ABB Introduces Automation Extended
I wrote a preview last week of two similar news items that have come my way. They suggest ways to deal with a persistent problem—especially one relevant these days with so few greenfield projects and so much need to upgrade old technology. This post looks at the ABB release.
ABB launched an aggressive acquisition campaign a quarter-century ago accumulating the leading share of process control installations. I say this based on the old Control Magazine/ARC Advisory Group rankings (well, along with ABB press releases that always touted market share leadership).
The first thing the company had to do was build a unifying structure—and along came the 800xA platform. They’ve improved that platform over time keeping current with technology advances.
I’m combing two news items here. The first explains their upgrade platform called Automation Extended. The second explains the first instantiation with the aforementioned 800xA.
I am interested in learning about any of your experiences upgrading 800xA to current technology.
- The Automation Extended program helps industries modernize distributed control systems without disruption by building on ABB’s proven platforms and safeguarding existing investments
- A modern, open and modular automation ecosystem enables advanced analytics, AI and IoT integration, allowing technologies to be adopted at customers’ pace without operational risk
- A separation-of-concerns architecture protects the core control while enabling new digital capabilities to be deployed at scale – without touching mission-critical operations
Here is the problem statement.
ABB has introduced its Automation Extended program, a strategic evolution of its distributed control systems (DCS), designed to help industries modernize without disruption. Building on ABB’s long-standing leadership with the world’s largest DCS installed base and vision in process automation, Automation Extended outlines how future automation capabilities can be introduced progressively – preserving system integrity while enabling the flexibility, scalability and efficiency needed for the next era of industrial operations.
The ABB platforms affected.
Operators can continue to rely on trusted ABB systems such as ABB Ability System 800xA, ABB Ability Symphony Plus and ABB Freelance, while introducing new technologies progressively and without operational interruption. This approach provides a structured, low risk path to modernization, preserving continuity while enabling innovation.
An explanation of the implementation including the required adjective I pointed out in my earlier piece. The best I see to define “open” is a reference to OPC/UA. Many companies point to this technology referring to their being open.
The Automation Extended program is implemented through a modern, open and modular environment designed for interoperability, scalability and seamless integration across industrial domains. Based on separation of concerns principles, the automation ecosystem includes two distinct yet securely interconnected environments:
- The control environment, a software‑defined domain that ensures robust, reliable and deterministic control for critical processes.
- The digital environment, securely connected to the control layer, enabling advanced applications, edge intelligence and real‑time analytics. This space leverages artificial intelligence (AI) and machine learning for decision support without disturbing proven control structures.
- A single, unified and comprehensive automation service approach for ecosystem lifecycle management and optimization is applied for the management and maintenance of these diverse technological environments.
ABB launches System 800xA 7.0 DCS, bridging today and tomorrow’s automation
Building on ABB’s long-standing approach to modernization without disruption, ABB Ability System 800xA 7.0 distributed control system (DCS) acts as a bridge to future automation technologies
In brief:
- Introduces Automation Extended functionality, enabling gradual uptake of advanced digital capabilities while maintaining core system reliability
- Long Term Support (LTS) ensures predictable, secure system operation with extended lifecycle coverage and minimal disruption
As a Long-Term Support (LTS) release, System 800xA 7.0 provides a stable, predictable path for both existing installations and new projects, with broad Windows OS compatibility, expanded virtualization support, and long-term continuity without disruptive upgrade cycles.
As the first DCS adopting ABB’s recently announced Automation Extended program, System 800xA enables stepwise digital adoption for process and system monitoring and optimization. Through the “separation of concerns” architecture, with distinct yet securely interconnected control and digital environments, customers can deploy system performance monitoring, advanced analytics, and AI-based decision support applications without impacting the mission-critical control layer that safeguards operations.
Key enhancements:
- Extension packs as a new delivery model—System 800xA 7.0 introduces a new, modular software delivery approach through Extension Packs, enabling customers to stay on their base software version while adopting innovations on an independent lifecycle in a non-disruptive way. This reduces the need for large-scale upgrade events, minimizes operational risk and lowers lifecycle costs.
- Broader operating system and virtualization support—The system supports two generations of Microsoft operating systems, including Windows Server 2025/2022 and Windows 11/10, enabling flexible upgrade paths. It also supports multiple virtualization platforms including VMware and Hyper-V, giving users more flexibility in how they deploy and maintain their automation system’s infrastructure.
- Strengthened cybersecurity and system hardening—System 800xA 7.0 incorporates native Microsoft Defender malware protection, IEC 62443-aligned security capabilities, improved certificate management, and updated core components. Together, these measures help protect critical systems against modern cyber threats while simplifying security maintenance.
- Modern engineering tools and expanded connectivity—Enhancements to OPC UA client/server functionality, Ethernet-APL device integration, and network-centric I/O performance improve project scalability and interoperability. Version 7.0 also supports the latest MTP standards for ABB’s Modular Automation Orchestration Designer, helping customers meet emerging requirements for modular production.
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