Advant® OCS Advant® Controller 160

with Master software

Version 2.1

Product Guide
3BSE 014 721R401
 Use of DANGER, WARNING, CAUTION, and NOTE
This publication includes, DANGER, WARNING, CAUTION, and NOTE information where appropriate to point out safety
related or other important information.
DANGER Hazards which could result in severe personal injury or death
WARNING Hazards which could result in personal injury
CAUTION Hazards which could result in equipment or property damage
NOTE Alerts user to pertinent facts and conditions.
Although DANGER and WARNING hazards are related to personal injury, and CAUTION hazards are associated with
equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational
conditions, result in degraded process performance leading to personal injury or death. Therefore, comply fully with all
DANGER, WARNING, and CAUTION notices.

TRADEMARKS
Master, MasterPiece, MasterView and MasterAid are registered trademarks of ABB Asea Brown Boveri Ltd. MasterNet,
MasterBus, and MasterBatch are trademarks of ABB Asea Brown Boveri Ltd. Advant, AdvaCommand, AdvaInform,
AdvaBuild, AdvaSoft and AdvaControl are reg. trademarks of ABB Process Automation Corp. HART is a trademark of HART
Communication Foundation. HP and all HP-products are registered trademarks of Hewlett-Packard Company. IBM and all
IBM-products are trademarks of International Business Machines Corporation. KERMIT is copyright 1985, Trustees of
Colombia University. Lotus 1-2-3 is a trademark of Lotus Development Corporation. MATLAB is a registered trademark of The
MathWorks Inc., USA. MODBUS is a registered trademark of GOULD Electronics. MOTIF and OSF are trademarks of Open
Software Foundation. MS-DOS, Microsoft, Microsoft Excel, and Word for Windows are registered trademarks of Microsoft
Corporation. Postscript is a registered trademark of Adobe Systems Inc. PROFIBUS and PROFIBUS-DP are trademarks of
Profibus International (P.I.). Siemens and all Siemens-products mentioned in this publication are trademarks of Siemens AG.
UNIX is a registered trademark of AT&T Corporation. VAX, VMS, Digital, DEC, VT100 - VT420 are trademarks of Digital
Equipment Corporation. X-window Systems is a trademark of Massachusetts Institute of Technology. All rights to other
Trademarks reside with their respective owners.

NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by ABB
Automation Products GmbH. ABB Automation Products GmbH assumes no responsibility for any errors that may appear in this
document.
In no event shall ABB Automation Products GmbH be liable for direct, indirect, special, incidental or consequential damages of
any nature or kind arising from the use of this document, nor shall ABB Automation Products GmbH be liable for incidental or
consequential damages arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB Automation Products GmbH’s written
permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in accordance
with the terms of such license.

CE MARKING
This product meets the requirements specified in EMC Directive 89/336/EEC and in Low Voltage Directive 72/23/EEC and
93/68/EEC.
Copyright© ABB Automation Products GmbH 2001.
3BSE001264/E

Template: 3BSE001286/E

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 Advant® Controller 160 Product Guide
Table of Contents

Chapter 1 - Overview
1.1 Introduction..................................................................................................................1
1.2 Features........................................................................................................................2
1.2.1 General........................................................................................................2
1.2.2 Performance, Reliability, and Safety ..........................................................3
1.2.3 Process Interface .........................................................................................3
1.2.4 Operator interfaces......................................................................................4
1.2.5 Engineering.................................................................................................4

Chapter 2 - Software Functions

2.1 Process Control Software.............................................................................................7
2.1.1 AMPL .........................................................................................................7
2.1.2 PC Elements................................................................................................7
2.1.3 Data Base Elements ....................................................................................8

Chapter 3 - Hardware Functions

3.1 Controller Hardware .................................................................................................. 11
3.1.1 Processor Modules....................................................................................11
3.1.2 Interface Module Carrier ..........................................................................13
3.1.3 Communication Interfaces........................................................................13
3.1.4 Subrack .....................................................................................................14
3.1.5 Cable Duct ................................................................................................15
3.1.6 Power Supply............................................................................................16
3.2 Input/Output Hardware ..............................................................................................17
3.2.1 S600 Local I/O..........................................................................................17
3.2.2 S800 Distributed I/O.................................................................................18
3.3 Field Communication Hardware................................................................................19
3.3.1 Advant Fieldbus 100.................................................................................19
3.3.2 PROFIBUS-DP.........................................................................................22

Chapter 4 - Advant Controller 160 Configurations

4.1 Configuration Overview ............................................................................................25
4.2 Preconditions and Restrictions...................................................................................27
4.3 Product Components..................................................................................................27
4.3.1 Software Components...............................................................................27
4.3.2 Hardware components ..............................................................................31

Chapter 5 - Mechanical Design

Chapter 6 - Technical Data and Performance

6.1 General Data ..............................................................................................................45

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6.2 Communication ......................................................................................................... 45

6.2.1 RCOM/RCOM+ Communication ............................................................ 47
6.2.2 PROFIBUS-DP Communication ............................................................. 48
6.3 Event Transfer and Detection.................................................................................... 48
6.4 Interface for a Local Operator Station ...................................................................... 49
6.5 Cycle and Scan Times ............................................................................................... 49
6.6 I/O Scanning.............................................................................................................. 50
6.7 CPU Load Calculation .............................................................................................. 50
6.8 CPU Load Calculation, Data Set Communication.................................................... 50
6.9 Memory Requirements.............................................................................................. 51

Chapter 7 - Environmental Immunities

7.1 Environmental Considerations .................................................................................. 53

Chapter 8 - Ordering
8.1 Price List Structure.................................................................................................... 55
8.2 Assembled Delivery or Loose Part Delivery ............................................................ 55
8.3 Loose Part Delivery and CE-marking ....................................................................... 55
8.4 Reference Guide........................................................................................................ 56
8.4.1 General and Normative Requirements ..................................................... 56
8.4.2 Basic Unit................................................................................................. 56
8.4.3 Hardware Options .................................................................................... 57
8.4.4 Upgrade and Update................................................................................. 58
8.4.5 Communication ........................................................................................ 58
8.4.6 Power System........................................................................................... 60
8.4.7 S600 I/O ................................................................................................... 62
8.4.8 Cables and Connectors ............................................................................. 66
8.4.9 Assemby and Test .................................................................................... 67
8.4.10 Packaging Options ................................................................................... 67
8.4.11 S800 I/O ................................................................................................... 68
8.4.12 Documentation ......................................................................................... 68

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Table of Contents

Figure 1-1. Typical System Layout, for Protection Applications .......................................1

Figure 1-2. Advant OCS System Configuration with Advant Controller 160 ....................2
Figure 3-1. Advant Controller 160, Controller Subrack ...................................................11
Figure 3-2. Basic Subrack RF616 and Extension Subrack RF620 ...................................15
Figure 3-3. Physical Layout of Subrack and Cable Duct..................................................15
Figure 3-4. Configuration of I/O Stations for AC 160 with Redundant Bus Extension ...17
Figure 3-5. Redundant Advant Fieldbus 100 Configuration Using Coaxial Media..........20
Figure 3-6. Media Conversion in Advant Fieldbus 100....................................................21
Figure 3-7. Dual Advant Fieldbus 100 Configuration ......................................................22
Figure 3-8. Sample PROFIBUS Configuration.................................................................23
Figure 3-9. Hierarchy of DB Elements for PROFIBUS-DP Configurations ....................24
Figure 4-1. Advant Controller 160, Basic Unit.................................................................25
Figure 4-2. Advant Controller 160 System Structure, Redundant Configuration.............26
Figure 4-3. Advant Controller 160 with 2x PM, 2x CI, and 2x SA610 ............................32
Figure 4-4. Dual redundant Processor Module within one Advant Controller 160 ..........36
Figure 4-5. Dual Parallel Processor Module within one Advant Controller 160..............37
Figure 4-6. Triple Parallel Configuration with 3 Advant Controllers 160........................38
Figure 4-7. System Clock Synchronization within an Autonomous Control System
using AC 160 and AdvaSoft 2.0 for Windows NT.........................................40
Figure 4-8. System Clock Synchronization within a Control System using
AC 160 with Superordinate AC 450 and AS 500OS .....................................41
Figure 4-9. Time Synchronization of Several Processor Modules....................................42
Figure 5-1. Physical Layout of Subrack............................................................................43
Figure 5-2. Dimensions of Subrack and Cable Duct.........................................................44
Figure 6-1. Data Set Communication................................................................................46

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Table of Contents

Table 2-1. PC Elements for Advant Controller 160.......................................................... 7

Table 2-2. DB Elements for Advant Controller 160 ......................................................... 8
Table 3-1. Submodule Carrier......................................................................................... 13
Table 3-2. Communication Interfaces............................................................................. 14
Table 3-3. Station Voltage Specifications ....................................................................... 16
Table 3-4. Bus Extender Modules................................................................................... 17
Table 3-5. I/O units with Redundant Bus Extension....................................................... 18
Table 3-6. S800 I/O Modules Supported by Advant Controller 160 .............................. 18
Table 4-1. PC Elements in BASE Program Module ....................................................... 28
Table 4-2. PC Elements in OPT1: extended PC.............................................................. 29
Table 4-3. Supported MODBUS functions ..................................................................... 30
Table 4-4. PC Elements in OPT6: St. Red. + RSM......................................................... 30
Table 4-5. Basic Unit for Advant Controller 160, Components ..................................... 31
Table 4-6. Number of Buses Connected to Advant Controller 160 ................................ 34
Table 4-7. System Time Masters for Synchronization via AF 100................................. 39
Table 4-8. Connection Hopf 7001 DCF to Com B ......................................................... 42
Table 6-1. Maximum Configuration of Advant Controller 160...................................... 45
Table 6-2. Data Set Communication for Advant Controller 160 .................................... 46
Table 6-3. Data Set Transfer Times for Advant Fieldbus 100 ........................................ 47
Table 6-4. Data Communication on RCOM/RCOM+ .................................................... 47
Table 6-5. Data Communication on PROFIBUS-DP...................................................... 48
Table 6-6. Distance Based on Transmission Speed on PROFIBUS-DP ......................... 48
Table 6-7. Event Transfer and Detection ........................................................................ 49
Table 6-8. Event Transfer and Detection Resolution ...................................................... 49
Table 6-9. Maximum Usable CPU Load for Application Program ................................ 50
Table 6-10. Memory Requirements for 7 Different Application Programs ...................... 51
Table 8-1. General and Normative Requirements........................................................... 56
Table 8-2. Basic Units..................................................................................................... 56
Table 8-3. Hardware Options .......................................................................................... 57
Table 8-4. Upgrades and Updates of Advant Controller 160 Software .......................... 58
Table 8-5. Advant Fieldbus 100...................................................................................... 58
Table 8-6. Multi Vendor Interface................................................................................... 59
Table 8-7. Power Supply in Rack.................................................................................... 60
Table 8-8. Power Supply in RM5xx (width 800 mm)..................................................... 60
Table 8-9. Power Supply in RM5xx (width 700 mm)..................................................... 61
Table 8-10. Power Supply for Field Equipment ............................................................... 61
Table 8-11. Main Supply Filter ......................................................................................... 61
Table 8-12. S600 I/O Units ............................................................................................... 62
Table 8-13. S600 Analog Input Modules .......................................................................... 62
Table 8-14. S600 Analog Output Modules ....................................................................... 63

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Table 8-15. S600 Analog Input/Output Modules ..............................................................63

Table 8-16. S600 Pulse Counting Module.........................................................................64
Table 8-17. S600 Digital Input Modules ...........................................................................64
Table 8-18. S600 Digital Output Modules.........................................................................65
Table 8-19. Cables and Connectors ...................................................................................66
Table 8-20. Cable Set for Redundant and Parallel Processing ..........................................66
Table 8-21. Assembly and Test..........................................................................................67
Table 8-22. RM500V1 Cabinets (width 800 mm) .............................................................67
Table 8-23. RM500V2 Cabinets (width 700 mm) .............................................................68
Table 8-24. S800 I/O modules for Advant Controller 160 ................................................68
Table 8-25. Documentation on Advant Controller 160 .....................................................68

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Table of Contents

vi 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 1.1 Introduction

Chapter 1 Overview

1.1 Introduction
Advant Controller 160 is a scalable highly modular controller used within Advant OCS system
for general applications which require high availability and redundancy.
It is offering a full complement of control and communication functions and meets high require-
ments concerning performance, reliability and safety for burner management, safety systems,
turbine control etc. through redundancy for all central components.
Advant Controller 160 is designed to work stand alone as well as an integrated part of the
Advant OCS system to suit a wide range of applications.
The following key words summarize the philosophy of the system:
• Integration
• Distribution
• Reliability
• Openness
• User Friendliness
• Investment Security and Expandability
Figure 1-1 demonstrates a typical system configuration with Advant Controller 160 only.
One example of an Advant OCS system configuration including Advant Controller 160 is
shown in Figure 1-2.

Advant Station 100 series

Advant OPC-Server with Engineering station
SattGraph 5000 or any OPC-Client

Control Bus redundant

AF 100 Advant Controller 160

AF100
S800 I/O

serial
Interface PROFIBUS-DP
AF100
M M Distributed Peripheral
S800 I/O
Modules
~

Figure 1-1. Typical System Layout, for Protection Applications

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Advant® Controller 160 Product Guide
Chapter 1 Overview

X-terminal Personal
Computer MES or ERP
Server

Plant Network

Advant Station 510 Advant Station 515 Advant Station 520i Advant Station 530
OS OS, IMS OS, IMS, ES IMS
AdvaCommand AdvaCommand AdvaCommand AdvaInform
AdvaBuild AdvaBuild AdvaBuild AdvaBuild
AdvaInform AdvaInform

Control Network

Advant Controller 450 Advant OPC Server Advant Controller 410

with SattGraph 5000
or any OPC-Client

Control Bus AF 100

Advant Controller 110 S800 I/O Advant Controller 70 Advant Controller 160

Advant Station 130 ES

AdvaBuild for Windows

serial
Interface PROFIBUS-DP
RCOM
AF100
M Distributed Peripheral
Advant Controller 55 S800 I/O
Modules
~

Figure 1-2. Advant OCS System Configuration with Advant Controller 160

1.2 Features

1.2.1 General
Advant Controller 160 offers powerful features covering all aspects of process control. The fol-
lowing are examples of control functions provided by the system:
• Logic and sequence control
• Regulatory control
• Supervisory control
• Positioning
• Counting, calculations and process optimization
• Sequences
• Recording of alarms and events

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 Advant® Controller 160 Product Guide
Section 1.2.2 Performance, Reliability, and Safety

• Process interfacing
• Open interface to other systems
– via standard serial interfaces, such as MODBUS and Siemens 3964R
– via OPC for Advant Fieldbus 100
– Interface to PROFIBUS-DP
– Support for SERCOS and Interbus
• Password protection for application
• Password protection for Engineering Station access to the controller

1.2.2 Performance, Reliability, and Safety

Advant Controller 160 meets high requirements concerning performance, reliability and safety
for burner management, safety systems and turbine control through
• multiprocessing
• redundancy for all central components
• multi-channel controller configurations
• hot replacement of all modules
• self diagnostics

1.2.3 Process Interface

Advant Controller 160 communicates with the process through various types of sensors and
actuators connected to process interface units, or input/output (I/O) units.There are I/O units
which can be placed directly in an Advant Controller 160 rack or units to be used at remote
locations. The following signal types are supported:
• Analog Inputs
– Isolated and non-isolated inputs. Standard voltage (0 to 10 V, 0 to ±20 mA), Pt 100
and thermocouple inputs.
• Analog Outputs
– Isolated standard voltage or current outputs.
• Digital Inputs
– Isolated and non-isolated 24 to 60 V d.c., 24 to 250 V a.c./d.c, with SOE capabilities.
• Digital Output
– Isolated and non-isolated 24 to 60 V d.c., 24 to 250 V a.c./d.c., transistor and relay
outputs.
• Pulse Counters
– Isolated, 5 V, 24 V d.c. or ±13 mA, max 100 kHz.

