Description

The ABB KUC711AE01(Order Code:3BHB004661R0001)is a controller unit from ABB’s Industrial IT AC 800M High Integrity(HI)platform,specifically engineered for safety-critical and high-availability applications requiring compliance with IEC 61508 SIL 3 and IEC 61511 standards.It serves as the central processing module in ABB Ability™System 800xA High Integrity safety systems,commonly deployed in oil&gas,chemical processing,power generation,and mining industries where functional safety is non-negotiable.

Unlike standard PLCs,the KUC711AE01 operates within a 1oo2D(One out of Two with Diagnostics)or 2oo3(Two out of Three)redundant architecture,using diverse dual-channel processing to detect and tolerate both random hardware faults and systematic software errors—ensuring fail-safe operation even during partial system degradation.

Application Scenario

At a North Sea offshore oil platform,a high-pressure gas compression train required a SIL 3-certified emergency shutdown(ESD)system to prevent catastrophic overpressure events.ABB deployed a 2oo3 redundant KUC711AE01-based safety system,interfacing with:

Pressure transmitters(via FS242 safety analog input modules)

Emergency isolation valves(via FS252 safety DO modules)

Fire&gas detectors

During a simulated pipeline rupture test,all three KUC711AE01 controllers independently detected rising pressure beyond threshold.The 2oo3 voting logic triggered a full shutdown in<100 ms,closing block valves and venting gas safely.The system also logged a detailed diagnostic report via System 800xA Safety Portal,confirming no spurious trips occurred.Since commissioning,it has maintained zero safety incidents over 8 years of continuous operation.

Key Specifications

Parameter Value/Description

Model KUC711AE01

ABB Order Code 3BHB004661R0001

Product Family AC 800M High Integrity(HI)–part of System 800xA Safety

Safety Certification IEC 61508 SIL 3,IEC 61511,EN 50205(Type B),ATEX,cULus

Architecture 1oo2D(single controller with dual diverse channels)or 2oo3(triplicated)

Processor Dual diverse CPUs(different silicon architectures or firmware paths)for cross-checking

Memory

•Safety Application Memory:8 MB Flash

•Runtime RAM:16 MB(with ECC)

Execution Performance

•Boolean instruction:~0.2µs

•Typical safety scan cycle:50–100 ms(configurable)

Communication

•Dual Ethernet ports(10/100 Mbps):

–Safety Network:For I/O and peer synchronization(via CI871/CI872)

–Service Port:For engineering and diagnostics(secured)

•RS-232 for local service access

Redundancy&Synchronization

•Optical fiber link(via CI873)for inter-controller sync in 2oo3

•Deterministic state comparison every scan cycle

Programming Environment Control Builder M Safety(IEC 61131-3+safety extensions)

•Certified function blocks(e.g.,S_R_TRIG,S_AND,S_VALVE)

•Automatic safety integrity validation

Diagnostics

•Continuous self-test(CPU,memory,I/O paths)

•Built-in web server for status monitoring

•Full audit trail compliant with ISA-84

Power Consumption~12 W

Mounting DIN rail in TK871/TK872 safety-certified cabinets

Operating Temperature 0°C to+60°C(derated above 50°C)

Note:The“AE01”suffix denotes the base variant.The full safety system requires companion modules like CI871(communication),FS2xx(safety I/O),and PS872(redundant power).

Technical Innovations&Safety Principles

Innovation 1:Diverse Dual-Channel Design–Each channel uses independent execution paths;mismatches trigger safe state—preventing common-cause failures.

Innovation 2:Integrated Safety&Control–Shares engineering environment(System 800xA)with basic process control,reducing lifecycle costs while maintaining segregation.

Innovation 3:Certified Development Lifecycle–Hardware and firmware developed under V-model with full traceability from requirements to test cases.

Innovation 4:Cyber-Secure by Design–Supports encrypted firmware updates,role-based access,and network segmentation per IEC 62443.

Typical Applications

Emergency Shutdown(ESD)systems

Fire&Gas(F&G)detection and suppression

Burner Management Systems(BMS)

High-integrity pressure protection systems(HIPPS)

Turbine overspeed protection

Rail signaling interlocks

Required Companion Modules(Typical 2oo3 Setup)

Module Function

CI871 Safety communication interface(Ethernet)

CI873 Optical sync link between controllers

FS242 8-channel safety analog input(4–20 mA,HART)

FS252 8-channel safety digital output(contact or solid-state)

PS872 Redundant 24 VDC power supply

TK872 Certified cabinet with shielding and grounding

Engineering&Validation

Design safety logic in Control Builder M Safety using certified libraries.

Perform FMEA/HAZOP integration within System 800xA.

Validate with automatic safety reports(PFHd,MTTF,DC).

Test using offline simulation and hardware-in-the-loop(HIL).

Commission with forced I/O testing and proof test procedures.

⚠️Critical:Only certified ABB Safety Engineers should modify safety application logic.Unauthorized changes void SIL certification.

Lifecycle Status&Support(2025)

The KUC711AE01 remains actively manufactured and supported by ABB as a core component of the System 800xA High Integrity platform.ABB guarantees:

Availability until at least 2035

Firmware security patches

Spare parts and repair services

We provide:

New original units with full safety documentation(FMEDA,TÜV certificate)

Pre-configured safety templates(e.g.,HIPPS,ESD)

On-site FAT/SAT support

Training for certified safety engineers

All units include:

TÜV Rheinland SIL 3 certificate

Conformity declaration(EU/UKCA)

Traceable serial number linked to test records

Final Note

The ABB KUC711AE01 is not just a controller—it’s a certified guardian of people,assets,and the environment.By combining rigorous safety engineering with seamless integration into modern automation ecosystems,it enables industries to operate at the highest levels of risk management without compromising on efficiency.

Contact us for SIL-compliant system design,urgent delivery,or legacy safety system migration.When failure is not an option,trust the KUC711AE01 to keep your process safe—every millisecond,every day.

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