ABB TC560 Controller Modules: TC560V2 3BSE022178R1

Technical Dossier

Product Details And Specifications

ABB TC560 Series: Comprehensive Module Range and Technical Overview

The ABB TC560 series is a family of controller and communication modules developed for the ABB Advant Controller 160 (AC160) platform, also marketed under the Masterpiece 200/1 designation. This platform achieved widespread deployment across global heavy industry sectors including petrochemical refineries, nuclear power auxiliary systems, pulp and paper mills, and offshore oil and gas installations. The AC160 architecture was engineered for high-availability process control, featuring redundant CPU configurations, deterministic scan cycles, and a modular backplane bus that allowed field expansion without process interruption. The TC560 controller modules serve as the computational core of this architecture, executing ladder logic, function block programs, and sequential control tasks in real time.

The Evolution of TC560 Architecture

The TC560 series traces its lineage to ABB's Advant OCS (Open Control System) initiative of the late 1980s, which sought to unify process control and discrete automation under a single hardware platform. Early AC160 deployments used the TC560V1 controller, which operated on the proprietary MasterBus 300 fieldbus and supported a maximum of 512 I/O points per station. The architecture relied on a parallel backplane bus with a fixed 10 ms scan cycle floor.

The TC560V2 (3BSE022178R1) represented a significant revision: expanded memory addressing, support for the MasterBus 300E extended protocol, improved diagnostics via the system status word, and compatibility with the AMPL (Advant Master Programming Language) toolset running on the Advant Workstation (AWS). This version became the dominant installed base across the 1995–2008 deployment window.

Subsequent generations introduced Ethernet-based engineering access and IEC 61131-3 programming compatibility, but the TC560V2 remained in active service due to the long capital replacement cycles typical of process industries. ABB formally transitioned support for the AC160 platform to its Extended Lifecycle Support program, meaning spare parts are no longer manufactured but are available through authorized distributors and specialist suppliers.

TC560 Full Catalog & Functionalities (SKU List)

Controller Modules (CPU)

• TC560V1 / 3BSE001378R1: First-generation AC160 CPU; MasterBus 300 only; 256 KB RAM.
• TC560V2 / 3BSE022178R1: Revised CPU; MasterBus 300E; expanded I/O addressing; primary spare.
• TC560V3 / 3BSE022179R1: Enhanced diagnostics variant; extended temperature range option.
• TC561V1 / 3BSE001379R1: Redundant CPU module; hot-standby pair with TC560V1.
• TC561V2 / 3BSE022180R1: Redundant CPU for TC560V2 systems; synchronization via backplane.

Digital Input (DI) Modules

• DI810 / 3BSE008508R1: 24 VDC digital input; 16 channels; AC160 backplane compatible.
• DI811 / 3BSE008510R1: 24 VDC DI; 16 channels; individually isolated inputs.
• DI820 / 3BSE008512R1: 120 VAC digital input; 16 channels; surge-protected.
• DI821 / 3BSE008514R1: 230 VAC digital input; 16 channels; CE-marked.

Digital Output (DO) Modules

• DO810 / 3BSE008516R1: 24 VDC transistor output; 16 channels; 0.5 A per channel.
• DO820 / 3BSE008518R1: Relay output; 16 channels; 2 A per contact; AC/DC load.
• DO821 / 3BSE008520R1: High-current relay output; 8 channels; 5 A per contact.

Analog Input (AI) Modules

• AI810 / 3BSE008522R1: 8-channel analog input; 4–20 mA / 0–10 V; 12-bit resolution.
• AI820 / 3BSE008524R1: 8-channel AI; RTD/thermocouple input; Pt100 linearization.

Communication & Fieldbus Adapters

• MB510 / 3BSE002540R1: MasterBus 300 communication interface; coaxial bus termination.
• CI522A / 3BSE012672R1: PROFIBUS DP master adapter; up to 125 slave nodes.
• CI526V1 / 3BSE012868R1: AF100 fieldbus interface; connects AC160 to Advant field units.

Power Supply Modules

• SS822 / 3BSE018172R1: 24 VDC system power supply; 5 A; redundancy-capable.
• SS823 / 3BSE018174R1: Redundant power supply module; automatic switchover on failure.

Sourcing Hard-to-Find & Obsolete TC560 Parts

ABB discontinued active production of TC560-series hardware following the platform's transition to Extended Lifecycle Support status. Lead times through OEM channels are typically 16–52 weeks for any remaining new-old-stock units, and many part numbers are no longer available through ABB's standard distribution network.

DriveKNMS maintains a dedicated inventory of AC160 / TC560 spare parts sourced from decommissioned plant equipment, controlled-environment warehousing, and verified secondary market channels. All units are catalogued by part number, hardware revision, and firmware version where applicable. For end-users operating AC160 systems beyond their original design life, DriveKNMS provides lifecycle extension support including cross-reference verification, compatibility mapping between TC560V1 and TC560V2 hardware revisions, and documentation of known firmware dependencies.

Customers requiring long-term supply agreements for maintenance contracts or plant turnaround schedules are encouraged to contact the procurement team directly to discuss consignment stock arrangements.

Quality Control for the TC560 Range

TC560 controller modules present specific test challenges due to their integrated backplane bus interface, battery-backed SRAM, and real-time clock circuitry. DriveKNMS applies a structured inspection and functional verification protocol to all TC560-series units prior to dispatch:

• Visual inspection: PCB for corrosion, capacitor bulge, solder joint integrity, and connector pin condition.
• Power-on test: Module energized in an isolated AC160 test rack; boot sequence and LED status verified against ABB diagnostic codes.
• Memory integrity: SRAM retention test with battery load simulation; flash memory checksum verification.
• Backplane bus communication: Module inserted into live test rack; MasterBus 300/300E token-passing protocol confirmed via bus analyzer.
• I/O channel scan: Where applicable, all I/O channels exercised through the test rack's signal injection harness.
• Firmware version logging: Hardware revision and firmware build recorded and included with shipment documentation.

Units that do not pass all stages are quarantined and not offered for sale. Test records are retained for a minimum of 24 months.