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Advant® Controller 160 Product Guide
Chapter 1 Overview

1.2.4 Operator interfaces

1.2.4.1 SattGraph 5000 Operator Station with Advant OPC Server

SattGraph 5000 is an ABB SCADA (Supervisory Control and Data Acquisition) system based
on Windows NT 4.0.
For interaction between operator and process it provides an HMI (Human Machine Interface),
based on process graphics including information zooming, multiple windows and handling for
control operations, events, alarms and historical value recording.
SattGraph 5000 and Advant Controller 160 communicate via OPC Server for Advant Fieldbus
100. This software is an ABB product that provides a standard OPC interface to connect any
OPC Client (also third party products) to Advant Fieldbus 100 and thus establishes access to
Advant Controller 160.

1.2.4.2 AdvaSoft 2.0 for Windows NT with Advant OPC Server

AdvaSoft 2.0 for Windows NT is an Operator Station based on Windows NT 4.0.
For interaction between operator and process it provides an HMI (Human Machine Interface),
based on process graphics including information zooming, multiple windows and handling for
control operations, events, alarms and historical value recording.
Advasoft 2.0 and Advant Controller 160 communicate via OPC Server for Advant Fieldbus
100. This software is an ABB product that provides a standard OPC interface to connect any
OPC Client (also third party products) to Advant Fieldbus 100 and thus establisher access to
Advant Controller 160.

1.2.4.3 Advant Station 500 Operator Station

Within Advant Station 500 Operator Station (AS 500OS) all process objects are operated by
dynamic function keys which pop up by just clicking on the symbol of the object, e.g., a pump,
in the process display. Additionally to the buttons for process operation these keys provide a
wide range of functions as acknowledgement, alarm blocking, limit and parameter setting, etc.
AS 500OS supports binary history and archiving as well as retrieval.

1.2.5 Engineering

1.2.5.1 Advant Station 100 Series Engineering Station

Advant Station 100 Series Engineering Station (AS 100ES) is a ready to use system and
includes everything necessary for configuration and programming of Advant Controllers.
AS 100ES is an PC-based programming and service tool suitable for use in industrial environ-
ment and satisfying the Advant OCS environmental immunity specifications and safety stan-
dards. It supports program entry, testing, documentation and fault tracing. It also features
graphical function chart programming and a user interface with windows, pull-down menus and
“point and click” selection.

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 Advant® Controller 160 Product Guide
Section 1.2.5 Engineering

The software Control Builder A (CBA) installed on Advant Station 100 Series Engineering Sta-
tions is offering the following main functions:
• Application data administration with Application Builder.
• System and application configuration of Advant Controller 400 Series, MasterPiece 200/1,
MasterGate 230/1, Advant Station 500 Series Operator Station, and MasterView 800/1 by
On-line Builder.
• Application configuration of Advant Controller 400 Series and MasterPiece 200/1 process
stations off-line using Function Chart Builder.
• Application configuration and commissioning, including fault tracing of Advant Control-
ler 100 Series on-line and off-line by Function Chart Builder.
• Configuration support for AF 100 OPC by Bus Configuration Builder.
Advant Station 100 Series Engineering Board is needed for command execution and serves as
an interface between Advant Station 100 Series Engineering Stations and target systems of type
Advant Controller 400 Series.
For more detailed information see:
– Advant Station 100 Series Engineering Station User’s Guide
– AMPL Configuration Advant Controller 100 Series Reference Manual
– Application Builder User’s Guide.
– Function Chart Builder User’s Guide
– Bus Configuration Builder User’s Guide
– PROFIBUS Library Editor User’s Guide

1.2.5.2 Control Builder A

Control Builder A (former name: AMPL Control Configuration) includes all software necessary
to configure Advant OCS. It is delivered on CD-ROMs and includes:
• Application Builder
• Function Chart Builder
• Bus Configuration Builder.
As options are available:
• On-line Builder
• AMPL PC and DB Element Libraries including libraries for:
– Advant Controller 100 Series
– Advant Controller 400 Series
– MasterPiece 200/1
– AdvaSoft.

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Advant® Controller 160 Product Guide
Chapter 1 Overview

NOTE
To work with Function Chart Builder, at least one AMPL PC or DB Element
Library must be installed. Further AMPL PC and DB Element Libraries are avail-
able from various Business Units and other ABB companies for application spe-
cific extensions of controllers.

Control Builder A 1.0 supports Advant Controller 160 version 2.1 in two target variants:
1. Target “AC 160 with PM64x 2.1” for Processor Modules PM640, PM644, PM645, or
PM646.
2. Target “AC 160 with PM66x 2.1” for the new Power PC based Processor Module PM665.
These two targets will be available in Application Builder as soon as the option AC160 AMPL
Libraries 3.0 is being installed on your system.

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 Advant® Controller 160 Product Guide
Section 2.1 Process Control Software

Chapter 2 Software Functions

2.1 Process Control Software

Process control applications are programmed in the ABB Master Programing Language
(AMPL). The building blocks of AMPL are called PC elements which covers a wide range of
functions.
The Engineering Stations support type circuits; standard solutions to control problems in an
application area or in a specific application project. A type circuit may comprise all the func-
tions to control motors, pumps, valves, temperature loops, etc., including all the necessary defi-
nitions for I/O and operator communication. It can be tested and corrected before it is
multiplied. This means optimization of engineering work by using standard solutions.

2.1.1 AMPL
AMPL is a function-block language with graphic representation, which is especially oriented
towards process control. The function blocks offer a high level of configurability from simple to
complex. The language is common for all controller products within Advant Power System and
Advant OCS.
The general description is given within the Advant OCS Product Guide with the same chapter
number.

2.1.2 PC Elements
For Advant Controller 160 a comprehensive library of PC elements is available (Table 2-1).
Chapter 4.3.1 shows in which options they can be found.

Table 2-1. PC Elements for Advant Controller 160

Type PC Elements
Structure Elements PCPGM, CONTRM, FUNCM, MASTER, SLAVEM,
BLOCK, SEQ 1, STEP 1, GRC, P_STEP
Logic AND, OR, XOR, INV, AND-TRG, OR-TRG, ADD-MR,
THRESH-L, SR, SR-D, SR-AA, SR-AO, SR-OA, SR-
OO, AND-O, OR-A, BGET, BSET
Arithmetic ADD, SUB, MUL, DIV, ABS, SQRT, LIM-N, ADD-MR,
DIV-MR, MULDIV
Time MONO, MONO-UT, TON, TOFF, TON-RET, TRIGG,
OSC-B, TIMER
Registers FIFO, MOVE, REG, REG-G, REG-G-UT, SHIFT
Multiplexers MUX-I, MUX-MI, MUX-MN
Code Converters CONV, CONV-BI, CONV-IB

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Advant® Controller 160 Product Guide
Chapter 2 Software Functions

Table 2-1. PC Elements for Advant Controller 160 (Continued)

Type PC Elements
Counters COUNT
Comparators COMP-B, COMP-I, COMP-R, COMP-B, MAX, MIN
Switches SW, SW-C
Measurement Elements RSM 2
Signal Selector MOON
Function Generator FUNG-1V
Filter FILT-1P
Feedback P-1, INT, DER, PI, PID, PIP, PDP, CON-PU1, RAMP
Redundancy MOVERED, TRAC, SW-RED, RED_STAT
PROFIBUS PB-IN, PB-OUT
Protection and Safety PC_AX646, CONV-AX, PC_DX610, SYS-CRC
Supervision SYSL, SYSTIME
1 SEQ and STEP cannot be used with redundant processing (CPU or station redundancy). Instead
GRC and P_STEP can be used.
2 RSM cannot be used with PM646.

2.1.3 Data Base Elements

The following Data Base elements are available for Advant Controller 160 version 2.1

Table 2-2. DB Elements for Advant Controller 160

Type DB Elements
Processor Modules PM640, PM644, PM645, PM6461, PM6652
High speed link HSLR, HSLS, MDAT(IL), MDAT(NB), MDAT(NI),
MDAT(R)
S600 I/O CI610, CI615, AI610, AI620, AI625, AI630, AI635,
AO610, AO650, AX645, AX646, DI610, DI620, DI621,
DI622, DI635, DI636, DI650, DI651, DI652, DI685,
DO610, DO620, DO625, DO630, DX610, DP620,
DP640
S800 I/O CI810, CI820, AI801, AI810, AI820, AI830, AI835,
AO801, AO810, AO820, DI801, DI810, DI811, DI814,
DI820, DI821, DI885, DO801, DO810, DO814, DO815,
DO820, DO821

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 Advant® Controller 160 Product Guide
Section 2.1.3 Data Base Elements

Table 2-2. DB Elements for Advant Controller 160 (Continued)

Type DB Elements
HSI DAT_AI, DAT_AO, DAT_DAT, DAT_DI, DAT_DO
Advant Fieldbus 100 AF100S, CI626, CI627, CI630, CI631, DSP, DAT(B),
DAT(I), DAT(II), DAT(IL), DAT(R)
Multi Vendor Interface SC610, CI532, MVICHAN, MVINODE, MVB,
MODCHAN, PARDAT(B), PARDAT(I), PARDAT(II),
PARDAT(IL), PARDAT(R), PARDAT(NB),
PARDAT(NI), PARDAT(T), PARDAT(TR)
PROFIBUS-DP PB, PBS, CI830, PB_ACS600, S800 I/O 3
Event Handling AIC, DIC, EVS(S), EVS(T)
S600 I/O AX645, AX646, DX610
Extended DB Elements AIS, AOS, DIS, DOS, MB, MI, MIL, MR
1 PM640, PM644, PM645, PM646 are only available when target “AC 160 with PM64x 2.1” is
selected in Control Builder A.
2 PM665 is only available when target “AC 160 with PM66x 2.1” is selected in Control Builder A.
3 S800 DB elements starting with PB_… connected via CI830.

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Chapter 2 Software Functions

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 Advant® Controller 160 Product Guide
Section 3.1 Controller Hardware

Chapter 3 Hardware Functions

3.1 Controller Hardware

The hardware of Advant Controller 160 consists of Processor Modules, Communication Inter-
face modules, Submodule Carrier, I/O modules with process connectors, subracks, cable ducts
and power supplies.
Subracks and cable duct are designed for wall mounting or mounting in cabinets. Normally they
are mounted in cabinets.
The modules are housed in a sheet-steel enclosure which protects the circuit boards. The enclo-
sure has openings at the top and bottom for air convection. It meets the IP20 protection class of
IEC 529.

3.1.1 Processor Modules

Six different types of Processor Modules are available for Advant Controller 160:
1. Processor Module PM640 for non redundant processing.
2. Processor Module PM644 for non redundant processing with PROFIBUS-DP master inter-
face on the Processor Module.
3. Processor Module PM645 (type B) for parallel processing with data exchange via high
speed link and with rotational speed signal input onboard.
4. Processor Module PM646 for redundant processing with additional hardware and software
monitoring functions required for safety application systems.
5. Processor Module PM665. Same features as PM645, but based on Motorola Power PC
microprocessor, with more RAM and approximately sixfold better performance.

Figure 3-1. Advant Controller 160, Controller Subrack

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Advant® Controller 160 Product Guide
Chapter 3 Hardware Functions

Processor Module PM640

• Processor Module PM640 uses a Motorola MC68360 processor, 1 MByte nonvolatile
memory (Flash PROM) for user built applications and 2 Mbyte nonvolatile memory (Flash
PROM) for the system software, and 2 MBytes SRAM. At start-up the application is cop-
ied from the nonvolatile memory into the SRAM memory where it is executed. The mem-
ory is not expandable.
• PM640 has two RS 232-C ports at 9,600 Baud dedicated for connection of an Advant Sta-
tion 100 Series Engineering Station and for connecting a local Operator Station via MOD-
BUS I protocol.

Processor Module PM644

Processor Module PM644 has all features of PM640 as described above plus the following
ones:
• Processor Module PM644 contains a second Motorola MC68360 processor with extra 2
MByte nonvolatile memory (Flash PROM) for the system software and extra 2.25 MByte
SRAM for PROFIBUS communication.
• Processor Module PM644 has a PROFIBUS-DP master interface with RS 485 port for
data exchange with PROFIBUS slaves.
• PM644 additionally contains two rotational speed signal input ports of type RS-422.

Processor Module PM645 (type B)

The Processor Module PM645 (type B) has all features of PM640 as described above, plus the
following ones:
• A second Motorola MC68360 processor with extra 512 kbyte nonvolatile memory (Flash
PROM) for the system software and extra 2 MByte SRAM.
• Two RS-422 ports (high-speed-serial-links) for signal and data exchange between Proces-
sor Modules for application and system purposes.
• A redundancy voter for dual and triple redundancy.
• Two rotational speed signal input ports RS-422.

Processor Module PM646

Processor Module PM646 has all features of a PM640 as described above, plus the following
ones:
• Processor Module PM646 contains a second Motorola MC68360 processor with extra
2 MByte nonvolatile memory (Flash PROM) for the system software and 2 MByte
SRAM.
• The 2 MBytes SRAM is extended with a secondary 2 MBytes SRAM (Mirror-RAM) for a
redundant data storage with a hardware-based data comparison.
• Processor Module PM646 contains two RS-422 ports (high-speed-serial-links) for signal
and data exchange between Processor Modules for application and system purposes.

