Introduction to ABB 800xA DCS

Shivali Sharma | Updated on 19 May, 2025 | Embedded Systems Training and Certification Courses | 54

ABB (Asea Brown Boveri) is a globally renowned leader in industrial automation, robotics, power, and electrification technologies. Founded through the merger of ASEA (Sweden) and BBC (Switzerland), ABB has consistently been at the forefront of industrial innovation. The company delivers solutions across industries like oil and gas, utilities, mining, chemicals, and manufacturing. One of ABB’s most transformative contributions to industrial automation is its advanced 800xA Distributed Control System (DCS), designed to offer integrated control, safety, asset management, and electrical automation on a unified platform.

Introduction to Distributed Control Systems (DCS)

A Distributed Control System (DCS) is an automated control system used in complex, large-scale, and geographically distributed industrial processes. Unlike centralized control systems, DCS training distributes control tasks across multiple interconnected components, enabling greater flexibility, scalability, and fault tolerance.

DCS integrates real-time process control, supervisory functions, and data acquisition across various subsystems. Its key benefits include:

Enhanced reliability through redundancy
Improved operator interface and alarm handling
Real-time monitoring and data analysis
Seamless integration with enterprise systems

Importance of ABB 800xA in Modern Industries

Multisoft’s ABB’s 800xA DCS online training stands out as one of the most versatile and robust automation platforms. The “xA” in 800xA stands for “Extended Automation,” highlighting its ability to unify different automation layers—control, electrical, safety, and enterprise systems—within a single architecture.

Key reasons for its adoption include:

Integration of multiple automation functions such as process control, safety systems, asset management, and electrical integration.
Operator efficiency improvements through high-performance HMI, advanced alarm management, and intuitive workflows.
Modular scalability, allowing expansion from small control systems to enterprise-wide automation.
Compliance with industry standards such as ISA, IEC, and OPC.
Support for digital transformation via seamless connectivity to IIoT, cloud platforms, and analytics.

ABB 800xA empowers industries to reduce downtime, optimize operations, enhance safety, and increase return on investment. It’s not merely a control system but a platform for integrated operational excellence.

Architecture of ABB 800xA DCS

System Components and Hardware

The ABB 800xA DCS architecture is built around a layered design comprising the following core components:

1. Control Network (ACN - Aspect Control Network)

Connects controllers, I/O units, and operator workplaces.
Uses redundant Ethernet-based communication.

2. Controllers

AC 800M is the core controller of 800xA, offering high performance and flexibility.
Supports multiple programming languages per IEC 61131-3.
Modular and scalable for a wide range of applications.

3. I/O Modules

S800 and S900 I/O families support both local and remote configurations.
Support HART, Profibus, Foundation Fieldbus, and Modbus.

4. Aspect Servers

Host system configuration, graphic displays, trends, and alarms.
Ensure distribution of operator interface and system data.

5. Operator Workplaces

Offer high-performance human-machine interfaces (HMI).
Enable intuitive control and monitoring.

6. Field Devices

Communicate via fieldbus protocols and are integrated seamlessly into the system.

Network Topology

The network topology of ABB 800xA DCS is built on a robust, layered client-server architecture, ensuring high performance, scalability, and reliability. It features two main communication layers: the Aspect Network for operator workplaces and engineering stations, and the Control Network (ACN) for controllers and I/O systems. Both networks support redundant Ethernet configurations to eliminate single points of failure and ensure continuous operations. ABB employs protocols like Media Redundancy Protocol (MRP) and Rapid Spanning Tree Protocol (RSTP) to maintain network integrity and fast recovery. The system also supports secure fieldbus integration—such as Profibus, Foundation Fieldbus, HART, and Modbus—ensuring seamless connectivity between field devices, controllers, and supervisory systems across distributed plant environments.

Integration Capabilities

ABB 800xA is designed to be an integration platform rather than a standalone control system.

Electrical Integration
- Supports IEC 61850 for electrical substation automation.
- Integrates medium and low voltage switchgear and protection systems.
Safety Integration
- TUV-certified SIL 3 solutions using ABB’s HI controllers.
- Integrated safety graphics, alarms, and diagnostics.
Information Integration
- Direct integration with MES and ERP systems.
- Interfaces for SAP, OSIsoft PI, OPC, SQL, and more.
Multisystem Integration
- Capable of integrating legacy ABB and third-party DCS/PLC systems.
- Unified interface for operations and asset management.

Redundancy and High Availability Design

ABB 800xA DCS is engineered with a strong focus on redundancy and high availability to ensure continuous and fault-tolerant operations in critical industrial environments. Redundancy is embedded across all core layers, starting with the AC 800M controllers, which support CPU redundancy—allowing a backup controller to seamlessly take over if the primary fails without disrupting the process. The network infrastructure offers dual redundant Ethernet paths using Media Redundancy Protocol (MRP) or Rapid Spanning Tree Protocol (RSTP) to eliminate single points of failure. Redundant Aspect and Connectivity Servers ensure that system data, alarms, and graphics are continuously available to operator stations, even during a server failure. Operator Workplaces can also be configured redundantly, enabling uninterrupted access to process monitoring and control. Additionally, redundant power supplies in I/O modules and system components further protect against power-related failures. For field-level communication, ABB supports dual-channel configurations for fieldbus protocols, maintaining device communication integrity. These layered redundancies are complemented by diagnostics and watchdog mechanisms that enable predictive maintenance and real-time status monitoring. As a result, ABB 800xA certification offers a highly resilient control system architecture, minimizing downtime and maximizing operational uptime in industries where reliability is paramount.

