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ASEA Master and Advant Master DCS System Evolution

Choose a step-by-step evolution or a complete migration to a newer generation ABB DCS for ASEA Master (MasterPiece controller, MasterView HMI) and the Advant Master family (AC450 controller, Advant Station HMI)

With the world’s largest installed base of Distributed Control Systems, ABB is the market leader and truly understands your need for step-wise improvement and continuous modernization of production equipment. 

Our strategy is a clear– ‘only evolve what is needed and when it makes sound economic sense’.

We have developed comprehensive solutions with different levels of step-wise evolution for the ABB Master family, introduced as ASEA Master (MasterPiece controller, MasterView HMI) in 1984, and the Advant Master family (AC450 controller, Advant Station HMI) introduced in 1992.

Our evolution experts make a complete review of a system in order to identify upgrade opportunities offering the greatest ROI. As a result of the study, a long-term roadmap will suggest the best evolution path to increase the efficiency and the productivity of the plant. 

From our experience, step-wise evolution through the system layers can commonly be prioritized for ABB Master and Advant Master as laid out below, from left to right:

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System Evolution by system layer and product

Information Management
Evolve to
ABB MasterView
800xA for Advant Master SV 6.1
AdvaCommand for Unix Workstations
800xA for Advant Master SV 6.1
800xA for Advant Master SV 3.1 to 6.0 800xA for Advant Master SV 6.1
Evolve to
MB300 Thick Ethernet coax system MB300 based on 800xA Network switches
MB300 based on Hubs MB300 based on 800xA Network switches
Evolve to
Advant Station 100 Engineering Stations Control Builder A 1.4
Control Builder A 1.0 to 1.3 Control Builder A 1.4
Evolve to
Enterprise Historian for Unix 800xA History
Enterprise Historian for Windows NT 800xA History
Evolve to
MasterPiece 200 and 200/1 Advant Controller 450 2.3 or AC 800M
Advant Controller 450 1.0 to 2.2 Advant Controller 450 2.3 or AC 800M
Advant Controller 410 Advant Controller 450 2.3 or AC 800M
Advant Controller 70 AC 800M
Advant Controller 55 AC 800M
Advant Controller 110 Advant Controller 160 ver 2.2 or AC 800M
Advant Controller 160 1.0 to 2.1 Advant Controller 160 ver 2.2
Evolve to
S100 for Advant Master first version S100 For Advant Master A version
S400 for Advant Master S800 I/O with evolution kit
S800 on AF100 for Advant Master S800 on Profibus DP for AC800M

Typical System Evolution scenarios


What is the most cost efficient way to evolve to a newer system generation?

The answer is Automation Sentinel, in the Maintain and Evolve level!

A big part of the cost of System Evolution from ABB Master and ABB Advant Master to a current system is the software license cost, something that is provided by using Automation Sentinel Maintain and Evolve.

Automation Sentinel remains the key program for life cycle system support as customers continue to upgrade and evolve their installed systems to our latest generation offerings.

What is gained by evolving each system layer?

To remain competitive, manufacturers need to change and improve their business processes. The changes made to the system must be limited to the specific areas where they will create most gain, and there must be a solid Return on Investment (ROI).

HMI replacement
  • Single unified HMI/control room consolidation
  • Common plant object structure
  • Vertical integration
  • Increased operator efficiency
  • Increased safety
  • Remove bottlenecks / increase capacity
Controller replacement
  • Architecture
  • CPU power
  • Footprint
  • Asset management/predictive maintenance
  • Increased availability
  • Increased maintenance efficiency
  • Lower equipment cost
  • Lower energy cost
I/O / Field Termination Assemblies (FTA) replacement
  •  I/O connectivity solutions
  • Cabling solutions
  •  Retain I/O and/or cabling

What differentiates System Evolution from Migration?

Migration is commonly known as moving from one place to another, from one state or another, or in our case, from one DCS system generation to another. 

System Evolution takes a holistic approach to the need, by carefully choosing what subsystems and in what order to replace, to minimize negative productivity impact on the running system while maximizing the benefits of new functionality.

Simplified, one could say that migration is simply a rip and replace of the old system, and System Evolution is a step-wise planned improvement of the system.

Case studies

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