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 Advant® Controller 160 Product Guide
Section 3.1.2 Interface Module Carrier

• Processor Module PM646 additionally contains a redundancy voter for dual and triple
redundancy.
• Both printed circuit boards of PM646 contain a watchdog circuit with outputs combined
for triggering the on-board relay (Implementation of an independent “Second Shutdown
Path” for safety systems).
• Processor Module PM646 has an extended 5 V power supply supervision with under- and
overvoltage detection.

Processor Module PM665

• The Processor Modules PM665 uses a Motorola MPC8240, a member of the Power PC
microprocessor family, with 1 MByte nonvolatile memory (Flash PROM) for user built
applications and 2 Mbyte nonvolatile memory (Flash PROM) for the system software, and
64 MBytes SDRAM. At start-up the application is copied from the nonvolatile memory
into the SDRAM memory where it is executed.
• PM665 has all features of PM645B as described above. In addition
– both RS 232-C ports can operate at 116 kBaud.
– port Com A is dedicated for connecting an Advant Station 100 Series Engineering
Station and for loading the communication software and system software.
– port Com B is equipped with full modem signals for connecting a local Operator Sta-
tion or panel via MODBUS I protocol. Com B uses a male 9 pin connector.

3.1.2 Interface Module Carrier

The purpose of the submodule carrier is to carry communication interfaces. Each Advant Con-
troller 160 can accommodate one SC610 submodule carrier module. Note that an SC610 can
only be operated with a PM640, a PM644, a non redundant PM645, a PM646, or with a
PM645B, PM646, or PM665 in station redundancy.

Table 3-1. Submodule Carrier

Consists of Description
SC610 Submodule Carrier, required for CI532. Two submodules fit
into one carrier; one SC610 per controller is allowed.

3.1.3 Communication Interfaces

Communication interfaces are designed as modules or submodules. A submodule is a small
board which fits into a slot on the submodule carrier, SC610. Modules can be exchanged while

3BSE 014 721R401 13

Advant® Controller 160 Product Guide
Chapter 3 Hardware Functions

the system is running. New modules can also be inserted live. Every unit has a red LED to indi-
cate fault.

Table 3-2. Communication Interfaces

Consists of Description
CI532V01 RCOM/RCOM+ communication. Each interface holds two buses.
CI532V02 MODBUS communication. Each interface holds two buses.
CI532V03 Siemens 3964(R) communication. Each interface holds two buses.
CI5901 SERCOS interface.
CI626 Advant Fieldbus 100, coaxial cable.
CI627 Advant Fieldbus 100, twisted pair cable.
CI630 Advant Fieldbus 100, coaxial cable, redundant coupling with 2
interface modules.
CI631 Advant Fieldbus 100, twisted pair cable, redundant coupling with 2
interface modules.
CI6801 Interbus S.
1 Distributed by CHIND – BU Printing.

3.1.4 Subrack
The 10-position controller subrack, RF616, is the primary subrack of an Advant Controller 160.
It provides dedicated positions for Processor Modules, communication and bus extender mod-
ules.
There is a two-digit thumb wheel switch for setting the station address. The individual module
address is given by its position in the subrack.
The bus connector links the controller subrack to an optional extension subrack via a bus cable
(TK612).
The 10-position extension subrack, RF620, extends the number of I/O modules of a station.

14 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 3.1.5 Cable Duct

The individual module address is given by its position in the subrack.

Position 1 2 3 4 5 6 7 8 9 10

Position 11 12 13 14 15 16 17 18 19 20

Figure 3-2. Basic Subrack RF616 and Extension Subrack RF620

482 (19)
320 (12.6)
440 (17.3)
ABB ABB ABB ABB ABB ABB ABB ABB ABB ABB 40.7 (1.6) 120
(4.7)
57.15 (2.25)
269 (10.6)

76.2 (3.0)

57.15 (2.25)

87.7 (3.5)
(4.0)

Cable duct
100

464 (18.3) 325 (12.8)

Figure 3-3. Physical Layout of Subrack and Cable Duct

3.1.5 Cable Duct

The cable duct RC610 holds the process cables. It also provides 10 screw terminals for connect-
ing the cable shields of process cables to ground.

3BSE 014 721R401 15

Advant® Controller 160 Product Guide
Chapter 3 Hardware Functions

3.1.6 Power Supply

Advant Controller 160 can be connected to the following types of primary supply:
• 120 V or 230 V a.c., 47 to 450 Hz, using the power supply module SA610.
• 110 V/125 V or 220 V/250 V d.c., using the power supply module SA610.
• 24 V d.c., direct supply to Advant Controller 160 from an external power supply.
The electronic circuits of the modules are fed by means of two redundant power rails. The 0 V
level is connected to the metallic part of the subrack.

Table 3-3. Station Voltage Specifications

Description Value
Nominal voltage 24 V d.c.
Acceptable voltage range 19.2 to 30 V d.c.
EMI protection level None (station voltage must be filtered)

The use of the power supply module SA610 is recommended. SA610 is housed in the standard
module enclosure and occupies one position in the subrack. SA610 provides reinforced primary
voltage isolation, excellent EMI filtering and buffering of short (10 ms for 110 V d.c. input and
20 ms for 230 V a.c. input) primary voltage drop out. If one SA610 is not sufficient, two can be
used in parallel within one subrack, i.e., up to four modules SA610 within one station (basic sta-
tion or I/O station).
Advant Controller 160 can be powered from an external 24 V d.c. power source (i.e. without
SA610). Special attention must be paid to grounding and noise level. An EMI filter must be
used, and the negative pole of the supply be grounded in the metallic part of the subrack.
All available power supply solutions are listed in the reference guide.

16 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 3.2 Input/Output Hardware

3.2 Input/Output Hardware

3.2.1 S600 Local I/O

The S600 I/O system consists of I/O modules with typically 16 or 32 input or output channels,
depending on the type of module. The I/O modules are placed in I/O stations which are built up
by one or two I/O subracks. I/O modules can also be inserted into the controller subrack.
The general description of the I/O system is given within the Advant OCS Product Guide with
the same chapter number.
The following chapter contains specific information for Advant Controller 160.

3.2.1.1 I/0 Station with Redundant Bus Extension

For Advant Controller 160 the I/O bus extension can be configured for redundancy with two
CI615 interface modules and two extension bus lines. This configuration provides increased
system reliability compared to non redundant I/O bus extension.
Each I/O station connected to both extension bus lines contains two bus extenders, CI610,
which must be put in position 1 and 2.

Table 3-4. Bus Extender Modules

Consists of Description
CI610 Bus extender module for I/O station
CI615 Bus extender module for Basic Station

The maximum bus cable length of each bus line is 20 m (65 ft.).

Advant Controller 160

CI615
CI615

(3) Cable length: max. 20 m (65 ft.) (4)

(1) (1) (2)

(1) CI610 in I/0 station must be put in
CI610

CI610
CI610

CI610

position 1 and 2 Bus extension

(2) Bus terminator TC610 required cables TK610
(3) Built-in bus termination I/O station I/O station
(4) Total length of all TK610 used per
bus line

Figure 3-4. Configuration of I/O Stations for AC 160 with Redundant Bus Extension

The I/O stations may be mounted in the same or in adjacent cabinets. The stations must be con-
nected to a common ground; the voltage difference at the ground terminals must be less than
± 2 volts.

3BSE 014 721R401 17

Advant® Controller 160 Product Guide
Chapter 3 Hardware Functions

The bus extension cable TK610 can be delivered in lengths of 2.5, 5 and 10 m (6.6, 16.4 and
32.8 ft.). The above figure shows the configuration with redundant bus extension.
The table below specifies the equipment used to build up I/O stations with redundant bus exten-
sions.

Table 3-5. I/O units with Redundant Bus Extension

Units Description
Subrack RF615, Cable duct RC610 and two Bus extenders I/O station with redun-
CI610. dant bus extender.
Subrack RF620, Cable duct RC610, Bus cable TK612 and I/O extension kit.
Power cable TK615.
2× (Bus extenders CI615 for base station and Bus termina- 2× I/O bus extension
tors TC610 for I/O extension bus). kit.
RC620 I/O Fan unit 24 V.

3.2.2 S800 Distributed I/O

The S800 I/O is a distributed I/O for Advant Controller 110, Advant Controller 160, and Advant
Controller 450 via Advant Fieldbus 100. S800 I/O is also used as a directly connected I/O to
Advant Controller 70.
The S800 I/O system consists of I/O modules with typically 4, 8 or 16 input or output channels,
depending on the type of module.
The I/O station is connected to Advant Fieldbus 100 via a redundant or non redundant Fieldbus
Communication Interface (FCI).
The S800 I/O System General Information and Installation User’s Guide gives more details
about these modules. The S800 I/O Product Guide gives a first overview.
The following S800 I/O modules are supported:

Table 3-6. S800 I/O Modules Supported by Advant Controller 160

Module type Type designation

CI CI810, CI820, CI830
AI AI801, AI810, AI820, AI830, AI835
AO AO801, AO810, AO820
DI DI801, DI810, DI811, DI814, DI820, DI821, DI885
DO DO801, DO810, DO814, DO815, DO820, DO821

18 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 3.3 Field Communication Hardware

3.3 Field Communication Hardware

3.3.1 Advant Fieldbus 100

Advant Fieldbus 100 (AF 100) is a high performance fieldbus which is used for communication
between Advant Controllers and Advant Stations.
The general description is given within the Advant OCS Product Guide with the same chapter
number.
Each Advant Controller 160 supports up to 4 independent AF 100 buses. The following chapter
contains more specific information.

Communication Interfaces for Advant Controller 160

With Advant Controller 160 the following Communication Interfaces and modems can be used:
• CI630, CI626 and CI626V1 for coaxial cable.
• TC630 for conversion between coaxial and optical cable.
• TC513 for conversion between coaxial and twisted pair.
• CI631, CI627 for twisted pair cable.
• TC514 for conversion between twisted pair and optical cable.
• TC515 for repeating twisted pair to twisted pair.

NOTE
• Up to 4 independent Advant Fieldbus 100 can be connected. For increased
availability, CI630 or CI631 can be used as redundant pairs (altogether 8 cou-
plers).
• If CI630 and/or CI626 and/or CI631 and/or CI627 are used, media redun-
dancy is fully supported.
• If CI626 is used: Coaxial media redundancy only is supported, with restric-
tions in cable length difference between the two redundant cables. With opti-
cal bus cable, only one physical bus line is possible.
CI630 and CI631 supervise if each Data Set to be sent via Advant Fieldbus 100 is cyclically
updated by the Processor Modules. In case of missing update CI630, CI631 stops sending the
respective Data Sets which is automatically detected by each receiving node.

3BSE 014 721R401 19

Advant® Controller 160 Product Guide
Chapter 3 Hardware Functions

Supported Configurations
Advant Controller 160 supports the following Advant Fieldbus 100 configurations:
• Communication with Advant Controller 70, 110, 160, 450, SattGraph 5000, AdvaSoft 2.0
Operator Station with OPC Server (Figure 3-5 to Figure 3-7).
• Coaxial, twisted pair and optical bus cables (Figure 3-5 to Figure 3-7).
• Redundant bus cables (Figure 3-5 to Figure 3-7).
• Redundant Communication Interfaces to Advant Fieldbus 100 (Figure 3-5).
• Second Advant Fieldbus 100 with redundant Communication Interface to communicate
with S800 I/O stations and subordinate Advant Controller 70, 110 or 160 (Figure 3-7).
When redundant media are used, redundancy must be maintained through the whole bus; this
comprises bus lines as well as connections of nodes to the bus.

Advant Controller 450 Advant OPC Server with

2 × SC510 (SC520)
AdvaSoft 2.0, SattGraph 5000
or any OPC Client

2 × CI522

CI526

4 × TC625 SB512 SB512

power 2 × TC625
power

CT CT
CT CT

2 × TC513
CI626

CI630
CI630

TT TT

TT TT
Advant Controller 110 Advant Controller 160
CT 75 Ω BNC termination
TT Twisted Pair termination

Advant Controller 70

Figure 3-5. Redundant Advant Fieldbus 100 Configuration Using Coaxial Media

20 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 3.3.1 Advant Fieldbus 100

Advant Controller 450

Optical media
TC630 TC630

Coaxial media Coaxial media

CI520 CT CT CT CT

TC512 TC513

CI630
CI630

CI631
CI626
Twisted pair media
TT TT

Advant Controller 110 Advant Controller 160

TT
Twisted pair media TT TT
Twisted pair media TT
PM810
Optical media
Advant Controller 70 TC514 TC514

S800 I/O S800 I/O

Station Station

CT 75 Ω BNC termination

TT Twisted Pair termination

Figure 3-6. Media Conversion in Advant Fieldbus 100

3BSE 014 721R401 21

Advant® Controller 160 Product Guide
Chapter 3 Hardware Functions

Advant Controller 450

SC510 (SC520) SattGraph 5000 or any OPC client
using Advant OPC Server

CI520

CI526

2 × TC625 SB512 SB512

power 2 × TC625 power
main bus Advant Fieldbus 100
CT CT
CT CT

2 × TC513 CI626

CI630
CI630

CI631
CI631
Advant Controller 160
TT TT

TT TT
Advant Controller 110 subordinate bus
Advant Fieldbus 100
TT TT

TT TT

Advant Controller 70

CT 75 Ω BNC termination S800 I/O

TT Twisted Pair termination Station

Figure 3-7. Dual Advant Fieldbus 100 Configuration

3.3.2 PROFIBUS-DP
PROFIBUS is a high performance fieldbus which is used for communication between Advant
Controllers and PROFIBUS slaves (PROFIBUS DPMs, Distributed Peripheral Modules).
Therefore the PROFIBUS variation PROFIBUS-DP (Decentralized Periphery) is used.
The PROFIBUS-DP interface in Advant Controller 160 allows to connect PROFIBUS slaves. It
conforms with the PROFIBUS-DP standard EN 50170 and a subset of the extensions known as
PROFIBUS-DPV1.

Communication Interface for Advant Controller 160

Traffic on a PROFIBUS link is controlled by a master station. Direct communication is possible
only between the master and the slaves.
In Advant Controller 160, the Communication Interface within Processor Module PM644 is a
PROFIBUS-DP master class 1.
S800 I/O and ACS600 Standard Drives can be connected to Advant Controller 160 using the
Communication Interface CI830 which acts as PROFIBUS-DP slave.

