HIGH INTEGRITY CONTROLLERS
Achieve certified protection for your most critical processes with AC 800M High Integrity Controllers. Designed for SIL3 safety applications, they provide the foundation for dependable safety system implementation. Unlike standard AC 800M Process Controllers used for process automation, High Integrity Controllers are dedicated safety controllers engineered specifically to execute safety-critical functions.
OVERVIEW
Create a certified TÜV safety environment for your most demanding process applications with the AC 800M High Integrity Safety Controllers: PM857, PM863 and PM867 which run on the supervision module SM812. These advanced Industrial Safety Controllers are engineered to deliver dependable performance across both integrated and stand‑alone environments, giving you the confidence to operate safely, efficiently, and without compromise.
The AC 800M HI controller pairs with the diverse co‑processor SM812 to execute continuous diagnostics, monitor application performance, and ensure reliable I/O scanning. This built‑in intelligence enables your Smart Safety Controllers to adapt to varied network designs, supporting separate but integrated safety operations or fully unified safety and process control within a single controller. This ensures seamless coordination of business‑critical processes while maintaining full safety integrity.
By combining proven TÜV‑certified reliability with flexible design options and intuitive engineering workflows, ABB’s High Integrity Safety Controllers enable you to simplify compliance, reduce lifecycle risk, and keep people, assets, and production running safely — for now and for the future.
KEY BENEFITS
Certified safety
<p>Know you’re supported by TÜV-certified SIL3 controllers designed for the most demanding safety-critical applications.</p>Fully integrated
<p>Deploy stand-alone safety systems or integrate safety and process control within a single System 800xA environment.</p>Scalable and flexible
<p>Choose dual or quad configurations and adapt system architecture to meet your operational and availability requirements.</p>High-performance safety control
<p>Execute safety and process control strategies with continuous diagnostics and advanced supervision for dependable operation.</p>Efficient engineering
<p>Reduce engineering effort through reusable libraries, automated safeguards, and streamlined lifecycle management tools.</p>Reliability and availability
<p>Maximize uptime with continuous diagnostics, redundant architectures, and availability levels exceeding 99.9999% for critical processes.</p>SIL3-CERTIFIED ARCHITECTURE
Its modular, scalable design enables seamless integration with the 800xA process control system, delivering measurable savings at every lifecycle stage, from engineering and commissioning to operation and maintenance.
Beyond integration, High Integrity controllers incorporate advanced safety design features, including:
- Embedded software and hardware diversity in both the logic solver and I/O subsystems
- Diverse execution paths that prevent random failures from going undetected
- Robust diagnostics that enhance reliability across all operating mode
The system is available in both Dual and Quad configurations, allowing you to configure the exact level of availability and redundancy required. Both configurations are SIL3 certified, ensuring consistent safety integrity. For continuous processes, the Quad configuration enables availability of more than 99.9999%, reducing unplanned interruptions and safeguarding production uptime.
SAFETY ENGINEERING
With SIL‑compliant function libraries and automated safeguards, the 800xA engineering environment ensures that your ABB High Integrity Safety Controllers are always configured in line with required safety standards.
As soon as an application is identified as safety‑critical, System 800xA automatically guides engineers toward compliant design choices. Non‑SIL‑approved options are restricted, and downloads are blocked if SIL requirements are not met, reducing human error, simplifying compliance, and protecting the integrity of your safety system.
System 800xA strengthens safety engineering further with capabilities that streamline development, documentation, and lifecycle management, including:
- IEC 61131‑3 compliant language usage
- Access control and controlled overrides (force control)
- Automatic application change reporting
- Standardized, reusable application libraries and solutions
- Flexible programming language support
With AC 800M Engineering, you’re not just developing safer systems, you’re equipping your plant with a long‑term, future‑ready safety platform that reduces engineering time, improves accuracy, and enhances the performance and reliability of your operations.
PROGRAMMING LANGUAGE
Function block diagram (allowed for Non-SIL and SIL1-3)
Function Block Diagram (FBD) provides a graphical method for developing control logic and visualizing signal flow. It simplifies development, troubleshooting and maintenance of safety applications.
Structured text (allowed for Non-SIL and SIL1-3)
Structured Text (ST) enables advanced, maintainable control strategies using a high-level programming language. For SIL-rated applications, IEC 61131-3 restrictions help ensure predictable and compliant execution.
Sequential function chart (allowed for Non-SIL and SIL1-2)
Sequential Function Chart (SFC) provides a structured approach to developing time- and event-driven processes using clearly defined steps and transitions.
APPLICATION LIBRARIES
System 800xA includes a comprehensive library of standard reusable components that include extended automation entities such as faceplates, graphic elements, trends, document links, alarms, and events. We also provide a broad family of industry specific libraries that contain pre-configured control modules, function blocks, and graphic elements. These pre-tested proven libraries significantly reduce the time required to engineer, test, and maintain control applications, while minimizing project risks.
ABB's extensive experience in designing, implementing and maintaining safety systems is reflected in a wide range of proven applications, including:
- Burner Management and Boiler Protection (BMS)
- Emergency and Process shutdown (ESD and PSD)
- Fire and Gas systems
- Interlock systems
- Critical Control
- High Pressure Protection Systems (HIPPS)
- Pipeline Protection systems (PPS)
- Certified Safety Libraries
CERTIFIED SAFETY LIBRARIES
Supervision Library:
Includes control module types for detector inputs, monitoring, system control, visualization and output handling. Certified for use in SIL2 applications.
Supervision Basic Library:
Focuses on SIL‑compliant shutdown logic. Certified for SIL3 applications, it provides robust and reliable shutdown sequences that strengthen the overall performance of your safety critical control systems.
Burner Management Library (BMS):
Reduces engineering effort and simplifies lifecycle maintenance for burner applications. Its SIL3‑capable function blocks support all key BMS operations, from ignition sequencing and valve leak testing to precise air/fuel control.
Fire & Gas Library:
Includes modules for monitoring and controlling fire and gas protection systems. Certified for SIL2 applications.
Communication Library:
Provides certified communications between SIL-marked applications. Certified for SIL2 and SIL3 environments.
For further details, refer to the 800xA Safety Manual.
SELECT YOUR SAFETY HARDWARE
<p>Browse, find, compare and export data sheets instantly for System 800xA hardware, including Controllers, I/O Systems, I/O MTU’s and Power Supplies and Voters. </p>