Key Features and Functionalities

1. Control and I/O Functionality

ABB 800xA offers sophisticated control capabilities using its powerful AC 800M controllers:

Supports both continuous and batch processes.
IEC 61131-3-based programming for flexibility.
Advanced regulatory control and PID tuning.
Function block libraries for rapid configuration.
Supports hot-swappable I/O, reducing downtime.

S800 and S900 series I/O modules are highly modular and allow integration of HART and Profibus DP/PA for advanced diagnostics.

2. Operator Interface (HMI)

The 800xA Operator Workplace delivers a unified and highly customizable HMI experience:

High-performance graphics with ISA 101 standards.
Role-based access control and personalized displays.
Alarm and event summary, trends, faceplates, and process history.
Context-sensitive navigation and process control.
Integrated navigation to electrical diagrams and safety systems.

The HMI enhances situational awareness, helping operators make faster and safer decisions.

3. Alarm Management

ABB 800xA includes robust alarm management tools:

Alarm shelving, filtering, and prioritization.
ISA 18.2 compliant alarm design.
Alarm analytics for identifying nuisance alarms.
Integrated alarm audit trail and reporting.
Alarm KPIs and dashboards for continuous improvement.

Effective alarm management reduces operator overload and improves safety response.

4. Asset Management and System Diagnostics

ABB 800xA supports integrated asset management through its Field Information Manager (FIM) and System 800xA Asset Optimization tools:

Predictive maintenance and condition monitoring.
Integration with HART and FDT/DTM-based field devices.
Automatic device diagnostics and failure alerts.
Inventory management and maintenance scheduling.
Health monitoring of system components—controllers, servers, networks.

This enables a proactive maintenance strategy, reducing unplanned downtimes.

Engineering and Configuration Tools

1. Control Builder

Control Builder is the main engineering tool used to configure logic in ABB 800xA systems:

Supports Function Block Diagram (FBD), Structured Text (ST), and Ladder Diagram (LD).
Real-time simulation and testing without deploying on live systems.
Debugging tools, variable watch, and online editing.
Reusability via function block libraries and templates.

It is tightly integrated with the system, enabling collaborative engineering between multiple users.

2. IEC 61131-3 Programming Languages

ABB 800xA supports all five standard IEC 61131-3 programming languages:

Function Block Diagram (FBD) – Visual programming ideal for process logic.
Structured Text (ST) – High-level, Pascal-like language for calculations and loops.
Ladder Diagram (LD) – Popular in discrete and batch automation.
Instruction List (IL) – Low-level, assembly-like commands (deprecated).
Sequential Function Chart (SFC) – Used for step-based batch processing.

This flexibility allows control engineers to choose the best method for each application.

3. Object-Oriented Engineering

Object-oriented principles are central to ABB 800xA engineering:

Aspect Objects: Combine functional data (process values, alarms) and presentation (graphics, documentation) into reusable templates.
Inheritance and Instances: Once a template is updated, all instances inherit changes, saving time and ensuring consistency.
Modularization: Complex systems can be broken into manageable sub-systems.

This structure simplifies system maintenance, promotes standardization, and improves project execution time.

4. Reusability and Templates

Engineering in 800xA is optimized for reuse:

Predefined templates for valves, motors, pumps, controllers, etc.
Libraries for control modules and visualization objects.
Version control and change management.
Reusable code blocks improve project efficiency and reduce errors.

Templates ensure engineering consistency, reduce commissioning time, and simplify future expansions or upgrades.

Conclusion

ABB 800xA DCS stands as a comprehensive and future-ready automation platform, combining advanced control, seamless integration, and robust architecture to meet the complex needs of modern industries. With its modular design, high availability, and powerful engineering tools, it enhances operational efficiency, reduces downtime, and supports digital transformation initiatives. The system’s flexibility, cybersecurity readiness, and real-time monitoring capabilities make it ideal for critical applications across various sectors.

By unifying process control, electrical systems, and asset management under one platform, ABB 800xA training delivers measurable business value—enabling industries to operate smarter, safer, and more sustainably in today’s competitive landscape. Enroll in Multisoft Virtual Academy now!

Training Schedule

Start Date	End Date	No. of Hrs	Time (IST)	Day
24 May 2025	07 Jun 2025	16	06:00 PM - 09:00 PM	Sat, Sun	Enroll Now
25 May 2025	08 Jun 2025	16	06:00 PM - 09:00 PM	Sat, Sun	Enroll Now
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About the Author

Shivali Sharma

Shivali is a Senior Content Creator at Multisoft Virtual Academy, where she writes about various technologies, such as ERP, Cyber Security, Splunk, Tensorflow, Selenium, and CEH. With her extensive knowledge and experience in different fields, she is able to provide valuable insights and information to her readers. Shivali is passionate about researching technology and startups, and she is always eager to learn and share her findings with others. You can connect with Shivali through LinkedIn and Twitter to stay updated with her latest articles and to engage in professional discussions.

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06:00 PM - 09:00 PM

Sat, Sun

$ 550

Introduction to ABB 800xA DCS

Introduction to Distributed Control Systems (DCS)

Importance of ABB 800xA in Modern Industries

Architecture of ABB 800xA DCS

Network Topology

Integration Capabilities

Redundancy and High Availability Design

Key Features and Functionalities

Engineering and Configuration Tools

Conclusion

Training Schedule

About the Author

Shivali Sharma

Enquire Now

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Introduction to ABB 800xA DCS

Introduction to Distributed Control Systems (DCS)

Importance of ABB 800xA in Modern Industries

Architecture of ABB 800xA DCS

Network Topology

Integration Capabilities

Redundancy and High Availability Design

Key Features and Functionalities

Engineering and Configuration Tools

Conclusion

Training Schedule

About the Author

Shivali Sharma

Enquire Now

Tranding Now

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