22 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 3.3.2 PROFIBUS-DP

Dimensioning
In Advant Controller 160, PROFIBUS can be configured as follows:
• Communication with up to 125 PROFIBUS-DP slaves per PROFIBUS, via twisted pair
bus cables according to EN 50170 (Figure 3-8).
• Up to 32 devices (master or DPMs or repeaters) per cable segment.
• Cable segment length up to 1,200 m.
• Up to 244/244 input/output bytes process data per PROFIBUS slave.
• Up to 236 input diagnostic data bytes per PROFIBUS slave.
• Transmission speed from 9,600 Baud up to 12 MBaud.
• Up to 6 Processor Modules PM644 can be used in an Advant Controller 160.
• It is recommended to use only certified PROFIBUS-DP slaves

PM644

PROFIBUS-DP master (class 1)

Advant Controller 160

PT
PROFIBUS-DP PT

DPM DPM DPM DPM

PROFIBUS-DP slaves
PT PROFIBUS termination

Figure 3-8. Sample PROFIBUS Configuration

PROFIBUS Configuration in Control Builder A

A PROFIBUS-DP configuration consists of two parts:
6. The standardized part of PROFIBUS-DP master implemented by the Processor Module
(PM644) with the integrated PROFIBUS-DP interface
7. The variable part of PROFIBUS slaves implemented by different vendors. The latter are
described by their GSD file.
In Control Builder A
• The PROFIBUS-DP master and the PROFIBUS-DP slave devices as types are represented

3BSE 014 721R401 23

Advant® Controller 160 Product Guide
Chapter 3 Hardware Functions

by DB element types.
• The PROFIBUS-DP master and the PROFIBUS-DP slave devices are represented by DB
element instances.
When you are working with Control Builder A, the following tools and resources are available
to produce a PROFIBUS-DP DB element library which reflects the actual PROFIBUS-DP
slaves, modules, and signals as applicable:
• Model element library containing only the description of the PROFIBUS master and a
compact slave, the later serving as template
• PROFIBUS Library Editor that allows to extend the model element library with the
description of actual PROFIBUS slaves, modules, and signals.
The DB elements types created with the PROFIBUS Library Editor can be instantiated with the
Function Chart Builder of your Advant Controller applications.
In the next figure the hierarchy of the DB elements is shown:

PM644
The Processor Module with
reference PROFIBUS-DP interface is configured
by an instance of DB element PM634/PM644.
GSD files
PB The PROFIBUS-DP characteristics are
configured by an instance of DB element PB.
same bus number

The PROFIBUS-DP slaves are represented

Compact Modular by instances of special DB elements for each
Slave DB Slave DB slave. The station numbers are unique on a bus.
Elements Elements

same bus and

station number
Module Modules of modular slaves are represented
DB by instances of special DB elements for each
Elements module. The position numbers are unique
within a slave.

same left part of

item designation
Signal Signals of modules are represented by
DB automatically created instances of special
Elements DB elements (subordinates) for each
signal type.

Figure 3-9. Hierarchy of DB Elements for PROFIBUS-DP Configurations

24 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 4.1 Configuration Overview

Chapter 4 Advant Controller 160 Configurations

4.1 Configuration Overview

ABB’s Advant Controller 160 is a high performance modular controller for logic and regulatory
control with redundancy. Advant Controller 160 and its S600 local I/O, S800 distributed I/O, or
PROFIBUS-DP I/O can be used stand-alone or it can communicate with other controllers. Com-
munication with Advant Controller 400 Series is possible via Advant Fieldbus 100 and RCOM.
Communication with external PLCs is possible via MODBUS and Siemens 3964R protocol.
The controller is specifically designed for high speed PLC-type applications, but it also brings
considerable problem-solving power to all analog signal handling and arithmetic applications.
Advant Controller 160 covers a wide range of applications. As programming language AMPL is
used. The function element library contains a complete set of functions. Application programs
can be shared between Advant Controller 55, Advant Controller 70, Advant Controller 110,
Advant Controller 160, and Advant Controller 400 Series, provided that a common set of
AMPL elements is used.
Program entry, testing, documentation and fault tracing are supported by the Advant Station 100
Series Engineering Stations. These stations feature graphical Windows based function-chart
programming and a user interface with multiple windows, pull down menus and “point-and-
click” selection. Advant Controller 160 communicates with the engineering station through its
standard serial interface or via Advant Fieldbus 100.

Figure 4-1. Advant Controller 160, Basic Unit

Advant Controller 160 is fully modular, with modules mounted in 19" subracks. The subracks
are designed for mounting on the rear wall in a cabinet.

3BSE 014 721R401 25

Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

A minimal Advant Controller 160 configuration consists of one or two subracks containing the
two redundant Processor Modules and up to 18 I/O and communication modules.
In order to extend the number of I/O modules, up to 7 I/O stations may be connected to the
Basic Station, each consisting of up to two subracks.
To increase the numbers of I/Os, it is also possible to connect decentralized S800 I/O (Advant
Fieldbus 100 via CI627/CI631) and decentralized PROFIBUS-DP I/O (PROFIBUS-DP via
PM644), to the Advant Controller 160.

SattGraph 5000, AdvaSoft 2.0, or any

OPC Client using Advant OPC Server

PM645

SA610
SA610
PM645
CI630
CI630
Advant Fieldbus 100 #2 (redundant)

Advant Fieldbus 100 #1 (redundant)

PM645

SA610
SA610
PM645
CI630
CI630

SA610
SA610
PM645
PM645
CI630
CI630

CI615
CI615
CI630
CI630
Controller
Basic
Station

Advant Station 100 Series

Engineering Station

extension
cable
SA610
SA610
CI610
CI610

Controller
I/O
Station

redundant I/O Bus

extension cables

Figure 4-2. Advant Controller 160 System Structure, Redundant Configuration

26 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 4.2 Preconditions and Restrictions

For connection of a local operator station (3rd party product), the Processor Module of Advant
Controller 160 is equipped with a MODBUS I serial interface.
SattGraph 5000 or AdvaSoft 2.0 for Windows NT Operator Stations using Advant OPC Server
are easily connected via Advant Fieldbus 100.
Using dual redundant Processor Modules, dual redundant communication interface modules to
Advant Fieldbus 100 and to I/O extension bus, dual redundant power supply modules and mains
supplies an increased availability of the Advant Controller 160 can be achieved.
Advant Controller 160 is fully modular with use of subracks for all modules. The subracks can
be installed in cabinets or can be mounted directly on the wall. All process connections can be
made to screw terminals on connections units.

4.2 Preconditions and Restrictions

To support Advant Controller 160 version 2.1, Control Builder A version 1.0 or higher includ-
ing Function Chart Builder 6.0 has to be used.

4.3 Product Components

The functional extent of Advant Controller 160 is determined by enabling or adding optional
software modules and by adding hardware units to the Basic Unit.
All standard software options are built-in, some of them already enabled, others need to be
enabled to achieve the desired functional configuration.
Custom made software modules (add-on options, see Section 4.3.1.7 System Software Exten-
sions (Add-on Options)) can to be loaded to the Processor Module to add even more functional-
ity.
Optional hardware units are additional Processor Modules, local or remote I/O, Communication
Interface modules, etc.

4.3.1 Software Components

The system software for Advant Controller 160 is stored in one single program module. This
program module consists of a BASE software providing the basic functionality plus several
built-in options. These options can be combined in any way that is needed to solve the applica-
tion task. A description of the basic functionality and all options is given below.

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Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

4.3.1.1 BASE Software Module

The contents of the PC element library in the BASE software module is shown in Table 4-1. The

Table 4-1. PC Elements in BASE Program Module

Type PC Elements
Structure Elements PCPGM, CONTRM, FUNCM, MASTER, SLAVEM,
BLOCK, SEQ 1, STEP 1, GRC, P_STEP
Logic AND, OR, XOR, INV, AND-TRG, OR-TRG, ADD-MR,
THRESH-L, SR, SR-D, SR-AA, SR-AO, SR-OA, SR-
OO, AND-O, OR-A, BGET, BSET
Arithmetic ADD, SUB, MUL, DIV, ABS, SQRT, LIM-N, DIV-MR,
MULDIV
Time MONO, MONO-UT, TON, TOFF, TON-RET, TRIGG,
OSC-B, TIMER
Registers FIFO, MOVE, REG, SHIFT
Multiplexers MUX-I, MUX-MI, MUX-MN
Code Converters CONV, CONV-BI, CONV-IB
Counters COUNT
Comparators COMP-I, COMP-R, COMP-B, MAX, MIN
Switches SW, SW-C
Redundancy MOVERED 2, RED-STAT
PROFIBUS PB-IN, PB-OUT
Protection PC_AX646, CONV-AX, PC_DX610, SYS-CRC
Supervision SYSL, SYSTIME
1 SEQ and STEP cannot be used with redundant processing (CPU or station redundancy). Instead
GRC and P_STEP can be used.
2 MOVERED is used for planned recursions and for operator commands within application programs
of redundant Processor Modules PM645, PM646, or PM665.

4.3.1.2 Option OPT1: Extended PC

The option “OPT1: Extended PC” extends the PC element library with a set of elements for reg-
ulatory control.

28 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 4.3.1 Software Components

The contents is shown in Table 4-4.

Table 4-2. PC Elements in OPT1: extended PC

Type PC Elements
Registers REG-G, REG-G-UT
Function Generator FUNG-1V
Filter FILT-1P
Feedback P-1, INT, DER, PI, PID, PIP, PDP, CON-PU1, RAMP

4.3.1.3 Option OPT2: MVI Handling

In conjunction with the MVI module CI532V01, V02 or V03, the option “OPT2: MVI Han-
dling” extends the functionality of the controller with the following communication facilities.
1. RCOM/RCOM+
2. Siemens 3964(R)
3. MODBUS

NOTE
Option OPT2 is already enabled in the system software.

CAUTION
Use only one channel on the CI532Vxx board in slave mode.

4.3.1.4 Option OPT3: Events

Option “OPT3: Events” extends the functionality of Advant Controller 160 with event handling
capabilities:
• Detection of events from digital or analog output terminals (calculated events)
• Handling of events from modules DI650, DI651, DI652, DI685, and DI885
• Event handling and event transfer via Advant Fieldbus 100
• Event handling via RCOM/RCOM+ (requires also OPT2)
• Time tagging of events
• Transit of events
OPT3 is already enabled in the system software of Advant Controller 160.

4.3.1.5 Option OPT4: Modbus I RTU

Option “OPT4: Modbus I RTU” extends the functionality of Advant Controller 160 with the
MODBUS I protocol (RTU = binary mode), which is intended for communication with a PC

3BSE 014 721R401 29

Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

based local Operator Station or panel. Advant Controller 160 can be used only as a slave on
MODBUS. Serial interface Com B of the Processor Module is used for this purpose.
The following MODBUS functions (read/write commands) are supported:

Table 4-3. Supported MODBUS functions

01 = Read coil status 06 = Load single register

02 = Read input status 07 = Read exception status
03 = Read holding register 08 = Diagnostic loop-back
04 = Read input register 15 = Force multiple coils
05 = Force single coil 16 = Load multiple registers

4.3.1.6 Option OPT6: St. Red. + RSM

Option “OPT6: St. Red. + RSM” extends the controller functionality with
• Station redundancy and
• Rotational speed measurement.
The contents of the PC element library in OPT6 is shown in Table 4-4.

Table 4-4. PC Elements in OPT6: St. Red. + RSM

Type PC Elements
Measurement elements RSM
Signal Selector MOON
Redundancy TRAC, SW-RED

4.3.1.7 System Software Extensions (Add-on Options)

Although the built-in options often bring great enhancement to the functionality, the need for
customer-specific PC elements may arise to match business unit specific applications.
An extension—in this context—is a PC element or a group of PC elements embraced from a
library that can be loaded to the controller to “extend” its capabilities. If description files for
Control Builder A are added, we rather speak of customer specific add-on options.
In contrast to standard options, these add-on options are usually distributed on a diskette con-
taining:
• the option loader,
• the binary image to be loaded to the controller,
• a batch file for loading the image file
• several description files for Control Builder A plus

30 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 4.3.2 Hardware components

• documentation.
The customer is able to apply the option to Advant Controller and Control Builder A himself.
The loader “adds” the code to the Advant Controller’s system software during run-time.
The advantage is, that there is no need to modify the system software itself. Thereby, the only
limitation for the number of add-on options is the available system FPROM memory of the pro-
cessor module, respectively its RAM size.
The description files for Control Builder A are read and compiled by the Setup Add-ons Utility
on the PC (for instance Advant Station 100 Series Engineering Station). An Add-on option may
also be distributed together with complete PC program applications that make use of PC ele-
ments that are included in the option.

4.3.2 Hardware components

4.3.2.1 Basic Unit

The Basic Unit for Advant Controller 160 comprises the following components (Table 4-5):

Table 4-5. Basic Unit for Advant Controller 160, Components

Component Description
RF616 Subrack.
RC610 Cable duct.
System Software CD-ROM containing System Software, AMPL Libraries,
documentation.

The basic subrack of the controller may consist of one or two subracks.
In accordance to the desired Advant Controller 160 functionality the Basic Unit may be
equipped with a various number of the available Processor Modules and Communication Inter-
faces.
The following rules apply for hardware configuration of the basic station of a controller:
• The two subracks must be put in the same cabinet.
• The power supply terminals (USA, USB, ZD) of the two subracks must be linked. For
EMI considerations, the subracks should be grounded with a 16 mm2 copper lead.
• Up to six Processor Modules can be used within one Basic Unit.
• The Processor Modules must always be put in position 3 to 8 in the basic subrack
• At least one Communication Interface module CI626, CI627, CI630, or CI631 in position
2 is required within any Advant Controller 160 configuration—even if no Advant
Fieldbus 100 communication is required.
• The Communication Interface module for the main Advant Fieldbus 100 must be put in
position 2 (non redundant interface), or in position 1 and 2 (redundant interface) of the
same subrack. Usable Communication Interfaces are CI630 or CI631 for non redundant or

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Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

redundant interface, CI626 or CI627 for non redundant interface only.

• The Communication Interface module for the subordinate Advant Fieldbus 100 must be
put in position 9 or 10 (non redundant interface), in position 9 and 10 (redundant interface)
of the same subrack. Usable Communication Interfaces are CI630 or CI631 for non redun-
dant or redundant interface, CI626 or CI627 for non redundant interface only.
• One Submodule Carrier module per controller is supported. SC610 is not supported by
dual redundant Processor Modules (CPU redundancy). It requires a single Processor Mod-
ule or a Processor Module of type PM645B, PM646, or PM665 within station redundancy.
• If I/O stations are connected, the bus extender modules CI615 can be put in position 3...10
of the basic subrack.
• Up to two optional power supply modules SA610 per subrack can be put in position 9 and
10 (basic subrack) and 19 and 20 (extension subrack).
All modules can be replaced during system operation.

