Bonner. 800xa. The power
of integration.
of integration.
System 800xA is the only automation platform capable of engineering, commissioning, controlling, and operating diverse automation strategies — including process, power, electrical, and safety — all within one redundant and highly reliable system. This unique capability makes 800xA the true collaboration enabler, breaking down traditional barriers to create a seamless environment and culture of integrated operations.
With the power to execute multiple, typically separate systems in a single, common platform, 800xA comes pre-integrated with essential applications such as Batch, Device, and Asset Management. It offers seamless connectivity to both ABB and third-party DCS and PLC systems, plus the flexibility to integrate a wide range of external applications including ERP systems, video surveillance, historians, and telecommunications.
Alongside extensive functionality, 800xA reduces hardware requirements by leveraging virtualization technology and offering one of the most powerful controllers in its class. Its pre-integrated components work harmoniously to consolidate control room systems, significantly reducing the number of computers and monitors needed — delivering efficiency without compromise.
Electrical Integration
Integration of electrical systems with System 800xA
System 800xA’s built-in electrical control system offers complete oversight of your entire electrical network — from high-voltage switchgear down to low-voltage motor control. Whether integrated with the 800xA DCS or operated independently, it provides an ideal solution for managing your electrical infrastructure.
Leveraging its robust and scalable architecture, 800xA enables a unified platform to operate and maintain all electrical assets in industrial plants. This includes substation equipment such as circuit breakers, transformers, power generators, and switchgear, as well as medium and low-voltage motors equipped with smart relays, drives, and intelligent motor control panels.
Because 800xA uses the same platform for process automation, it seamlessly combines Electrical Control System (ECS) functions with DCS applications. This integration allows you to manage process I/O signals and intelligent field instruments within a single database, correlating energy consumption and maintenance data directly with production rates — providing enhanced visibility and operational efficiency across your plant.
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Reduced Capital and Lifecycle Costs
Minimise equipment, cabinets, and wiring requirements to lower upfront and ongoing expenses. -
Faster Commissioning and Installation
Streamline project timelines with reduced commissioning time and installation costs. -
Enhanced System Visibility
Gain improved insight into your entire electrical system for better monitoring and control. -
Native IEC 61850 Compliance
Ensure seamless substation automation with industry-standard protocol support. -
Improved Availability and Safety
Increase system uptime and maintain a safer operational environment. -
Better Collaboration Across Departments
Facilitate communication and coordination between teams for more efficient operations. -
Accelerated Troubleshooting and Remote Maintenance
Quickly diagnose issues and perform maintenance remotely to reduce downtime. -
Optimised Energy Efficiency
Implement proven power management solutions to reduce energy consumption.
Integrated Safety
Enhancing Protection and Efficiency
The integrated safety capabilities of ABB 800xA significantly improve plant safety by enabling operators to effectively respond to abnormal conditions with enhanced event visibility and contextualised information. This integration ensures a safer operational environment and faster, more informed decision-making.
System 800xA fully supports functional safety requirements, offering SIL 3 capability with independent execution of Safety Instrumented Functions (SIF). It provides physical and logical separation, along with robust access control measures to protect critical safety functions.
Lifecycle support is simplified through a consistent engineering and troubleshooting environment. Integration within the 800xA platform eliminates the need for custom-made interfaces, reducing complexity and lowering maintenance costs over the system’s lifetime.
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Enhanced Plant Safety
Operators receive clear, contextualised event information to respond rapidly and effectively to abnormal conditions. -
Compliance with Functional Safety Standards
Supports SIL 3 safety integrity level, ensuring highest standards in safety instrumented functions. -
Independent and Secure Safety Execution
Safety functions run independently with physical and logical separation, protecting critical processes. -
Access Control for Safety Functions
Restricts access to Safety Instrumented Functions (SIF), ensuring only authorised personnel can make changes. -
Simplified Engineering and Maintenance
Consistent environment for engineering and troubleshooting reduces complexity and errors. -
Reduced Lifecycle Costs
Integration removes the need for custom interfaces, lowering maintenance and support expenses. -
Improved Operational Efficiency
Faster incident detection and response minimise downtime and enhance overall plant productivity.
Asset Management
Built-in Plant Asset Management
The 800xA Asset Optimization system is fully integrated within the 800xA platform, eliminating the need for separate condition monitoring systems and thereby reducing total cost of ownership. Understanding the status of your critical assets is essential to effective maintenance—knowing not only what needs attention but also what doesn’t. This insight is key to reducing maintenance costs and optimising asset life.
Modern field equipment communicates precisely when maintenance is required—and just as importantly, when it is not. Moving towards predictive maintenance strategies with ABB 800xA significantly extends asset life and delivers substantial lifecycle savings.
