ABB Advant Controller 450 User’s Guide

ABB Advant Controller 450 User’s Guide

I. Product Overview

1. Functional purpose: Advant Controller 450 is a programmable system for industrial automation, 

which can realise logic, sequence, positioning, regulating control and other functions, and can handle a large number of input 

and output signals, and is suitable for a variety of industrial scenarios, 

and can be operated independently or as an integrated controller for distributed control systems.

2. Product structure: It consists of CPU, communication sub-module, system software backup sub-module, backup power supply, etc. 

It supports a variety of I/O systems (S100 I/O, S400 I/O, S800 I/O) and is connected through different buses. 

The software contains basic system programme module and function library programme module, which can be selected according to requirements.

3. Communication capability: It supports various communication protocols such as MasterBus 300/300E, GCOM, Advant Fieldbus 100, etc., 

which can communicate with many kinds of devices to achieve data exchange and system integration.

4. Version information: The product version is expressed in the form of Advant Controller 450 ∗X.Y/Z, 

and the software module also has the corresponding version number. Different versions have different new functions, 

such as ∗ 1.0 version adds more powerful CPUs, etc., and ∗ 2.0 version adds redundant S100 I/O buses.

II. Installation Guide

1.Site Planning

Environmental requirements: 

The temperature, humidity, vibration and electromagnetic compatibility of the installation environment are required, 

and cabinets with different protection levels (IP21, IP41, IP54) are suitable for different environments.

Space layout: the size and shape of the control room, lighting, the weight of the equipment on the floor requirements, etc., 

while reserving space for equipment movement and maintenance.

Power supply: 

AC (120/230V) or DC (24 - 48V) power supply can be used, redundant power supply options are available, 

attention should be paid to grounding and power distribution.

2.Installation Steps

Equipment Installation:

 Install cabinets and subracks according to the standard layout to ensure the stability of the equipment, 

pay attention to the distance between cabinets and the installation order.

Wiring and grounding: 

Follow the wiring rules when connecting all types of cables, pay attention to signal shielding and grounding, 

and different types of cables have different grounding requirements.

Safety Measures: 

Strict safety regulations should be followed during installation to prevent electrostatic discharge and electrical accidents 

and to ensure the safety of personnel and equipment.

3.Start-up process

Preparation: 

Check the connection and configuration of the equipment to ensure that there is no looseness or error.

Start-up operation: 

Turn on the power in sequence, set the start-up mode, initialise and configure the system, and connect the engineering station for subsequent operations .

Verification test: check the system status after startup, carry out function test to ensure normal operation of the system.

III. Configuration and Application Construction

Design considerations: 

including hardware selection, software function module selection, CPU load calculation, memory calculation, etc. 

The system configuration should be determined according to the actual requirements.

Technical data: 

covers the technical parameters of each part of the system, such as CPU performance, memory capacity, I/O system capacity, communication, and so on.

IV. Basic hardware parameters

(i) Central processing unit (CPU)

Model and performance: 

Processor modules such as PM511v16 are used. With a net depth/length of 274.5mm, a net height of 27mm, a net width of 270mm, 

and a net weight of 0.8kg, this processor module has a powerful computing power, 

with a processing power index of 3 - 4 (a significant increase compared to the masterpiece 200 and the Advant Controller 410), 

and can efficiently execute all kinds of control programmes.

Memory Configuration: 

The main memory is available in 8MB or 16MB options, 

with about 5.4MB (corresponding to 8MB main memory) or 13.4MB (corresponding to 16MB main memory) for application memory, 

which provides sufficient memory space to ensure the smooth operation of complex industrial control programmes 

and the processing of large amounts of data.

Redundancy design: 

Supporting redundant CPU boards (such as PM 511), up to two redundant CPU modules can be installed. 

When the main CPU fails, the backup CPU can be switched over quickly and seamlessly, 

and the switchover time is less than 25 milliseconds, ensuring uninterrupted operation of the system, 

which greatly improves the reliability of the system and meets the stringent requirements of industrial production for high stability.

