ABB Helps Factories Upgrade Bailey Infi90 and Harmony DCS Systems Without Stopping Production

2025-09-26

Introduction

Many factories still rely on older control systems like Bailey Infi90 and Harmony DCS. These platforms have been dependable for decades, but technology has moved forward. Replacing them entirely would mean high costs, long downtime, and major risks.

ABBoffers a smarter option: an evolutionary upgrade pathway to System 800xA. This approach lets plants keep much of their existing investment while adding new tools for modern HMI, asset optimization, and information management.



Protecting Past Investments

Instead of removing everything, ABBhelps factories keep their current Bailey Infi90 and Harmony DCS equipment—controllers, I/O modules, and wiring—while gradually moving toward System 800xA. This cost-effective modernization means companies protect their past investments while gaining access to new features.

Operators see immediate improvements:

  • Modern HMI screens that are easier to use.

  • Asset optimization tools that identify problems before breakdowns happen.

  • Information management functions that provide real-time insights.

This evolutionary upgrade minimizes risk and ensures production never stops.

ABB

What System 800xA Brings

By upgrading to System 800xA, plants get more than just new software. They gain a future-ready operation with advanced tools designed for today’s competitive environment.

Key benefits include:

  • Modern HMI for clearer, user-friendly displays.

  • Predictive maintenance as part of asset optimization.

  • Stronger information management for better decision-making.

  • Step-by-step upgrades for cost-effective modernization.

With these improvements, plants that once relied only on Bailey Infi90 or Harmony DCS can now operate with greater efficiency and flexibility.



Conclusion

ABB’s evolutionary upgrade strategy shows that modernizing doesn’t mean starting from scratch. By protecting past investments in Bailey Infi90 and Harmony DCS, while steadily moving toward System 800xA, businesses gain the benefits of modern HMI, asset optimization, and advanced information management.

The result is a cost-effective modernization path that leads to safer, more efficient, and truly future-ready operations—without the downtime and risks of a full replacement.


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