AF 100 Processor Modules

Communication PM640, PM644, Power supply
Interfaces CI630, PM645, PM646, PM665 SA610
CI631
ABB ABB ABB ABB ABB ABB Basic
subrack
RF616

Station voltage
Bus cable cables
TK612 2 × TK615
Slot 1 2 3 4 5 6 7 8 9 10

Ground line
≥ 16 mm2

Extension
subrack RF620

Slot 11 12 13 14 15 16 17 18 19 20

Figure 4-3. Advant Controller 160 with 2x PM, 2x CI, and 2x SA610

For the typical Advant Controller 160 applications the following Basic Unit controller configu-
rations are essential:
• Basic Unit with one Processor Module PM640 for non redundant processing.
• Basic Unit with one Processor Module PM644 for non redundant processing with on-

32 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 4.3.2 Hardware components

board PROFIBUS-DP (master class 1) interface and on-board rotational speed signal input
(e.g. for turbine control).
• Basic Unit with one Processor Module PM645 (type B) for dual or triple redundant pro-
cessing with on-board redundancy voter and on-board rotational speed signal input (e.g.
for turbine control).
– For dual redundancy an additional Processor Module PM645B within the same sta-
tion or in another station is necessary.
– For triple redundancy two additional Processor Modules PM645B within different
stations are necessary.
• Basic Unit with one Processor Module PM646 for dual or triple redundant processing
with on-board redundancy voter.
– For dual redundancy an additional Processor Module PM646 within the same station
or in another station is necessary.
– For triple redundancy two additional Processor Modules PM646 within different sta-
tions are necessary.
• Basic Unit with one Processor Module PM665 for dual or triple redundant processing
with on-board redundancy voter and on-board rotational speed signal input (e.g. for tur-
bine control).
– For dual redundancy an additional Processor Module PM665 within the same station
or in another station is necessary.
– For triple redundancy two additional Processor Modules PM665 within different sta-
tions are necessary.

4.3.2.2 I/O systems

For Advant Controller 160 the S600 local I/O and the S800 distributed I/O systems are used.
The maximum number of I/O signals for an Advant Controller 160 is 1,500. The actual CPU
load depends on the configured cycle times for the application program.

S600 I/O System

A range of I/O modules is available, covering analog and digital signals of various types. In
addition, there are modules for temperature measurement, pulse counting, position measure-
ment and rotational speed measurement applications. The process signals are connected to the
front of the I/O modules.
The controller may contain up to 75 I/O modules. All I/O modules may be exchanged during
system operation. The process signals are disconnected by removing the front connector. A
newly inserted module is automatically put into operation if the system identifies the module as
being of the correct type and without faults. For further information about S600 I/O please refer
to the S600 I/O section in the Input/Output Hardware section.
The S600 I/O Hardware Reference Guide and the S600 I/O Hardware Advant Controller 160
Reference Guide detail the various I/O modules available for Advant Controller 160.
• Unused supervised inputs

3BSE 014 721R401 33

Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

Unused supervised analog inputs of the Advant Controller 160 must be terminated with
external resistors in order to avoid respective error detection and signalling by the Proces-
sor Modules.
• Output set as predetermined
In case of a severe controller error the outputs can be set to predetermined values. This
output set as predetermined guarantees integrity of the process in case of controller fail-
ures.
Output set as predetermined can be configured with use of the relay outputs of the Proces-
sor Modules which are switched over in case of a severe error. Both an open and a closed
contact are provided per Processor Module. E.g. the relay outputs can be used to switch off
the external voltage for digital outputs if the Processor Module which controls theses out-
puts fails.

S800 I/O System

A range of I/O modules is available, covering analog and digital signals of various types. The
I/O system can be mounted horizontally or vertically on standard DIN-mounting rails according
to DIN EN50033–35×15. The process signals are connected via module termination units,
which are acting as I/O module carrier.
An I/O station may have of up to 24 I/O modules. All I/O modules may be exchanged during
system operation. A newly inserted module is automatically put into operation if the system
identifies the module as being of the correct type and without faults.
The general description of the I/O system is given within the Product Guide for Advant OCS
with Master Software, Overview.
• Output set as predetermined
In case of a severe module error, the outputs can be set to predetermined values. This out-
put set as predetermined guarantees integrity of the process in case of failures.

4.3.2.3 Communication
For communication with other Advant Controllers, Operator Stations, and Engineering Stations,
Advant Controller 160 can be connected to Advant Fieldbus 100 using the Communication
Interface module CI626, CI627, CI630, or CI631. Two Communication Interfaces of type
CI630 or CI631 can be used for redundancy. For communication with subordinate Advant Con-
trollers or S800 I/O two (redundant) communication interfaces CI630 or CI631 ore via one (non
redundant) communication interface CI626, CI627, CI630, or CI631 can be used.

Table 4-6. Number of Buses Connected to Advant Controller 160

Maximum number of
Maximum number of
Bus type Communication
buses
Interfaces
RCOM/RCOM+, CI532V01 4 2
MODBUS I, CI532V02 4 total 4 2 total 2

Siemens 3964 (R), CI532V03 4 2

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 Advant® Controller 160 Product Guide
Section 4.3.2 Hardware components

Table 4-6. Number of Buses Connected to Advant Controller 160 (Continued)

Maximum number of
Maximum number of
Bus type Communication
buses
Interfaces
PROFIBUS-DP, PM644 6 6
Advant Fieldbus 100 4 2×4 (redundancy)

NOTE
For performance reasons only one channel on the CI532Vxx can be used if the
module acts as slave.

4.3.2.4 Configurations for Increased Availability and Safety

Advant Controller 160 offers a wide range of configuration options for control system applica-
tions with high requirements concerning availability and safety.
For high availability—depending on the requirements—a single or even a double fault must be
tolerated by the control system. I.e. the configured functions e.g., the control functions of a tur-
bine must run without any interruption in case of a fault.
For safety a single or even a double fault must not impede a needed trip of the plant (e.g. a
boiler or a turbine). Additionally for high availability usually it is required that a single fault
must not activate a trip.
Availability can be increased through redundancy. Advant Controller 160 offers module redun-
dancy for all central system components (communication modules, Processor Modules, power
supply modules). For redundant signal I/O multiple I/O modules within separate controllers can
be used.
Safety can be increased through the use of multiple safety channels working in parallel.
In the following paragraphs the redundant and parallel configurations supported by Advant
Controller 160 and its Processor Modules are shown.
For more detailed information refer to the Advant Controller 160 Users Guide.

Configuration for Redundant Processing

The Processor Modules PM645B, PM646, and PM665 can be used for redundant processing:
Two Processor Modules within one station and with common I/O modules, synchronization via
high speed serial link (Figure 4-4).

3BSE 014 721R401 35

Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

For CPU redundancy Processor Modules PM645, PM646, or PM665 with Communication
Interfaces CI630/CI631 must be used in order to avoid single point of failure, even if no Advant
Fieldbus 100 communication is required.

CPU connection cable

High speed link for redundancy:
connectors:
TK662
link1
link2

PM645A/B
PM645A/B
Basic subrack RF616

Figure 4-4. Dual redundant Processor Module within one Advant Controller 160

Configuration for Parallel Processing with External Voting

All Processor Modules can be used for parallel processing with external voting if the Processor
Modules are allocated within one common station:
• Dual parallel Processor Module
Two Processor Modules within one station with separate output modules and common set
of input modules (Figure 4-5).
• Triple parallel Processor Module
Three Processor Modules within one station with separate output modules and common set

36 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 4.3.2 Hardware components

of input modules (configuration not shown, similar to dual parallel Processor Module).

binary output
binary output
PM64x
PM64x

input
input
Basic subrack RF616

1oo2 external
signal voting
(example: 1oo2)

Figure 4-5. Dual Parallel Processor Module within one Advant Controller 160

The Processor Modules PM645C or PM646 can be used for parallel processing with external
voting if the Processor Modules are allocated within separate stations:
• Dual parallel station
Two Processor Modules within separate stations each with its own set of I/O modules, sen-
sor signal exchange via high speed serial link (configuration not shown, similar to triple
parallel station)
• Triple parallel station
Three Processor Modules within separate stations each with its own set of I/O modules,
sensor signal exchange via high speed serial link (Figure 4-6)
Dependent on the specific configuration additional HW modules and cables for parallel pro-
cessing are needed:
• The parallel Processor Modules within different stations must be connected with one
another via its high speed serial link interfaces. Therefore one connection cable set TK661
is to be used per connection.
• For configurations with parallel Processor Modules the output signals to be provided via
two respectively three separate output modules must be voted externally. Therefore spe-
cific voter devices must be used.

3BSE 014 721R401 37

Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

For Turbine Protection of ABB Turbines, three solenoid valves with electro hydraulic
2oo3 voting is the standard solution.

CPU connection cables

for data exchange:
High speed link
connectors: 3 × TK661
link1
link2
Controller 1 Controller 2 Controller 3

binary output
binary output
binary output
PM645C

PM645C

PM645C

input
input

input
Basic Basic Basic
subrack subrack subrack
RF616 RF616 RF616

2oo3 external
signal
voting

Figure 4-6. Triple Parallel Configuration with 3 Advant Controllers 160

4.3.2.5 System Clock Synchronization

Methods and System Components

Dependent on the specific system configuration using Advant Controller 160 different methods
are available for synchronization of the system time:
• Time and date can be set via AS 100ES, AdvaSoft for Windows and can be downloaded to
Advant Controller 160 at the same Advant Fieldbus 100. Advant Controller 450 can be
loaded from AS 100ES via front connector.
• Clock synchronization via Advant Fieldbus 100 can be done by a controller which is con-
figured as time master through sending the actual time as broadcast message once a second
via Advant Fieldbus 100. Any Advant Controller 4501 or Advant Controller 160 but only
one can be configured as time master. The other controllers and the stations are time
slaves, receive the time sent and update its internal clocks.
• External clock synchronization with use of a minute pulse input is supported for Advant

1. Advant Controller 450 can only be used as time master on Advant Fieldbus 100.

38 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 4.3.2 Hardware components

Controller 160 (with Processor Module PM645, PM646, PM665 via I/O port) and for
Advant Controller 450. The minute pulse must be provided by a central clock, for example
as output of a radio clock.
• External time signal using a DCF77 clock connected to the Com B serial line connector of
the Processor Modules of Advant Controller 160.
• In case of missing synchronization the internal clocks of the controllers and stations pro-
vide the actual time with reduced accuracy.
Table 4-7 gives an overview on the controllers usable as time master for synchronization via
Advant Fieldbus 100 with its used methods and needed system components for system time
input and synchronization.

Table 4-7. System Time Masters for Synchronization via AF 100

System time input and synchronization

System time master
for the time master
Advant Controller 450 Manual setting of time and date via
AS 100ES1 directly connected to Advant
Controller 450 and external synchroniza-
tion via minute pulse input of TC520.
Advant Controller 160 Manual setting of time and date via
AS 100ES, AdvaSoft 2.0 for Windows NT
and external synchronization via minute
pulse input to PM645, PM646, PM665, or
external synchronization via DCF77 time
signal to all Processor Modules.
1 With option Online Builder and Engineering Board

Configurations
Two typical configurations as normally used for control systems are:
• Autonomous control system with Advant Controller 160 and Operator Station AdvaSoft
2.0 for Windows NT.
Control system with several Advant Controller 160 and superordinate Advant Controller 450
and Operator Stations Advant Station 500OS.

Autonomous Control System with Advant Controller 160 and AdvaSoft

The configuration is shown in Figure 4-7.
The Operator Station AdvaSoft 2.0 for Windows NT is time source, Advant Controller 160 on
left is time master and can be synchronized via an external minute pulse. The other controllers
are time slaves. The time master can contain a single Processor Module or dual or triple redun-
dant Processor Modules or up to six Processor Modules for multiprocessing.
In case of redundant Processor Modules, the minute pulse is connected to each Processor Mod-
ule. The active Processor Module is always the time master.

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Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

In case of single Processor Modules or station redundancy, the minute pulse is connected only to
one Processor Module in one controller, which is the time master.
The time master sends time and date cyclically once a second as broadcast message. All other
controllers receive these messages and set its internal clocks. Between two consecutive minute
pulses the time master’s internal clock runs independently ever providing the actual time.

external synchronization via

minute pulse input at I/O port
AdvaSoft 2.0
for Windows NT

Time Source
system time
input to
the time master

T T

actual time to

CI630

CI630
CI630

CI630
CI630

all time slaves

once a second

Advant Controller 160 Advant Controller 160 Advant Controller 160

Time Master Time Slave Time Slave

Figure 4-7. System Clock Synchronization within an Autonomous Control System

using AC 160 and AdvaSoft 2.0 for Windows NT

Control System with Superordinate Advant Controller 450

The configuration is shown in Figure 4-8.
The controller Advant Controller 450 is time master. It can be synchronized via MB300 or via
an external minute pulse. The other controllers at the Advant Fieldbus 100 are time slaves.
Advant Controller 450 cyclically sends time and date once per second as broadcast message via
Advant Fieldbus 100.
The other controllers receive these messages and set its internal clocks.

40 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 4.3.2 Hardware components

Between two consecutive minute pulses the time master’s internal clock runs independently
ever providing the actual time.

synchronization
via MB300
external synchronization
via minute pulse input

Advant Controller 450

actual time to
Time Master all time slaves
once a second

T T
CI630
CI630

CI630

CI630
CI630

CI630
Advant Controller 160 Advant Controller 160 Advant Controller 160
Time Slave Time Slave Time Slave

Figure 4-8. System Clock Synchronization within a Control System using

AC 160 with Superordinate AC 450 and AS 500OS

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Advant® Controller 160 Product Guide
Chapter 4 Advant Controller 160 Configurations

Synchronizing Multi Processor Systems with Minute Pulse

The configuration is shown in Figure 4-9. All Processor Modules receive the same minute
pulses from an external clock. Pin 4 (external time sync) and Pin 6 (GND) of the I/O port are
used.

PM645 or PM665

External
minute pulse
I/O port

Figure 4-9. Time Synchronization of Several Processor Modules

Connecting a DCF77 Clock to Com B

All Processor Module are capable to connect to a DCF77 clock via serial port Com B. The con-
nection depends on the type of DCF77 clock being used. The following example shows the pin-
out for the “Hopf 7001 DCF” clock:

Table 4-8. Connection Hopf 7001 DCF to Com B

Processor
Signal from
Module
Hopf 7001 DCF
Com B
Pin 2 – TxD Pin 3 – RxD
Pin 7 – GND Pin 5 – GND

42 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section

Chapter 5 Mechanical Design

Mechanically, Advant Controller 160 consists of subracks, cable ducts, modules and process
connectors.
The mechanical design of the S600 and S800 I/O modules is described in detail in two separate
Product Guides.
The subracks and cable duct are designed for wall mounting.
The 10-position controller subrack, RF616, is the primary subrack. It provides dedicated posi-
tions for Processor Module, Communication Interface and Bus Extender modules. There is a
two-digit thumb wheel switch for setting the station address. The individual module address is
given by its position in the subrack.
The bus connector links the controller subrack to an optional extension subrack via a bus cable
(TK612). The 10-position extension subrack, RF620, extends the number of I/O modules of a
station. The individual module address is given by its position in the subrack.
The cable duct, RC610, holds the process cables. It also provides ten screw terminals for con-
necting the cable shields of process cables to ground.
Figure 5-1 shows the physical layout and Figure 5-2 the dimensions of a fully equipped subrack
with cable duct.

