Tag: ABB HAC319AEV1

Description

The ABB HAC319AEV1 is a single-slot I/O module base designed for the ABB MasterPiece 200/300 distributed control system(DCS).It serves as the mechanical and electrical interface between standard I/O cards—such as analog input,digital output,or relay modules—and the system backplane.Engineered for decades of reliable service in demanding industrial environments,the HAC319AEV1 ensures stable signal transmission,power delivery,and seamless communication through its high-integrity connector architecture.

Application Scenarios

In a large ethylene cracker plant in Southeast Asia,an unexpected shutdown occurred due to intermittent communication loss from a critical temperature monitoring loop.After investigation,engineers traced the fault not to the I/O card itself,but to a degraded I/O baseplate with oxidized contacts.Replacing the faulty unit with a new ABB HAC319AEV1 restored consistent signal integrity and eliminated false alarms.This case underscores how the HAC319AEV1—though passive—acts as the silent guardian of process reliability,especially in safety-critical loops where contact resistance drift can cascade into production losses or safety incidents.

Parameter

Main Parameters Value/Description

Product Model HAC319AEV1

Manufacturer ABB AB(Sweden)

Product Category I/O Module Base/Carrier for DCS

Compatible Modules ABB HAE711(AI),HAE721(AO),HAE731(DI),HAE741(DO),etc.

Connector Type 64-pin gold-plated spring-loaded backplane connector

Hot-Swap Support Yes–with power pre-disconnect sequencing

Mechanical Dimensions 180 mm(H)×35 mm(W)×120 mm(D)

Mounting Method DIN rail or panel screw mount

Operating Temperature 0°C to+60°C

Electrical Life≥500 insertion/removal cycles(per IEC 60512)

Module Identification Built-in Module ID circuit for configuration validation

Protection Rating IP20(for indoor control cabinet use)

Technical Principles and Innovative Values

Innovation Point 1:Gas-Tight Contact Technology

The HAC319AEV1 uses spring-loaded,gold-plated pins that create gas-tight connections upon module insertion.This prevents micro-fretting corrosion—a common failure mode in high-vibration plants—ensuring contact resistance remains below 10 mΩover years of thermal cycling.

Innovation Point 2:Intelligent Module Recognition

Unlike generic sockets,the HAC319AEV1 includes dedicated Module ID lines that communicate with the MasterPiece controller during startup.If an incompatible or misconfigured card is inserted,the system flags a hardware mismatch,preventing operational errors.

Innovation Point 3:True Hot-Swap Architecture

Power pins disconnect before signal pins during removal,eliminating backplane voltage spikes.This allows maintenance teams to replace failed I/O cards without shutting down the entire rack—critical in continuous-process industries like refining or power generation.

Innovation Point 4:EMI-Shielded Housing

The metal enclosure provides full electromagnetic shielding,reducing crosstalk between adjacent analog channels.Field tests show>40 dB attenuation at 100 MHz,making the HAC319AEV1 suitable for installations near VFDs or RF sources.

Application Cases and Industry Value

At a 1,200 MW coal-fired power station in Eastern Europe,the boiler control system relied on over 200 ABB HAC319AEV1 bases to interface flame scanners,drum level transmitters,and sootblower limit switches.During a 10-year system life extension project,engineers opted to retain all existing HAC319AEV1 units while upgrading only the I/O cards and controllers.This decision saved€350,000 in rewiring costs and avoided a 3-week outage.Plant operators reported zero I/O-related faults in the following 18 months,attributing reliability to the robust baseplate design.

In another case,a pharmaceutical batch reactor system in Germany required GMP-compliant change control.Because the HAC319AEV1’s mechanical and electrical specifications remained unchanged since its original installation,regulatory auditors accepted it as a“like-for-like”replacement,accelerating validation and reducing documentation burden.

Related Product Combination Solutions

ABB HAE711:16-channel isolated analog input module–pairs with HAC319AEV1 for high-accuracy temperature/pressure monitoring.

ABB HAE741:16-channel digital output module–ideal for valve and motor control when mounted on HAC319AEV1.

ABB HAC320AEV1:Dual-slot I/O base–used alongside HAC319AEV1 in mixed-density racks.

ABB MP200 CPU:Central processing unit for MasterPiece 200–communicates seamlessly with I/O via HAC319AEV1-mounted cards.

ABB MasterView:Engineering workstation software–auto-detects modules installed in HAC319AEV1 bases during configuration.

ABB HAE791:Redundant I/O interface module–requires paired HAC319AEV1 units for failover support.

