ABB AC160 Controller Advant Controller 160 DCS Unit

Description

Product Introduction & Engineering Value

When high-speed steam or gas turbine trip loops demand millisecond-accurate execution, standard PLCs often fail to deliver the deterministic processing required. The ABB Advant Controller 160 (AC160) provides dedicated, high-availability multiprocessing engineered specifically for complex power generation and heavy industrial control setups.

Capable of running up to six PM665 PowerPC processor modules simultaneously within a single rack, the AC160 balances heavy control execution across independent tasks without throughput bottlenecking. Built-in support for redundant processing, Advant Fieldbus 100 (AF100) networks, and local S600/S800 I/O ensure continuous plant uptime even during primary component faults.

Technical Specifications

• Processing Architecture: Multiprocessing rack supporting up to 6 PowerPC-based CPU modules (PM660/PM665).
• Execution Performance: Up to 31 user-definable independent task execution loops down to 2 ms cycle times.
• Recommended I/O Capacity: Up to approximately 1,500 local and remote I/O points.
• Supported I/O Subsystems: Direct rack integration with central S600 I/O modules and distributed S800 I/O channels.
• Network & Bus Support: Advant Fieldbus 100 (AF100), PROFIBUS-DP, Modbus RTU, RCOM/RCOM+, and Siemens 3964R.
• Redundancy Capability: Bumpless hot-standby CPU, power supply unit, I/O bus extension, and AF100 communication redundancy.
• Sequence of Events (SOE): At-the-source time tagging with precise 1 ms resolution on digital inputs.
• Application Memory: Non-volatile electrically erasable memory (no battery backup required for program storage).
• Power Supply Integration: Dual-redundant 24 VDC / 110-230 VAC rack power supply modules (SD610 series).
• Operating Ambient: 0°C to +55°C (32°F to +131°F) continuous operating envelope.

AC160

AC160

Field Application & The “Trench” Experience

The Trench Story: During a full-load trip test on a 250 MW combined-cycle steam turbine, the primary processor card on an aging AC160 rack threw a hard memory parity error. Because the AC160 chassis was commissioned in a dual-redundant PM665 processor configuration, the standby CPU took over execution instantly without dropping a single valve-positioning output loop or tripping the unit. Technicians performed a live swap of the faulty processor board during normal operation, returning the turbine control system to full N+1 fault tolerance without taking the plant offline.

Target Industrial Applications:

• Combined-Cycle & Hydro Turbine Governing: Handling overspeed protection, fuel valve positioning, and auto-synchronization loops.
• Waste-to-Energy Process Automation: Managing multi-boiler combustion sequences and flue gas scrubbing controls.
• District Heating Control Nodes: Supervising multi-node regional distribution networks over AF100 and Modbus links.

Transparency SOP: QA & Testing

1. Backplane & Pin Inspection: High-magnification optical check of multi-slot backplane connectors and terminal pins for bent contacts or thermal oxidation.
2. Dual-CPU Bumpless Redundancy Test: Insertion of two PM665 processors to simulate a primary processor failure under active AF100 network traffic, verifying zero-lag switchover to the secondary card.
3. Communication Baud & Fieldbus Sweep: Verifying serial port communication across Modbus RTU and AF100 channels using Advant Station diagnostics.
4. I/O Bus Load Simulation: Fully loading local S600 and remote S800 I/O expansion lines under simulated 1 ms SOE triggers to confirm uninterrupted time-tag accuracy.

The Veteran’s Tech Trap Guide

• ⚠️ Bus Cable Termination: Advant Fieldbus 100 coax and twisted-pair segments require exact impedance-matched termination resistors. Missing or mismatched terminations will cause intermittent packet drops across the entire sub-network, triggering false node offline alarms.
• PRO TIP: When hot-swapping processor cards or communication interfaces (such as CI626/CI630) on an active basic rack, ensure the module locking levers are fully disengaged before seating to avoid uneven contact pin engagement.
• ⚠️ Non-Redundant MVI Slot Restrictions: Multi-Vendor Interface (MVI) cards installed in SC610 expansion subracks are not supported when running dual-redundant CPU modules. Verify system architecture before attempting to pair CPU redundancy with specialized serial interfaces.

Dynamic FAQ

Q: Can the program memory be preserved without an onboard lithium battery?

A: Yes. The stores its executable application logic in non-volatile electrically erasable memory, eliminating the risk of program loss due to battery drainage.

Q: What programming tool is used to engineer application logic for the ?

A: The is programmed using AMPL (Advant Controller Structure Language) graphic block language via the Advant Station 100 / Control Builder engineering tools.

Q: How many processor modules can be installed in a single controller chassis?

A: The architecture supports multi-processing configurations using up to 6 Processor Modules in a single controller subrack.

Q: Are replacement racks and processor modules covered by warranty?

A: Yes, all tested surplus and reconditioned ABB Advant units come backed by a 1-year replacement warranty.