Processor module Power supply

ABB ABB Basic
subrack
RF616

Station
Bus cable voltage cable
TK612 TK615
Slot 1 2 3 4 5 6 7 8 9 10

Ground line
≥ 16 mm2

Extension
subrack RF620

Slot 11 12 13 14 15 16 17 18 19 20

Figure 5-1. Physical Layout of Subrack

3BSE 014 721R401 43

Advant® Controller 160 Product Guide
Chapter 5 Mechanical Design

482 (19)
320 (12.6)
440 (17.3)
ABB ABB ABB ABB ABB ABB ABB ABB ABB ABB 40.7 (1.6) 120
(4.7)
269 (10.6) 57.15 (2.25)

76.2 (3.0)

57.15 (2.25)

87.7 (3.5)
(4.0)

Cable duct
100

464 (18.3) 325 (12.8)

Figure 5-2. Dimensions of Subrack and Cable Duct

Advant Controller 160 can be delivered as separate subracks for mounting in any suitable cabi-
net, but it can also be delivered in standard RM5xx cabinets, please refer to Chapter 8.
Full information for mounting Advant Controller 160 in cabinets is given in the cabinets chapter
of the Product Guide for Advant OCS with Master Software, Overview, or for details in the
Advant Controller 160 User’s Guide.

44 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 6.1 General Data

Chapter 6 Technical Data and Performance

6.1 General Data

The following configuration rules apply to an Advant Controller 160:

Table 6-1. Maximum Configuration of Advant Controller 160

Item Max. no.

I/O signals 1,500 1
S600 I/O modules 75 1
Basic Units 1
Subrack per Basic Unit 2
S600 I/O stations 7
Subracks per I/O station 2
S800 I/O stations connected to Advant Fieldbus 100 32
S800 I/O modules per I/O station 24
2,3
Advant Fieldbus 100 Communication Interface modules 1–8
S800 I/O clusters 24
Processor Modules 65
6,7
Submodule carrier module (SC610) 1
1 These limits are practical ones.
2 At least one Communication Interface (CI626, CI627, CI630, CI631) is required for any Advant
Controller 160 configuration. For redundant Processor Modules 2× CI630/CI631 are recommended.
3 For non redundant communication with Advant Fieldbus 100, max. 4 modules of type CI626/CI627
can be used instead of CI630/CI631. In redundant configurations 4 pairs of CI630/CI631 must be
used.
4 All I/O modules have to be configured without gap, so 24 modules occupy a maximum of 2 cluster.
5 Must be put into the controller basic subrack (position 3–8)
6 SC610 can hold up to 2 MVI modules.
7 Not supported by dual redundant Processor Modules (CPU redundancy), requires one PM640 or
PM644 or PM645B or one PM665 in station redundancy.

6.2 Communication
Data Set elements hold references to DAT elements. Up to eight DAT elements can be con-
nected to one Data Set.
A DAT element can hold one variable representing:
• 32 Booleans (32 bits) or 1 real number (32 bits) or
• 1 long integer number (32 bits) or 1 short integer number (16 bits).

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Advant® Controller 160 Product Guide
Chapter 6 Technical Data and Performance

The Data Set communication service cyclically transfers information from the DAT elements
specified in the sending controller to the DAT elements specified in the receiving controller. The
cycle time for each Data Set can be selected from the range 2 ms to 4 s.
The Data Set communication service is based on the broadcast principle, allowing any station to
receive any Data Set sent on the bus. The advantage of broadcasting is that information only
needs to be transmitted once regardless of the number of receiving stations. This principle is
highly efficient when the same information is required in two or more stations, especially in
time-critical applications.

Advant Fieldbus 100

Send Receive Receive

Data Data Data
Set Set Set
1 8 1 8 1 8
DAT DAT DAT
Station 1 Station 2 Station 3

Figure 6-1. Data Set Communication

The Data Set communication uses resources on Advant Fieldbus 100, in the Communication
Interface modules and also in the Processor Module. The system data shown in Table 6-2 and
Table 6-3 are valid both for the main control Advant Fieldbus 100 and the second (subordinate)
control Advant Fieldbus 100.

Table 6-2. Data Set Communication for Advant Controller 160

Description Maximum No.

Maximum number of Data Sets (send and receive) per Pro- 250
cessor Module
Maximum number of Data Sets (send and receive) per con- 400
troller
DAT elements per Data Set 1 to 8
Selectable cycle times 2 to 4096 ms

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 Advant® Controller 160 Product Guide
Section 6.2.1 RCOM/RCOM+ Communication

Advant Fieldbus 100 runs at 1.5 Mbits/s. The transfer time for one Data Set is shown in the fol-
lowing table.

Table 6-3. Data Set Transfer Times for Advant Fieldbus 100

Data Set Size

Transfer Time
(= DAT Element per
Ttr
Data Set)
1 0.088 ms
2 0.108 ms
4 0.156 ms
8 0.252 ms

To estimate the bus load for a given application, the following formula should be used.
Bus load in percent = ((N × Ttr) / Tc) × 100%, where:
N = the number of Data Sets (of the same size and Tc)
Ttr = the transfer time in ms (from the above table)
Tc = desired cycle time in ms (2, 4, 8, 16, …, 4096)
The resulting load must not exceed 75%, the remaining capacity must be reserved for back-
ground communication (e.g., remote programming).
Note that only the sending Data Sets are to be included in the calculation.

6.2.1 RCOM/RCOM+ Communication

An MVI channel may act as master or slave. In case of master operation it can have up to 25
slaves. Data between master and slave station is transferred using MVB elements (MVI data
block) which is similar to Data Set elements. MVB elements hold references to DAT elements.
1 to 8 DAT elements can be connected to one MVB with RCOM. RCOM supports 1 to 8 DAT
and RCOM+ supports 1 to 24 DAT’s.

Table 6-4. Data Communication on RCOM/RCOM+

Description Maximum No.

Number of nodes per MVI channel 25 1
Number of RCOM/RCOM+ networks per 4
Advant Controller 160 master
Number of slaves per Advant Controller 160 50 1
Number of MVB’s per Advant Controller 160 500
Number of MVB’s per MVI channel 340
1 The maximum number of event generating slaves in an AC 110/AC 160 network is limited to 16.

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Advant® Controller 160 Product Guide
Chapter 6 Technical Data and Performance

The number of MVI data blocks that can be exchanged via the serial interface depends on the
transmission speed and the specified cycle time. For performance estimation—including result-
ing CPU load—the figures for Advant Controller 110 within Advant OCS Product Guide as
worst case figures can be used.

6.2.2 PROFIBUS-DP Communication

The PM644 is installed in the basic station of Advant Controller 160. It is equipped with one
PROFIBUS-DP master interface which allows to use PROFIBUS I/O devices as distributed I/O.
The setup of this link is defined by a number of database elements. The PROFIBUS link forms
a local control network within the Advant system with the network numbers 1 to 9. Each I/O
device may have a number from 0 to 125.

Table 6-5. Data Communication on PROFIBUS-DP

Description Maximum No.

Number of buses per PM644 1
Number of slaves per bus 125
Number of nodes 1 per segment 32
1 A node is a PROFIBUS slave, the repeater or master.

The maximum distances that can be covered with PROFIBUS-DP depend on the used transmis-
sion speed:

Table 6-6. Distance Based on Transmission Speed on PROFIBUS-DP

Transmission Speed (Kbit/sec) Distance / Segment

9.6 1,200 m
19.2 1,200 m
93.75 1,200 m
187.5 1,000 m
500 400 m
1,500 200 m
12,000 100 m

6.3 Event Transfer and Detection

Events can be detected with Digital Input modules DI650, DI651, DI652, DI685, DI885 or as
calculated DI events. After the detection of an event in Advant Controller 160 the event can be
transferred via RCOM/RCOM+ or Advant Fieldbus 100 to a Advant Controller 400 Series or to
SattGraph 5000/AdvaSoft 2.0 for Windows NT Operator Station with OPC Server for further
treatment. For each event queue (database element EVS(T) or EVS(S) in Advant Controller

48 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 6.4 Interface for a Local Operator Station

160), up to 10 nodes on the Advant Fieldbus 100 network can be assigned to receive this event
message.
The relative time errors between events detected in different Advant Controllers 160 within the
same Advant Fieldbus 100 is < 10 ms. Relative time error within one controller is ≤ 1 ms. For
more information about event transfer and detection, please refer to Table 6-7.

Table 6-7. Event Transfer and Detection

Description Maximum No.

Event queues per Processor Module 32
Event entries per event queue 1,024
Event set elements per Processor Module 32
Event detection elements per event set element 32
Total number of event detection elements per Processor 1,024
Module

Table 6-8. Event Transfer and Detection Resolution

Description Minimum
Accuracy of calculated events DIC, AIC 10 ms 1
Resolution of events from digital inputs (DI650, DI651, 1 ms
DI652, DI685, DI885).
1 accuracy depends on selected scan time, with time stamp resolution 1 ms. Recommended scan
time is 640 ms.

6.4 Interface for a Local Operator Station

Advant Controller 160 Processor Modules include an asynchronous serial interface (Com B),
which is intended only for communication with a PC-based Human Machine Interface (HMI)
package (3rd party product). In Advant Controller 160 data is exchanged, with e.g. the HMI
package, by means of PARDAT elements. The supported communication protocol on this serial
interface is the MODBUS I protocol. The serial interface on the CPU can only be used as a
slave on MODBUS.
The number of MODBUS I commands that can be exchanged via the serial interface is depend-
ing on the type of command and also on the load of the CPU. For performance estimation the
figures for Advant Controller 110 within Advant OCS Product Guide as worst case figures can
be used.

6.5 Cycle and Scan Times

An Advant Controller 160 application program consists of one AMPL program (PCPGM)
which can be further divided into a maximum of 31 (PM665: 63) execution modules (CON-
TRM, MASTER) or sequence modules (SEQ). Note that SEQ and STEP cannot be used with

3BSE 014 721R401 49

Advant® Controller 160 Product Guide
Chapter 6 Technical Data and Performance

redundant processing. Instead GRC and P_STEP can be used. Different cycle-times may be
assigned to the execution modules so that the AMPL program can include both fast and slow
control functions. Cycle times can be chosen from the range 2 ms to 20 s in steps of 2 ms. For
applications with redundant Processor Modules cycle times smaller than 10 ms are not applica-
ble.
For triple redundant configuration maximum cycle time is 1 second.
Control tasks with shorter cycle times always have a higher priority than those with longer cycle
times. The execution order of modules with equal cycle times can be selected explicitly. Activa-
tion once at start can be chosen by the CONTRM’s call parameter C2.

6.6 I/O Scanning

The scanning of I/O modules is directly related to the cycle time of the execution module.
Each execution module reads its inputs before execution of its AMPL elements. This guarantees
a consistent image of the process signals. After execution of the AMPL elements, the module
writes the calculated results to the outputs.

6.7 CPU Load Calculation

To determine the CPU load for an Advant Controller 160, the maximum load values available
for the application program as shown in Table 6-9 must be considered.

Table 6-9. Maximum Usable CPU Load for Application Program

Maximum load Maximum load

Maximum
per controller per controller
CPU configuration load per CPU
with single CPUs with redundant
[%]
[%] CPU pairs [%]
2 single CPU’s or 70 2 × 70 70
1 redundant pair
4 single CPU’s or 70 4 × 60 2 × 60
2 redundant pairs
6 single CPU’s or 70 6 × 50 3 × 50
3 redundant pairs

6.8 CPU Load Calculation, Data Set Communication

The OCS Product Guides provides load data from Data Set communication for Advant Control-
ler 110. These data can be used for PM640, PM644, PM645, and PM646 if divided by 3. For
PM665 this has not been measured yet.

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 Advant® Controller 160 Product Guide
Section 6.9 Memory Requirements

6.9 Memory Requirements

1 Mbyte of memory is available for the application program. For a rough calculation of the
application memory requirements, the following table can be used.

Table 6-10. Memory Requirements for 7 Different Application Programs

Needed
Program Input/Output
Program description memory size
No. Data Set
(kByte)
1 1 CONTRM with 16 × 3 input AND. 48 inputs 3.25
16 outputs
2 1 CONTRM with 32 × 2 input AND. 64 inputs 3.75
32 outputs
3 1 CONTRM with 32 × 2 input AND + 96 inputs 6.0
1 CONTRM with 16 × 2 input AND. 48 outputs
4 5 CONTRM each with 32 × 2 input AND. 320 inputs 12.0
160 outputs
5 2 CONTRM each with 16 × 2 input AND + 1024 inputs 37.5
15 CONTRM each with 32 × 2 input AND. 512 outputs
6 As 3 plus 96 inputs 8.6
1 CONTRM with each 5 × 4 inputs and 48 outputs
outputs via Advant Fieldbus 100. 10 Data Sets
(each DS with
4 DAT’s)
7 As 3 plus 96 inputs 19.1
1 CONTRM with each 50 × 4 inputs and 48 outputs
outputs via Advant Fieldbus 100. 100 Data Sets
(each DS with
4 DAT’s)

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Chapter 6 Technical Data and Performance

52 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 7.1 Environmental Considerations

Chapter 7 Environmental Immunities

7.1 Environmental Considerations

General
Advant Controller 160 is designed for a demanding industrial environment. Alternative cabinets
is available for different degrees of protective rating (IP21, IP41, IP54). Interference from elec-
trical sources is suppressed by a suitable solid design and particular installation rules. The build-
ing where the system is to be stored or installed should provide an environment such that
established environmental conditions are not normally exceeded.
A hardened enclosure protects the printed circuit boards from mechanical and electrostatic dam-
age and from electromagnetic interference. The equipment complies with the EC directives 89/
336/EEC on electromagnetic compatibility, 73/23/EEC and 93/68/EEC on low-voltage appara-
tus. Limit values are given to: Corrosive gases, Temperature, Vibration, Moisture, Electro-Mag-
netic Compatibility, etc.
For further information about the environmental immunity, please refer to the Environmental
Immunities chapter in the Advant OCS with Master Software, Overview Product Guide.

