ABB Advant Controller 160 (AC160) – High‑Performance Modular Process Controller

Description

Technical Specifications

Core System Architecture

• Controller Type: Modular, rack‑mounted process controller (RF616 rack)
• Processor Modules: PM645B, PM665 (Motorola MPC8240 PowerPC)
• Multi‑Processing: Up to 6 processor modules per rack for parallel task execution
• Redundancy: Full redundancy for processors, I/O buses, fieldbuses, and power supplies
• I/O Capacity: Supports up to 1,500 I/O points via S600 central and S800 distributed I/O modules
• Backplane: BIOB (Backplane I/O Bus) for high‑speed internal communication

Communication Interfaces & Protocols

• Fieldbuses: Advant Fieldbus 100 (AF100), PROFIBUS‑DP
• Protocols: RCOM/RCOM+, Siemens 3964R, MODBUS I (RTU), OPC via Advant OPC Server
• Interfaces: EIA‑232 (for engineering), Ethernet, redundant communication ports
• Networking: Redundant bus systems for controller‑to‑controller and system‑level connectivity

Performance Parameters

• Control Cycle Speed: Sub‑millisecond fast closed‑loop control (CLC) for high‑dynamic processes
• Event Time Tagging: Microsecond‑precision source time stamping for sequence‑of‑events (SOE) recording
• Memory: High‑capacity RAM and flash for control logic, data logging, and configuration storage
• Processing Power: Multi‑core parallel processing for complex algorithms and multi‑tasking

Mechanical & Physical

• Mounting: Standard RF616 rack mounting, compatible with industrial control cabinets
• Dimensions: Rack‑mount form factor (standard 19‑inch cabinet compatible)
• Environmental Rating: Industrial‑grade, suitable for harsh plant environments
• Power Supply: Redundant 24 V DC industrial power inputs

Compliance & Compatibility

• System Integration: Fully integrated with ABB Advant Master DCS and System 800xA
• Standards: IEC 61131‑3, IEC 61508 (for safety‑related functions), CE, UL, CSA

Key Features

• High‑Speed Closed‑Loop Control: Delivers sub‑millisecond control cycles for precision turbine, motion, and process control.
• Full Redundancy Architecture: Redundant processors, buses, and power supplies eliminate single points of failure for 99.99% uptime.
• Modular & Scalable Design: Supports online addition of I/O modules and processor upgrades without system shutdown.
• Multi‑Processor Parallelism: Up to 6 processors per rack handle complex, multi‑task control workflows simultaneously.
• Microsecond SOE Recording: Precise event time stamping enables accurate diagnostics and root‑cause analysis.
• Hot‑Swappable Components: All modules support hot insertion/removal for maintenance without process interruption.
• Extensive I/O Compatibility: Works with S600 central and S800 distributed I/O for flexible signal interfacing.
• Advanced Control Functions: Integrates logic, sequence, regulatory, supervisory, and optimization control in one platform.
• Seamless System Integration: Native compatibility with ABB 800xA for unified HMI, engineering, and asset management.
• Long‑Term Investment Protection: Backward compatibility and continuous updates extend operational life for legacy and modern systems.

Application Scenarios

• Gas & Steam Turbine Control: High‑speed closed‑loop control for power generation turbines in combined‑cycle plants.
• Power Generation & Distribution: Boiler control, turbine governing, and substation automation in fossil, nuclear, and renewable power plants.
• Nuclear Reactor Protection: Safety‑critical control and monitoring for nuclear power plant reactor systems.
• Industrial Process Automation: Fast control for refining, chemical processing, and pharmaceutical manufacturing.
• Shaftless Printing Presses: Precision motion and registration control for high‑speed printing machinery.
• Metalworking & Machine Tools: High‑dynamic motion control for CNC machines, rolling mills, and forging equipment.
• Pulp & Paper Manufacturing: Distributed control for drying, calendering, and winding processes.
• Marine & Offshore Systems: Engine control, propulsion, and safety systems for ships and offshore platforms.
• System Retrofit & Modernization: Upgrade legacy control systems with high‑performance, backward‑compatible AC160 controllers.