(II) Power supply unit

Input power supply type

DC input: Supports direct (non-isolated) 24V DC input; 24/48V DC input through isolated DC/DC converter.

AC input: 120/230V AC (isolated) power supply can be accessed, power frequency range is 47 - 63Hz, 

rich power input options, so that it can be adapted to different industrial site power supply conditions.

Output Parameters: Take the voltage regulator unit for DC input/DC output as an example, when inputting 24VDC, 

the output is 5V DC regulated and the output current can be up to 10A, and it is equipped with 5A standby fuse, 

which can provide stable power supply for each module of the system.

Redundant Configuration: 

Supporting power supply redundancy, different power input types can be combined to achieve double redundant power supply, 

ensuring that the system can still work normally when a single power supply fails, improving the stability and reliability of the system power supply.

(III) Communication module

Type and Interface

Serial communication: V.24/RS 232 interface module (e.g. CI 531) with 2 communication channels, up to 4 can be installed, 

used for low-speed data communication with external devices supporting RS232 protocol, such as some sensors, small controllers and so on.

Fieldbus communication: Supports MasterBus 300/300E, Advant Fieldbus 100, PROFIBUS and other fieldbus protocols. 

Through the corresponding communication sub-module, high-speed data interaction with distributed I/O stations, 

other controllers and intelligent devices can be realised to build complex industrial control systems. Among them, 

Advant Fieldbus 100 uses twisted-pair media or has media redundancy, bus redundancy and other connection modes, 

with long communication distance and high reliability.

Other communication: Support GCOM protocol for communication with external computer and AdvaSoft for Windows software; 

through MVI (Multi - Vendor Interface) protocol, it can communicate with other brands of control systems (such as through MODBUS I, 

Siemens 3964R, or Allen-Bradley's DF1 protocol) to enhance the compatibility and openness of the system. 

This enhances the compatibility and openness of the system.

Quantity limitation: communication sub-modules are installed on sub-module carriers (e.g. SC 510/SC 520, maximum 6 or 7), 

and a total of 12 or 14 communication sub-modules can be installed, 

which meets the diversified communication connection requirements in different industrial scenarios.

(iv) I/O system

S100 I/O

Number of racks and modules: 

Up to 5 S100 I/O racks can be connected, and each rack can accommodate various I/O modules, and a total of up to 100 S100 I/O modules can be installed. 

The maximum number of analogue I/O modules per type is 32, and the maximum number of digital I/O modules per type is 48.

Communication distance: With the optical bus extension technology, S100 I/O racks can be distributed up to 500 metres away from the CPU rack, 

effectively reducing the amount of field wiring and making it suitable for industrial scenarios with a wide distribution of equipment.

I/O capacity: S100 I/O system can handle a large number of I/O signals, 

providing the basis for data acquisition and equipment control in industrial production.

S800 I/O

Number of Stations and Modules: 

Each Advant Fieldbus can connect up to 79 S800 I/O stations, and each I/O station can be installed with up to 246 S800 I/O modules.

Communication capability: Communicate with the controller via Advant Fieldbus 100, with fast transmission rate and high reliability, 

and can transmit a large amount of field data in real time.

I/O capacity: build a powerful I/O system together with S100 I/O, making the total number of I/O channels of the whole system as high as 5700, 

among which the maximum number of AI channels (including calculated value) is 910, 

the maximum number of AO channels (including calculated value) is 963, the maximum number of DI channels (including calculated value) is 2,340,

 the maximum number of DO channels (including calculated value) is 1,489, 

which can meet the complex I/O requirements of large-scale industrial automation system. 

This can meet the complex I/O requirements of large-scale industrial automation systems.

Special I/O modules: There are special types of I/O modules such as Pt100, thermocouple and pulse input modules, 

which can be used to meet the needs of special industrial applications such as precise temperature measurement and pulse signal counting. 

For example, Pt100 modules can accurately measure temperature and provide accurate data for temperature control in industrial production processes.