Temperature
It is important to note the temperature within cabinets and in the surrounding environment and
atmosphere. Lower temperatures mean increased system reliability and availability.
The lives of wet, electrolytic capacitors and most semiconductors are greatly reduced if the
maximum permitted temperatures are exceeded.
To avoid overheating, when ambient temperatures are high, take into consideration the heat dis-
sipated in the cabinet. This is particularly important with sealed cabinets (IP54) with consider-
able number of circuit boards and ambient temperatures at levels approaching 40°C. It might be
necessary to mount heat exchangers on the cabinet to bring down the temperature to levels
below limits given in the environmental data sheet.
The different hardware modules in the controller and the I/O system have different outputs of
heat. Accurate calculation of the heat produced by the system requires knowledge of the mod-
ules and the work cycle.
Maximum permitted temperature above the subracks in the cabinet is 55°C.

NOTE
There is normally no requirements for fans in an Advant Controller 160.

3BSE 014 721R401 53

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Chapter 7 Environmental Immunities

54 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 8.1 Price List Structure

Chapter 8 Ordering

8.1 Price List Structure

Depending on the desired I/O configuration one or several price books and price lists must be
used when ordering an Advant Controller 160 with local S600 I/O, distributed S800 I/O or addi-
tional hardware modules to support enhanced features, e.g., burner management, turbine con-
trol, or safety applications.

Advant Controller 160 Version 2.1 (3BSE020695/B)

Price Book AC 55/70/110/160, AdvaSoft and OPC Server (3BSE001780/L).
See this Product Guide.

S800 I/O Version 3.2 (3BSE014394/D)

Price Book S800 I/O (3BSE020696/A).
See S800 I/O Product Guide (3BSE015969R301).

Spare Parts (3BSE001783/K)

Price Book AC 55/70/110/160, AdvaSoft and OPC Server (3BSE001780/L).
See this Product Guide.

8.2 Assembled Delivery or Loose Part Delivery

The item Assembly and test in Table 8-1 determines if the controller shall be mounted in cabi-
nets or not. If this item is not ordered the delivery will be a loose part delivery.
Note also that in Table 8-1 the items for CE-marking are different for an assembled delivery and
for a loose part delivery.

8.3 Loose Part Delivery and CE-marking

If an Advant Controller 160 is ordered as a loose part delivery and the intention is to mount the
equipment in other cabinets than RM500, certain considerations must be taken to make it follow
the provisions of the EMC Directive 89/336/EEC, Low Voltage Directive 73/23/EEC, and 93/
68/EEC.
• The cabinet or series of cabinets mounted side by side must be radio-proof.
• Protection against line conducted radio emissions is obtained by means of a mains net fil-
ter placed in the cabinet close to the incoming mains cable.
• Communication cable shields must have a capacitive grounding at the point where they
enter the cabinet.
The conditional EC-Declaration of Conformity, which accompanies the loose part delivery,
must be signed by the person responsible for assembling the controller in cabinets.

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Advant® Controller 160 Product Guide
Chapter 8 Ordering

8.4 Reference Guide

This is the Reference Guide for Price List 3BSE020695/B.

8.4.1 General and Normative Requirements

Table 8-1. General and Normative Requirements

Description Consists of Article No.

CE-marking, Cabinet EC Declaration of Confor- 3BSE009129R1
Mounted Delivery mity Mains Filter.
CE-marking, Loose Parts Conditional EC Declara- 3BSE009130R1
Delivery tion of Conformity.

8.4.2 Basic Unit

Table 8-2. Basic Units

Description Consists of Article No.

Advant Controller 160 2.1 Basic Unit, RF616, RC610, 3BSE005559R3
Consisting of: Software on CD-
Subrack, cable duct, software license, CD- ROM.
ROM including system software, AMPL
Libraries, system software extensions, user
documentation.

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 Advant® Controller 160 Product Guide
Section 8.4.3 Hardware Options

8.4.3 Hardware Options

Additional hardware modules and equipment to support enhanced features, e.g., burner manage-
ment, turbine control, or safety applications, can be ordered directly via Price List Advant Con-
roller 160 Special Items (3BDS 100 580) of Regional Center Germany.t

Table 8-3. Hardware Options

Description Consists of Article No.

Dummy Module RB601 3BSE002803R1
I/O Fan Unit 24 V RC620 3BSE003097R1
CPU Communication Cable Set W173 GKWF310703R1
used to load the communication section
(CS) software of a Processor Module.
PM640 Processor Module, PM640 3BSE010534R1
for non redundant processing
PM644 Processor Module, PM644 3BSE014664R1
for non redundant processing, PROFIBUS-
DP, rotational speed signal input.
PM645B Processor Module1, PM645B 3BSE010535R1
for redundant processing, high speed link,
rotational speed signal input.
PM646 Processor Module, PM646 3BSE014700R1
for redundant processing with additional
monitoring functions for safety application
systems.
PM665 Processor Module, PM665 3BDS005799R1
Power PC based. For redundant process-
ing, high speed link, rotational speed signal
input, and high performance requirements.
1 PM645B replaces Processor Modules PM645A and PM645C that are no longer available.

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Advant® Controller 160 Product Guide
Chapter 8 Ordering

8.4.4 Upgrade and Update

Available upgrades and updates of Advant Controller 160 Software. for an upgrade or update
order you have to state the SEAPR order number of the original delivery. An upgrade or update
cannot be ordered together with any other item in the price list.

Table 8-4. Upgrades and Updates of Advant Controller 160 Software

Description Consists of Article No.

Upgrade Advant Controller 160 Software Software on CD- 3BDS005572R3
to version 2.1. The upgrade license is valid ROM.
for all Processor Modules in one Basic Rack
RF616.
Update Advant Controller 160 Software to Software on CD- 3BDS005591R3
latest revision of version 2.11 ROM.
1 Updates can be ordered after release of a new revision and approved Status Report.

8.4.5 Communication
Table 8-5. Advant Fieldbus 100

Description Consists of Article No.

Advant Fieldbus 100 terminator kit 1 × 75 Ω BNC terminator 3BSE006244R1
coaxial (1 kit required per bus cable) plug
1 × ditto with ground lead
Modem for Advant Fieldbus 100 TC630 3BSE002253R1
conversion coaxial/optical
CI626 Advant Fieldbus 100 interface 1 Bus interface CI626, 3BSE004006R1
kit to single line (coaxial) AF 100 connector kit for
one bus line only
CI627 Communication Interface 1 Bus interface CI627, 2 3BSE009799R1
(twisted pair) connectors for AF 100
CI630 Advant Fieldbus 100 interface 1 Bus interface CI630, 3BSE011001R1
kit to single line (coaxial) AF 100 connector kit for
one bus line only
CI630 Advant Fieldbus 100 interface 1 Bus interface CI630, 3BSE011002R1
kit to redundant bus (coaxial) AF 100 connector kit for
both bus lines
CI631 Communication Interface 1 Bus interface CI631, 2 3BSE016347R1
(twisted pair) connectors for AF 100
Modem for Advant Fieldbus 100 TC513V1 3BSE018405R1
conversion coaxial/twisted pair

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 Advant® Controller 160 Product Guide
Section 8.4.5 Communication

Table 8-5. Advant Fieldbus 100 (Continued)

Description Consists of Article No.

Modem for Advant Fieldbus 100 TC514V2 3BSE013281R1
conversion twisted pair/optical
Modem for Advant Fieldbus 100 TC515V2 3BSE013284R1
repeater twisted pair/twisted pair
Advant Fieldbus 100 terminator TC501V150 3BSC550038R1
twisted pair (1 required per bus
cable)
Advant Fieldbus 100 Trunk Tap for TC506 3BSC840074R1
twisted pair
Advant Fieldbus 100 Connection AF100K01 3BSE005544R1
Kit to optical
Advant Fieldbus 100 Connection AF100K02 3BSE005545R1
Kit to redundant bus coaxial (two
bus lines)
Advant Fieldbus 100 Connection AF100K03 3BSE006251R1
Kit for single line

Table 8-6. Multi Vendor Interface

Description Consists of Article No.

Submodule Carrier, required for connec- SC610 3BSE001552R1
tion of CI532. Two CI532 fit into one carrier.
MVI, Multi Vendor Interface with RCOM/ CI532V01 3BSE003826R1
RCOM+ protocol. It holds two buses.
MVI, Multi Vendor Interface with MODBUS I CI532V02 3BSE003827R1
protocol. It holds two buses.
MVI, Multi Vendor Interface with Siemens CI532V03 3BSE003828R1
3964(R) protocol. It holds two buses.
Short Distance Modem for cable length < TC562 3BSC630049R1
10 km. Power 24V d.c., width = 55 mm.
Cable Assembly for connection of CI53x to TK595 3BSE006830R1
modem TC562.

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Advant® Controller 160 Product Guide
Chapter 8 Ordering

Table 8-6. Multi Vendor Interface (Continued)

Description Consists of Article No.

SERCOS Interface.1 SC610, CI590, 3BHS105393
TC590V02
Interbus S Interface.1 CI680, software 3BHF000357R1
on diskette
1 Can be ordered directly at CHIND – BU Printing, Dept. IDR (phone: +41 56486 8859).

8.4.6 Power System

Table 8-7. Power Supply in Rack

Description Consists of Article No.

Power supply module SA610 3BSE000655R1
Input: 110/120/220/240 V a.c. or Open-ended mains cable
110/220/250 V d.c. Connector for relay output
Output: 24 V, 60 W, d.c. Fits sub-
rack

Table 8-8. Power Supply in RM5xx (width 800 mm)

Description Consists of Article No.

Power supply Kit SA161 3BSE005746R1
Input: 120 V a.c. Including power switch,
Output: 24 V, 10 A, d.c. mounting plate and cables
Power supply Kit SA162 3BSE005747R1
Input: 230 V a.c. Including power switch
Output: 24 V, 10 A, d.c. and cables
Power supply Kit SA610 3BSE005748R1
Input: 110/120/220/240 V a.c. or Including power switch,
110/220/250 V d.c. mounting plate and cables
Output: 24 V, 60 W, d.c.

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 Advant® Controller 160 Product Guide
Section 8.4.6 Power System

Table 8-9. Power Supply in RM5xx (width 700 mm)

Description Consists of Article No.

Power supply Kit SA161 3BSE007040R1
Input: 120 V a.c. Including power switch,
Output: 24 V, 10 A, d.c. mounting plate and cables
Power supply Kit SA162 3BSE007041R1
Input: 230 V a.c. Including power switch
Output: 24 V, 10 A, d.c. and cables
Power supply Kit SA610 3BSE007042R1
Input: 110/120/220/240 V a.c. or Including power switch,
110/220/250 V d.c. mounting plate and cables
Output: 24 V, 60 W, d.c.

Table 8-10. Power Supply for Field Equipment

Description Consists of Article No.

Single a.c Power Supply SA161 3BSE003591R1
Input: 120 V a.c., 50/60 Hz SX554
Output: 24 V, 10 A, d.c., unregulated TK402V027
Single a.c Power Supply SA162 3BSE003592R1
Input: 230 V a.c., 50/60 Hz SX554
Output: 24 V, 10 A, d.c., unregulated TK402V027
Single a.c Power Supply SA171 3BSE003593R1
Input: 120 V a.c., 50/60 Hz SX554
Output: 48 V, 5 A, d.c., unregulated TK402V027
Single a.c Power Supply SA172 3BSE003594R1
Input: 230 V a.c., 50/60 Hz SX554
Output: 48 V, 5 A, d.c., unregulated TK402V027

Table 8-11. Main Supply Filter

Description Consists of Article No.

Main Supply Filter, 250 V, 20 A – 3BSC740007R1

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Advant® Controller 160 Product Guide
Chapter 8 Ordering

Table 8-11. Main Supply Filter (Continued)

Description Consists of Article No.

Main Supply Filter, 250 V, 55 A – 3BSC740008R1
Main Supply Filter, 250 V, 80 A – 3BSC740009R1
For DC main supply, 24 V d.c., 48 V d.c.

8.4.7 S600 I/O

Table 8-12. S600 I/O Units

Description Consists of Article No.

I/O station, non redun- Subrack RF615, Cable duct RC610 3BSE000650R1
dant bus extender Bus extender CI610
I/O extension kit Subrack RF620, Cable duct RC610 3BSE011071R1
Bus cable TK612, Power cable
TK615
I/O bus extension kit Bus extender CI615 for base station 3BSE000756R1
Bus terminator TC610 for I/O exten-
sion bus
I/O station, redundant Subrack RF615, Cable duct RC610 3BSE011004R1
bus extender 2 Bus extenders CI610

Table 8-13. S600 Analog Input Modules

Description Consists of Article No.

32 channels, 12 bits resolution, single AI610 3BHT300000R1
ended, 0-20 mA, shunt 250 Ω
16 channels, 12 bits resolution, differen- AI620 3BHT300005R1
tial, 0-20 mA, 4-20 mA, ±20 mA or ±10 V,
shunt 250 Ω, CMV 100 V, CMRR > 80 dB
(16 2/3, 50 or 60 Hz)
16 channels, 12 bits resolution, galvanic AI625 3BHT300036R1
isolated as one group, 0-20 mA, CMV 50 V,
CMRR> 100 dB, Shunt 100 Ω

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 Advant® Controller 160 Product Guide
Section 8.4.7 S600 I/O

Table 8-13. S600 Analog Input Modules (Continued)

Description Consists of Article No.

12 channels for Pt100 or resistance, 3- or AI630 3BHT300011R1
4-wire (2 wire with extra wiring om process
connector), 13 bits resolution, -200 to
+600°C or 0-500 Ω, 0.5 V, CMRR > 100 dB,
opto-isolated as one group
14 channels for thermocouple or milli- AI635 3BHT300032R1
volts and 2 channels for ambient (CJ)
temperature measurement with Pt100,
12 bits resolution, CMRR > 120 dB, opto-
isolated as one group

Table 8-14. S600 Analog Output Modules

Description Consists of Article No.

16 channels, 12 bits resolution, 0-20 mA, AO610 3BHT300008R1
0-10 V, opto-isolated as one group
8 channels, 12 bits resolution, 0-20 mA, AO650 3BHT300051R1
4-20 mA ±20 mA, 0-5 V, 0-10 V, 1-5 V,
±10 V, each channel opto-isolated

Table 8-15. S600 Analog Input/Output Modules

Description Consists of Article No.

AX645, 16 analog input channels, 4- AX645 3BHB001914R1
20 mA, each configurable as input or output,
14 Bits resolution for input, 16 Bits resolu-
tion for output, opto-isolated as one group

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Advant® Controller 160 Product Guide
Chapter 8 Ordering

Table 8-16. S600 Pulse Counting Module

Description Consists of Article No.

