ABB Advant Controller 250
The ABB Advant Controller 250 (AC250) is currently in the "Limited" lifecycle phase, meaning original manufacturer support and new parts are increasingly difficult to source. At Moore Automation, we serve as the "special-grade emergency warehouse" for industrial giants. We maintain a massive inventory of PM253, PM254, and PM255 processor modules and communication interfaces to ensure your legacy systems—some running for over 20 years—remain operational.
1. Ideal Application Scenarios for ABB Advant Controller 250
The AC250 is a comprehensive process controller designed for medium to large-scale industrial applications. It is particularly effective in environments requiring high modularity and diverse communication protocols.
- Legacy System Life Extension: Because the AC250 is in the "Limited" lifecycle phase, it is the primary choice for facilities that need to maintain existing Satt DCS or Advant Master operations without committing to a full system migration to AC 800M.
- Hybrid I/O Configurations: It is ideal for plants needing to combine central and remote I/O in a single controller. It supports S200 and S200L I/O both centrally and remotely, and S800 I/O remotely via PROFIBUS-DP.
- Critical Infrastructure & Heavy Industry: The system is widely utilized in sectors where downtime is not an option, including:
- Power Generation: Controlling turbine auxiliaries and boiler feed systems.
- Pulp & Paper: High-speed production lines coordinating sensors and specialized machinery.
- Chemical & Process Industries: Managing decentralized, high-speed control within centralized frameworks.
- Space-Constrained Environments: Its compact design and DIN rail mounting make it suitable for narrow control cabinets where maximizing space is essential.
2. Model Selection Guide: Choosing the Right Processor (PM)
When replacing or expanding your AC250 system, the choice of Processor Module (PM) depends on your I/O count and required execution speed. Moore Automation stocks all three core variants:
| Model |
Clock Speed |
RAM Memory |
Max I/O Units Supported |
Built-in Interface |
| PM253 |
16.7 MHz |
1–2 MB |
32 to 64 units |
SattBus |
| PM254 |
28.8 MHz |
4–8 MB |
128 to 256 units |
SattBus |
| PM255 |
50 MHz |
4–8 MB |
256 to 512 units |
RS232 Only |
Selection Pro-Tip: If your system relies on SattBus supervision, stick with the PM253 or PM254. For high-speed data processing and the largest I/O capacity, the PM255 is the superior choice, though it requires an external interface for SattBus connectivity.
3. Key Purchasing Considerations
- Simplified Maintenance: All AC250 units utilize mechanical code keys. These ensure that modules cannot be damaged by being plugged into the wrong backplane slot during a high-pressure emergency replacement.
- Scalable Power: For larger configurations, we provide both the 200-PSMG Master Power Supply and the 200-PSSG Slave Power Supply to enhance system capacity.
- Remote Connectivity: We stock the 200-CIE Ethernet Interface, enabling remote programming and data exchange via TCP/IP protocols.
- Battery Reliability: Note that the PM254 battery lifetime is limited to 3,000 hours when the system is unpowered. We recommend keeping fresh PM253/254 lithium battery packs or PM255 NiMH rechargeable backups in your on-site spares kit.
Maximize Asset Longevity
Continuous manufacturing requires proactive inventory management, especially for systems like the ABB Advant Controller 250 currently in the "Limited" lifecycle phase. Rather than facing the volatility of the secondary market during a breakdown, secure essential components like the PM255 Processor and SattBus interfaces directly from available stock. Moore Automation provides the immediate hardware solutions needed to extend system life and uphold production commitments without compromise. Relying on in-stock, original modules ensures that aging DCS infrastructure remains operational even as manufacturer support diminishes.
FAQ: Resolving Your Purchase Doubts
Q: Can I use the same I/O units for both central and remote locations?
A: Yes. The AC250 allows S200 and S200L I/O units to be used both centrally via the serial I/O bus and remotely via PROFIBUS-DP or ControlNet.
Q: My AC250 is in the "Limited" lifecycle phase. Should I upgrade immediately?
A: While ABB encourages evolution to the AC 800M, a full system migration is costly and time-consuming. Moore Automation allows you to extend the life of your current system for years by providing guaranteed, warrantied spare parts that the OEM may no longer stock.
Q: How do I handle programming and configuration for a replacement module?
A: The system is configured using Advant Control Builder (Windows-based). We recommend maintaining backups of your .AAX and .BAX source files, as they are essential for rebuilding a controller if code is lost.
Q: How many I/O points and units can a single AC250 system manage?
A: The AC250 is a comprehensive process controller capable of handling up to 8,192 I/O points. The total number of supported I/O units depends on the specific Processor Module (PM) installed: PM253 supports 32 to 64 units, PM254 supports 128 to 256 units, and PM255 can manage up to 512 units.
Q: What are the critical battery maintenance requirements for the PM254 processor?
A: Unlike the PM255, which uses a rechargeable NiMH battery, the PM254 utilizes a lithium battery for RAM and real-time clock backup. Crucially, the PM254 battery lifetime is limited to a maximum of 3,000 hours when the system is unpowered, making regular inspections vital to prevent logic loss during facility shutdowns.