Benefits of Plant Asset Management with ABB 800xA
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Increased Asset Availability and Performance
Maximise uptime and ensure your assets operate at peak efficiency. -
Optimised Operations and Maintenance
Streamline workflows to reduce unnecessary maintenance and improve resource allocation. -
Reduced Time to Repair
Faster diagnostics and repair processes minimise downtime and production losses. -
Enhanced Collaboration
Improve communication and coordination between operations, automation, and maintenance teams. -
Plant-Wide Predictive and Proactive Maintenance
Adopt advanced maintenance strategies that anticipate issues before they occur. -
Consistent Reporting of Asset Health
Access reliable, standardised reports on plant asset conditions for informed decision-making. -
Real-Time Visualization of Asset Health
Monitor current health status across the plant with intuitive visual tools for quick assessment.
Operator Effectiveness
Empowering Operators for Optimal Plant Performance
ABB 800xA delivers powerful workplaces with rich, embedded functions designed to streamline operator tasks and enhance decision-making. Offering the most feature-rich operator interface available, 800xA consolidates all critical information into a single window, allowing users to switch between information contexts with just one mouse click.
The system includes flexible tools tailored to your plant’s unique needs, such as alarm grouping to manage alarms intuitively and efficiently, alarm shelving, detailed alarm response views, and real-time trend analysis. Built-in alarm analysis helps monitor alarm loads and supports corrective actions to keep operators focused and reduce overload.
Beyond software, 800xA supports complete control room design, control centres, and remote operation centres that integrate seamlessly with PLCs, DCS, safety systems, live video, maintenance, lab systems, ERPs, and more. This unified environment improves plant visibility and ensures fast access to relevant information—allowing operational issues to be addressed proactively before downtime occurs.
With a high-performance HMI, 800xA offers an intuitive interface that promotes fast operator-process interaction, reduces the risk of disturbances, and supports quicker recovery when incidents do occur. Providing operators with clear process overviews and contextualised information enables faster, better decisions—minimising unplanned downtime and maximising plant efficiency.
Benefits of Operator Effectiveness with ABB 800xA
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Comprehensive Information in One Window
Simplifies operator workflow by consolidating all relevant data in a single view. -
Intuitive Alarm Management
Features like alarm grouping, shelving, and detailed response views help operators handle alarms quickly and effectively. -
Reduced Alarm Overload
Built-in alarm analysis tools assist in monitoring and controlling alarm loads for improved focus. -
Seamless Integration Across Systems
Connects PLCs, DCS, safety systems, video, maintenance, ERP, and more within one unified platform. -
Enhanced Plant Visibility
Fast access to real-time data supports proactive issue resolution and prevents downtime. -
Realistic Operator Training
The 800xA Simulator provides a safe environment for operator skill development, reducing unplanned shutdowns. -
Optimised Human-Machine Interface
A high-performance HMI enables rapid interaction, improving decision speed and reducing operational risks. -
Improved Decision-Making
Clear process overviews and contextual information empower operators to make fast, accurate decisions. -
Faster Disturbance Recovery
Quick access to relevant data helps minimise downtime when issues occur.
Flexible I/O Solutions
Improve quality and reliability
ABB System 800xA introduces a new approach to I/O configuration that decouples engineering tasks, allowing hardware design and software configuration to progress in parallel. This flexibility means hardware freezes can occur later in the project cycle, reducing the impact of late changes and shortening overall schedules.
Integrated systems simplify engineering complexity and lower lifecycle costs. Cloud-enabled engineering capabilities support distributed, multi-user collaboration using efficient, time-saving tools. Hardware emulation and process simulation offer robust testing environments before physical startup, identifying potential issues early.
Flexible architecture, combined with Ethernet-based engineering workflows, enables soft marshalling and late binding for most I/O types, reducing field wiring and dependencies between hardware and software teams. Cabinets can be placed close to physical I/O instead of application locations, improving installation efficiency.
The ABB 800xA Ethernet I/O network supports efficient tag-based engineering, simplified location planning, and allows I/O tags to be shared across multiple applications. It integrates electrical, safety, and process controllers within one unified system.
Benefits of Flexible I/O with ABB 800xA
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Reduced Project Schedules
Parallel hardware/software configuration accelerates delivery and minimises delays. -
Lower Impact of Late Changes
Late hardware design freezes accommodate evolving project requirements smoothly. -
Simplified Engineering and Lower Lifecycle Costs
Integrated systems reduce complexity and ongoing maintenance needs. -
Distributed Multi-User Engineering
Cloud-enabled tools enable collaborative workflows across locations. -
Robust Testing Prior to Startup
Hardware emulation and process simulation identify issues early, reducing commissioning risks. -
Versatile I/O Options
Local, remote, Ethernet-based single/multi-channel, fieldbus, and mixed configurations fit any project size or scope. -
Soft Marshalling and Late Binding
Minimises field wiring and decouples hardware/software dependencies for faster commissioning. -
Optimised Cabinet Placement
Location flexibility reduces installation complexity and costs. -
Tag-Based Engineering Across Applications
Reuse I/O tags in multiple applications for efficiency and consistency. -
Seamless Integration of Electrical, Safety, and Process Controls
Unified platform simplifies management and improves system reliability. -
Predefined Network Configurations and Embedded Monitoring
Simplifies network setup with built-in diagnostics and full ABB support.
Contact us to discuss what ABB 800xa can bring to your manufacturing plant
more efficient and profitable?
Frequently Asked Questions
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