5 counter channels, each with two counter DP620 3BHT300016R1
inputs, max 100 kHz and one Strobe and
one Set input, ±13 mA, 24 V d.c. or 5 V d.c.
(only 24 V for Set), each input individually
opto-isolated, connection via 15 Pin Sub-D
for each channel.
Operation modes:
1. Up- & down- counting
2. Frequency & difference measurement
3. Difference measurement
4. Position & rotational speed measurement
Cable Kit for DP620. Connection unit TX620K01 3BSE009963R1
TX620 and cable assemblies TK620V030.
Speed meter input, max 50 kHz, ±13 mA, DP640 3BHT300057R1
24 V d.c. or 5 V d.c., detection of direction
through second speed meter input, over-
speeed trip logic with
trip signal output via solid state 24 V d.c.
and dry contact 60 V d.c., speed meter
inputs and solid state output are individually
opto-isolated.

Table 8-17. S600 Digital Input Modules

Description Consists of Article No.

32 channels, 24 V d.c., non-isolated DI610 3BHT300004R1
32 channels, 24 V d.c., opto-isolated in four DI620 3BHT300002R1
groups
32 channels, 48 V d.c., opto-isolated in four DI621 3BHT300012R1
groups
32 channels, 60 V d.c., opto-isolated in four DI622 3BHT300013R1
groups
16 channels, 120 V a.c., opto-isolated in DI635 3BHT300015R1
four groups
16 channels, 230 V a.c., opto-isolated in DI636 3BHT300014R1
four groups

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 Advant® Controller 160 Product Guide
Section 8.4.7 S600 I/O

Table 8-17. S600 Digital Input Modules (Continued)

Description Consists of Article No.

32 channels, 24 V d.c., opto-isolated in four DI650 3BHT300025R1
groups, sequence of event or pulse catching
capability
32 channels, 48 V d.c., opto-isolated in four DI651 3BHT300026R1
groups, sequence of event or pulse catching
capability
32 channels, 60 V d.c., opto-isolated in four DI652 3BHT300027R1
groups, sequence of event or pulse catching
capability
32 channels, 24/48 V d.c., internal 48 V DI685 3BSE011613R1
sensor power supply, opto-isolated,
sequence of event capability, wire break
supervision

Table 8-18. S600 Digital Output Modules

Description Consists of Article No.

32 channels, 24 V d.c., short-circuit proof DO610 3BHT300006R1
transistors, max. 200 mA, non-isolated
32 channels, < 60 V d.c., short-circuit proof DO620 3BHT300009R1
transistors, max. 0.5 A, opto-isolated in four
groups
16 channels, 24 V d.c., short-circuit proof DO625 3BHT300040R1
transistors, max. 2.4 A, isolated in eight
groups
16 channels, 24-250 V a.c./d.c., relay con- DO630 3BHT300007R1
tacts 1, 2
6 channels, < 60 V d.c., relay contacts DX610 3BSE013087R1
each output separately isolated.
1 Relay data Load current: max 2 A min 20 mA Breaking Capacity: a.c. max 500 VA d.c. max 40 W
2 Relay data Load current: max 2 A, Breaking Capacity: max 120 W for d.c. loads

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Advant® Controller 160 Product Guide
Chapter 8 Ordering

8.4.8 Cables and Connectors

Table 8-19. Cables and Connectors

Description Consists of Article No.

Front connector with screw terminals TF620 3BHT100013R1
Process cable w. fitted connector TF610, TK630V030 3BSC950007R1
unscreened, l = 3 m (9.8 ft.)
Process cable w. fitted connector TF610, TK630V050 3BSC950007R2
unscreened, l = 5 m (16 ft.)
Process cable w. fitted connector TF610, TK630V110 3BSC950007R3
unscreened, l = 10 m (32.8 ft.)
Process cable w. fitted connector TF610, TK640V030 3BSC950008R1
screened, l = 3 m (9.8 ft.)
Process cable w. fitted connector TF610, TK640V050 3BSC950008R2
screened, l = 5 m (16 ft.)
Process cable w. fitted connector TF610, TK640V110 3BSC950008R3
screened, l = 10 m (32.8 ft.)
Terminal unit TX650 AC110K11 3BSC840005R1
one per I/O module is required
Mounting bar for terminal unit RA620 AC110K09 2166 0559-F
Cable from base to I/O station, 2.5 m (8 ft.) TK610V025 3BHT200007R1
Cable from base to I/O station, 5 m (16 ft.) TK610V050 3BHT200008R1
Cable from base to I/O station, 10 m (32 ft.) TK610V110 3BHT200009R1

Table 8-20. Cable Set for Redundant and Parallel Processing

Description Consists of Article No.

CPU connection cable set for data TK661V003 3BSE010995R1
exchange (parallel processing), l = 30 cm
CPU connection cable set for data TK661V005 3BSE010995R2
exchange (parallel processing), l = 50 cm
CPU connection cable set for data TK661V060 3BSE010995R3
exchange (parallel processing), l = 6 m
CPU connection cable set for data TK661V080 3BSE010995R4
exchange (parallel processing), l = 8 m

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 Advant® Controller 160 Product Guide
Section 8.4.9 Assemby and Test

Table 8-20. Cable Set for Redundant and Parallel Processing (Continued)

Description Consists of Article No.

CPU connection cable set for redundancy, TK662V003 3BSE010996R1
l = 30 cm
CPU connection cable set for redundancy, TK662V060 3BSE010996R2
l=6m
CPU connection cable set for redundancy, TK662V080 3BSE010996R3
l=8m

8.4.9 Assemby and Test

Table 8-21. Assembly and Test

Description Consists of Article No.

Assembly and Test of subrack in RM500 – 3BSE016033R1
cabinet. Applicable if assembled by ABB
Automation Products in Västerås.

8.4.10 Packaging Options

Table 8-22. RM500V1 Cabinets (width 800 mm)

Description Consists of Article No.

Cabinet RM521 ventilated cabinet IP21, RM521 3BSE016063R1
height = 2125 mm
Cabinet RM522 ventilated cabinet IP41, RM522 3BSE016064R1
height = 2125 mm
Cabinet RM523 sealed cabinet IP54, RM523 3BSE016065R1
height = 2125 mm
Plate holder for one RM500V1 cabinets Plate holder 3BSE016259R1
(2125 mm)
End panel for RM500V1 cabinets End panel 3BSE016253R1
(2125 mm)
Replacement of single door to double Door 3BSE016260R1
door. For RM500V1 cabinets (2125 mm).
Shield plate, to be used between cabinets Shield plate 3BSE016256R1
in a row (2125 mm)
Locking Device Cylinder, RM500. Lock 3BSE016258R1

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Advant® Controller 160 Product Guide
Chapter 8 Ordering

Table 8-23. RM500V2 Cabinets (width 700 mm)

Description Consists of Article No.

Cabinet RM507 ventilated cabinet IP21, RM507 3BSE016051R1
(H= 2225 mm)
End panel for RM5xx cabinets End panel 3BSE016254R1
(H=2225 mm)
Shield plate, (H=2225 mm) Shield plate 3BSE016257R1

8.4.11 S800 I/O

S800 I/O modules need to be ordered from Price Book S800 I/O (3BSE020696/A), Price List
S800 I/O Version 3.2 (3BSE014394/E). Note that Advant Controller 160 version 2.1 does not
support all S800 modules that are mentioned in the Price List. The following table applies:

Table 8-24. S800 I/O modules for Advant Controller 160

Type Supported Modules

Analog Input AI801, AI810, AI820, AI830, AI835
Analog Output AO801, AO810, AO820
Digital Input DI801, DI810, DI811, DI814, DI820, DI821, DI885
Digital Output DO801, DO810, DO814, DO815, DO820, DO821
Pulse Counter –

8.4.12 Documentation
Table 8-25. Documentation on Advant Controller 160

Title Description Article No.

Advant OCS with Mas- Complete Documentation of Advant 3BSE008143R1101
ter SW User Documen- OCS with Master software on CD-
tation on CD-ROM ROM.
WWW Access to Subscription for one year, single user. 3BSE001228R0001
Advant OCS Documen-
tation
WWW Access to Subscription for 5 years, single user. 3BSE001503R0001
Advant OCS Documen-
tation

68 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Section 8.4.12 Documentation

Table 8-25. Documentation on Advant Controller 160 (Continued)

Title Description Article No.

AMPL Configuration Contains instructions about 3BSE009626R501
Advant Controller 100 configuration and application
Series programming, fault tracing, execution,
Reference Manual memory and load calculation of
Advant Controller 110 and 160.
Advant Controller 160 User’s Guide describing the 3BDS005555R201
User’s Guide AC 160 equipment and how to install
and commission the system.
Data Base Elements Reference Manual describing the DB 3BDS005556R301
Advant Controller 160 Elements used in
Reference Manual Advant Controller 160.
PC Elements Reference Manual describing the PC 3BDS005557R201
Advant Controller 160 Elements used with
Reference Manual Advant Controller 160.
S600 I/O Hardware Reference Manual describing the I/O 3BSE011123R0001
Reference Manual/ and interface modules used with / Rev B
Rev B Advant Controller 100 Series.
S600 I/O Hardware Reference Manual describing the I/O 3BDS005558R201
Advant Controller 160 and interface modules used with
Reference Manual Advant Controller 160.
Advant Fieldbus 100 User’s Guide for Advant Fieldbus 100, 3BSE000506R801
User’s Guide containing a technical description,
technical data and instructions for
installation, commissioning and fault
tracing used.
RCOM Contains a technical description, 3BSE003181R0001
Advant Controller 100 instruction for installation, start-up, Rev. A
Series design and fault tracing of Remote
User’s Guide COMmunication in Advant Controller
110 and 160.
Multi Vendor Interface - Contains a technical description, 3BSE006712R0001
MODBUS instruction for installation, start-up, Rev. A
Advant Controller 100 design and fault tracing for MVI/MOD-
Series BUS in Advant Controller 110 and
User’s Guide 160.
Multi Vendor Interface - Contains a technical description, 3BSE006713R0001
Siemens 3964(R) instruction for installation, start-up, Rev. A
Advant Controller 100 design and fault tracing for MVl/Sie-
Series mens 3964(R) in Advant Controller
User’s Guide 110 and 160.

3BSE 014 721R401 69

Advant® Controller 160 Product Guide
Chapter 8 Ordering

Table 8-25. Documentation on Advant Controller 160 (Continued)

Title Description Article No.

PROFIBUS-DP Advant Information about PROFIBUS-DP for 3BDS100313R301
Controller 110/160 Advant Controller 110 and Advant
User’s Guide Controller 160.
MODBUS Panel Con- How to connect a panel to Advant con- 3BDS004129R401
nections troller 160 via MODBUS interface.
User’s Guide
Installation Rules A description on the installation rules 3BSE009178R0001
User’s Guide for Advant OCS, to ensure correct Rev. A
function in environments where such
disturbances are present.
Interference-free Elec- Interference-free electronics teaches 3BSE000877R1
tronics. Design and how to design circuit boards,
Applications electronic devices and systems with
high immunity to interference. The
book also deals with process adapta-
tion, communication and power supply
with immunity to interference.

70 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Index

INDEX
A D
AC 160, DCF77 39
configuration rules 31 DI610 64
differences compared with AC 110 2 DI620 64
AC 450 20, 23, 38, 40 DI621 64
Advant Station DI622 64
100 Series Engineering Station 4 DI635 64
AF 100 19, 22 DI636 64
coaxial cable 19 DI650 65
main and subordinate bus 22, 35 DI651 65
optical cable 19 DI652 65
twisted pair 20, 23 DI685 65
AF100K01 59 Dimensioning 23
AF100K02 59 DO610 65
AF100K03 59 DO620 65
AI610 62 DO625 65
AI620 62 DO630 65
AI625 62 Documentation 68
AI630 63 DP620 64
AI635 63 DP640 64
AMPL 7 DX610 65
AO610 63
AO650 63 E
Availability 35 Engineering 4
AX645 63 Events 48

C F
CI532 14, 34 Function-block language 7
CI532V01 59
CI532V02 59 H
CI532V03 59 hierarchy of DB elements 24
CI590 14, 60
CI610 17
I
CI615 17
I/O
CI626 14, 19, 31
bus cable TK612 14, 32
CI627 14, 31
bus extender modules CI610, CI615 17
CI630 14, 19, 31
bus extension cable TK610 17
CI631 14, 31, 58
bus terminator TC610 17
CI680 14, 60
fan unit RC620 18
Communication Interfaces CI626, CI627, CI630, CI631 14,
station 17
19, 22, 31
Interbus S 60
CPU connection cableset
TK661 37
CPU load, AC 160 50 M
Cycle time 49 Mechanical Design 43
minute pulse 38
AC 160 39

3BSE 014 721R401 i

Advant® Controller 160 Product Guide
Index

AC 450 40 RM507 68
MODBUS 14 RM521 67
MODBUS I 34 RM522 67
Modems RM523 67
TC513 19
TC514 19 S
TC515 19 S600 I/O 33
TC630 19 S800 I/O 34
SA161 60 to 61
O SA162 60 to 61
OPT1 28 SA171 61
OPT2 29 SA172 61
OPT3 29 SA610 16, 60 to 61
OPT4 29 Safety 35
OPT6 30 SC610 13, 32, 59 to 60
OSP 34 SERCOS 60
Output set as predetermined 34 Siemens 3964 (R) 14, 34 to 35
Station voltage cable TK615 32
P Submodule carrier SC610 13, 32
Parallel processing 36 Submodules CI532 14, 34
PC elements 7 to 8, 28, 30 Subrack
PM640 12, 57 RF615 18
PM644 12, 57 RF616 14, 32
PM645 12 RF620 14, 32
PM645B 57 SX554 61
PM646 12, 57 System
PM665 13 Clock 38
Power supply 16 system time 38
module SA610 16
PPC applications 2 T
Processor modules PM640, PM644, PM645 11 TC501V150 59
PROFIBUS 12, 22 TC506 59
PROFIBUS Library Editor 23 TC513 19
PROFIBUS-DP 22 TC513V1 58
Protection class, AC 160 11 TC514 19
TC514V1 59
R TC515 19
RB601 57 TC515V1 59
RC610 56 TC562 59
RC620 18, 57 TC590V02 60
RCOM 14, 34, 47 TC610 17
Redundancy TC630 19, 58
AF 100 20 TF620 66
configurations 26, 32, 35, 44 TK402V02 61
Redundancy, I/O bus extension 17 TK402V027 61
Redundant processing 35 TK595 59
RF615 18 TK610 17
RF616 14, 32, 56 TK610V025 66
RF620 14, 32 TK610V050 66

ii 3BSE 014 721R401

 Advant® Controller 160 Product Guide
Index

TK610V110 66
TK612 14, 32
TK615 32
TK630V030 66
TK630V050 66
TK630V110 66
TK640V030 66
TK640V050 66
TK640V110 66
TK661 37
Turbine Protection 38

W
W173 57

3BSE 014 721R401 iii

Advant® Controller 160 Product Guide
Index

iv 3BSE 014 721R401

3BSE 014 721R401
October 2001