ABB System 800xA Gateway:Enables migration from MasterPiece;retains HAC319AEV1 bases during phased upgrades.

ABB HAE700 Terminal Block Kit:Field-wiring interface that snaps directly onto HAC319AEV1-mounted modules for rapid commissioning.

Installation,Maintenance,and Full-Cycle Support

Installing the ABB HAC319AEV1 is straightforward:mount it on a standard DIN rail inside the control cabinet,ensure the backplane guide rails are clean and aligned,then slide the base into position until it clicks.When inserting an I/O card,apply firm,vertical pressure until the locking mechanism engages—audible feedback confirms proper seating.Always verify wiring against terminal labels before energizing.For hot-swap operations,use ABB’s MasterView diagnostic tools to place the slot in“maintenance mode,”which isolates power safely.

Routine maintenance involves visual inspection for dust accumulation,terminal corrosion,or mechanical wear every 12–24 months.In high-humidity environments,applying conformal coating to exposed terminals can extend service life.Should a fault occur—such as intermittent channel dropout—the first troubleshooting step is to reseat both the I/O card and the HAC319AEV1 base.In most cases,this resolves contact-related issues without component replacement.

We provide comprehensive lifecycle support for the ABB HAC319AEV1,including functional testing(contact resistance,pin alignment,Module ID verification),12-month warranty,and expert guidance from engineers with hands-on MasterPiece commissioning experience.Whether you’re maintaining legacy infrastructure or executing a controlled migration to System 800xA,our team ensures your I/O foundation remains solid,secure,and service-ready.

Contact us for a customized solution—whether you need a single ABB HAC319AEV1 for emergency repair or a bulk order for plant-wide modernization.

Product Overview

The ABB HAC319AEV1 is a high-availability communication module engineered for the ABB AC 800M programmable automation controller(PAC)platform,serving as the critical network interface between the controller and higher-level systems such as engineering workstations,operator terminals,and enterprise networks.Designed to replace and enhance earlier modules like the CI854 series,the HAC319AEV1 delivers dual Gigabit Ethernet ports with full hardware redundancy,enabling seamless integration into ABB’s System 800xA distributed control architecture while supporting demanding real-time and safety-critical applications.

As a core component in power generation,oil&gas,and heavy process industries,the ABB HAC319AEV1 ensures continuous,deterministic data exchange even during network failures.It supports Media Redundancy Protocol(MRP)and Parallel Redundancy Protocol(PRP)—key IEC 62439 standards—for sub-10 ms failover times,making it suitable for SIL2-certified safety applications when deployed in appropriate configurations.The module handles multiple communication protocols simultaneously,including OPC UA,Modbus TCP,and native AC 800M peer-to-peer messaging,allowing flexible connectivity to third-party devices and legacy systems.With its robust design,advanced diagnostics,and hot-swap capability,the HAC319AEV1 significantly enhances system availability,cybersecurity readiness,and lifecycle management in modern industrial automation environments.

Technical Specifications

Parameter Name Parameter Value

Product Model HAC319AEV1

Manufacturer ABB Ltd.

Product Type Dual-Port Communication Module for AC 800M Controllers

Network Interfaces 2×10/100/1000BASE-T RJ45 Ethernet ports

Redundancy Protocols MRP(Media Redundancy Protocol),PRP(Parallel Redundancy Protocol)

Supported Protocols AC 800M native protocol,Modbus TCP,OPC UA(via controller),SNMP

Data Rate Up to 1 Gbps per port

Operating Temperature 0°C to+60°C(extended range option available)

Mounting Directly onto AC 800M CPU backplane(e.g.,PM864,PM865)

Hot-Swap Support Yes(in redundant controller configurations)

Cybersecurity Features VLAN tagging,MAC filtering,secure boot(firmware-dependent)

Power Consumption~8 W(supplied via controller backplane)

Compliance Standards IEC 61000-6-2/4,IEC 62439-2/3,CE,UL 61010

Main Features and Advantages

Dual Gigabit Ethernet with Sub-10ms Failover:The ABB HAC319AEV1 features two independent Gigabit Ethernet ports that support ring or parallel network topologies using MRP or PRP.In the event of a cable break or switch failure,network reconfiguration occurs in less than 10 milliseconds—faster than most process controllers can detect a communication loss—ensuring uninterrupted control and monitoring.This makes the HAC319AEV1 ideal for applications where network downtime equates to production loss or safety risk.

