic messages (diagnostic/config commands). It supports Profibus DP (up to 12 Mbps) and Modbus TCP protocols, enabling integration with legacy Procontic I/O and third-party devices. As part of the HESG series, the HESG216877K HESG441635R1 leverages ABB’s DCS platform advantages: uniform engineering tools (Procontic Engineer), hot-swappable components, and seamless compatibility with Procontic asset management suites. This design simplifies network scalability, reduces lifecycle costs, and ensures compliance with industrial communication standards.

ABB HESG216877K HESG441635R1

ABB HESG216877K HESG441635R1

HESG216877K HESG441635R1: Technical Specifications
  • Model Number: HESG216877K HESG441635R1
  • Manufacturer: ABB
  • Product Type: Communication Processor Module
  • Processor: PowerPC 440, 533 MHz
  • Memory: 512MB RAM, 2GB Flash (firmware/user configuration)
  • Redundancy: Dual-port active/standby (automatic failover ≤50ms)
  • Communication Protocols: Profibus DP (up to 12 Mbps), Modbus TCP, Ethernet IP (optional)
  • I/O Station Capacity: Up to 64 Procontic S800 I/O stations per segment
  • Data Throughput: Up to 8,000 I/O points per second (cyclic exchange)
  • Operating Temperature: -40°C to +70°C
  • Humidity Range: 5% to 95% non-condensing
  • Power Supply: 24V DC (nominal, 18-32V DC range), redundant inputs supported
  • Power Consumption: 12W (typical, dual ports active)
  • Dimensions: 245mm x 135mm x 115mm (width x height x depth, fits Procontic rack)
  • Weight: 1.1kg
  • Certifications: CE, UL, cULus, SIL 2 (IEC 61508, when integrated with safety logic)
Core Features & Customer Value​
Redundant Architecture Eliminates Communication Downtime: The HESG216877K HESG441635R1’s dual-port active/standby design ensures uninterrupted data flow, with automatic failover in ≤50ms. For engineers managing critical systems like refinery catalytic crackers, this prevents data loss during cable or module faults, avoiding unplanned shutdowns. Maintenance teams can repair the primary link without interrupting control, as the standby port maintains I/O updates, reducing mean time to repair (MTTR) by 40%.
Multi-Protocol Support for Legacy and Modern Integration: The module supports Profibus DP and Modbus TCP, enabling connection to legacy Procontic S800 I/O and third-party devices (e.g., Siemens S7-1200 PLCs). For a chemical plant upgrading its DCS, this avoids costly replacement of existing field devices, preserving prior investments in wiring and sensors. Engineers can integrate new and old assets into a single network, simplifying system architecture.
High Data Throughput for Dense I/O Networks: With a throughput of 8,000 I/O points per second, the module efficiently handles large-scale systems (e.g., 50+ I/O stations). In a power plant’s boiler control system, this ensures real-time transmission of 5,000+ temperature/pressure signals to the Procontic C200 controller, maintaining stable steam generation and compliance with emission standards.
Seamless Integration with Procontic Ecosystem: As a native HESG series component, the module uses ABB’s Procontic Engineer software for configuration, tuning, and firmware updates. Engineers reuse existing communication profiles across projects, cutting commissioning time by 20%. Hot-swappable design minimizes downtime during maintenance, critical for continuous processes like oil refining.
Rugged Design for Harsh Environments: Operating temperature range of -40°C to +70°C and 5-95% RH tolerance enable outdoor installations (e.g., power plant switchyards) and indoor harsh conditions (steel mill control rooms). Compact size (245x135x115mm) fits into space-constrained racks, simplifying retrofits in legacy systems.

ABB HESG216877K HESG441635R1

ABB HESG216877K HESG441635R1

Typical Applications​
The HESG216877K HESG441635R1 is deployed in Procontic DCS environments requiring reliable communication. In a petroleum refinery’s crude distillation unit, it links a Procontic C200 controller to 40 S800 I/O stations (monitoring 8,000+ temperature/pressure points). Dual-port redundancy ensures continuity if a cable is damaged during maintenance, preventing loss of tray temperature data critical for separation efficiency.
At a chemical plant’s ethylene cracker, the module connects the Procontic safety controller to S800 I/O stations hosting emergency shutdown (ESD) inputs (flame detectors, pressure switches). Its ≤50ms failover time meets SIL 2 requirements, while Modbus TCP sends ESD status to the plant’s historian for compliance reporting.
In a municipal water treatment plant, the HESG216877K HESG441635R1 interfaces the Procontic C100 controller with remote I/O racks (pump status, valve positions) via Profibus DP. The -40°C cold-start capability supports winter startups, and hot-swap functionality allows maintenance during planned turnarounds.

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