Native Integration with AC 800M and System 800xA:Unlike generic network cards,the HAC319AEV1 is purpose-built for ABB’s automation ecosystem.It enables direct,high-speed communication between AC 800M CPUs,I/O stations,and System 800xA servers without protocol converters or gateways.Engineering tools like Control Builder M automatically recognize the module,simplifying configuration and reducing commissioning time.

Enhanced Diagnostics and Cyber Resilience:The HAC319AEV1 provides detailed port-level diagnostics—including link status,packet error rates,and traffic statistics—accessible via Control Builder M or ABB’s Asset Optimization suite.It also supports foundational cybersecurity measures such as VLAN segmentation and MAC address filtering,helping facilities comply with IEC 62443 guidelines.These features allow operators to proactively identify network anomalies before they impact control performance.

Future-Ready and Scalable:With Gigabit bandwidth and support for modern industrial protocols,the HAC319AEV1 is prepared for data-intensive applications like edge analytics,remote access,and digital twin integration.Its compact form factor and backplane-powered design eliminate external power supplies,reducing cabinet space and wiring complexity while maintaining compatibility with existing AC 800M racks.

Application Field

The ABB HAC319AEV1 is widely deployed in industries requiring ultra-reliable,high-speed controller networking.In thermal and renewable power plants,the HAC319AEV1 connects boiler,turbine,and balance-of-plant AC 800M controllers to central System 800xA operator stations,ensuring real-time visibility during grid frequency events or load changes.Within oil&gas upstream and midstream operations,it links compressor station controllers across wide-area networks using PRP for zero-loss communication—even during lightning-induced switch failures.

In water and wastewater treatment facilities,the HAC319AEV1 enables secure,redundant data flow between remote pumping stations and the main SCADA center,supporting regulatory compliance and remote diagnostics.Similarly,in mining and metals processing,where electromagnetic interference from large drives is common,the HAC319AEV1’s robust Ethernet implementation maintains stable communication for mill control and material handling systems.Across all these sectors,the HAC319AEV1 serves as the digital backbone that transforms isolated controllers into a unified,responsive,and resilient automation fabric.

Related Products

PM864A:Primary AC 800M CPU controller commonly paired with HAC319AEV1 for standard automation tasks.

PM865A:Redundant AC 800M CPU that leverages HAC319AEV1 for synchronized state transfer and failover.

CI854A:Legacy Profibus DP communication module;HAC319AEV1 replaces it for Ethernet-based architectures.

TK801:Terminal base for S800 I/O modules;used alongside HAC319AEV1 in full AC 800M system deployments.

System 800xA:ABB’s integrated DCS platform that relies on HAC319AEV1 for controller-to-server communication.

Control Builder M:Engineering software used to configure and diagnose HAC319AEV1 network parameters and redundancy settings.

HAC320AEV1:Higher-end variant with fiber-optic SFP ports for long-distance or EMI-sensitive installations.

Installation and Maintenance

Pre-installation preparation:Before installing the ABB HAC319AEV1,confirm that the target AC 800M CPU(e.g.,PM864 or PM865)has available backplane slots and compatible firmware(minimum version specified in ABB documentation).Plan the network topology—ring(MRP)or parallel(PRP)—and ensure managed switches support the chosen redundancy protocol.Use shielded Cat 6 cables with proper grounding,and assign static IP addresses or configure DHCP reservations in advance.The HAC319AEV1 must be configured in Control Builder M with correct IP settings,redundancy mode,and VLAN tags before insertion.

Maintenance recommendations:Although the HAC319AEV1 is solid-state and requires no routine servicing,periodic review of network diagnostics in Control Builder M is advised to detect rising error counts or port flapping that may indicate cabling or switch issues.Firmware updates should be applied during scheduled outages using ABB-approved procedures.In redundant CPU systems,the HAC319AEV1 can be replaced online—always verify synchronization status post-replacement.Store spare HAC319AEV1 modules in anti-static packaging away from moisture and extreme temperatures to preserve long-term reliability.

Product Guarantee

We guarantee that every ABB HAC319AEV1 module we supply is 100%genuine,factory-new,and fully tested on live AC 800M hardware.Each unit undergoes verification of both Ethernet ports,redundancy failover timing,and communication integrity with System 800xA servers.We provide a 12-month warranty against defects in materials and workmanship,along with lifetime access to certified ABB automation engineers for configuration and troubleshooting support.Should your HAC319AEV1 encounter any issue,we will assist promptly to minimize operational disruption.Our mission is to deliver not just a network card,but a trusted enabler of continuous,secure,and intelligent industrial operations.

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