Category: Industry trends

Can you imagine a process with a cycle time of less than 100 μs? We can – and we’ve built the AC 800PEC to achieve it,

High-performance applications with extremely fast control algorithms – cycle times that range from 100 microseconds for fast control loops to seconds for long-term operational transients – require specialized control devices.

That is why we have designed the AC 800PEC, extending the capabilities of ABB’s well-known ControlIT automation technology to handle the very high-speed algorithms of processes such as power electronics applications. We’ve even gone a step further: now, a single processor unit combines these high-speed controls with the low-speed process control tasks usually carried out by separate PLC units.

To facilitate the implementation of control algorithms, the AC 800PEC can be programmed using MATLAB® / Simulink® – the code is automatically generated from the model and can be downloaded without manual interaction.

Embedded into a robust and flexible system structure with integrated standard communication, the AC 800PEC is unique in the field of industrial process controllers.

The AC 800PEC, the ultimate approach for high demands

The AC 800PEC provides the unique combination of features required in demanding applications:

− Short cycle times down to 100 μs

− High processing power

− Fast communication and I/O

− Programming tools:

− System engineering with IEC61131-3 languages using ABB’s Control Builder, either as Compact or Professional version

− Product & control development using MATLAB® / Simulink® for model-based design, easily bridging the gap from simulation to implementation

− Full integration into ABB’s System 800xA

− Innovative and flexible use of FPGAs to include protocols and application functionality in the devices without creating additional processor load

− Optical communication

− Industrial grade hardware with no moving parts

− Long life cycle, easy upgrading

Built to control power – in industry, utilities and traction

ABB is a globally active company with full process know-how in a wide field of industrial, utility, traction, marine and other applications. As a result, the AC 800PEC is a key controller for ABB’s own range of industrial applications, and also for third party products and systems.

The AC 800PEC is an efficient and flexible controller family. Thanks to its short cycle times, fast I/O, high processing power and advanced control using MATLAB® / Simulink®, the AC 800PEC:

− Increases process quality and output − Saves development and engineering costs

− Reduces the energy consumption of your products − Shortens time-to-market for your development project

− Saves headcount and resources in engineering and software development − Enhances Return on Assets (ROA)

The modular structure of the AC 800PEC control system means it can adapt to any application size, from the largest industrial plants and propulsion systems down to very compact products where space and cost are critical. All over the world, many thousands of processors are now proving their worth in a wide variety of extremely demanding applications.

Tuned for performance and efficiency

Powerful hardware for efficient high-speed processing

The AC 800PEC combines the floating-point computing performance of the CPU with the flexibility and high speed capability of an FPGA.

The system is separated into three performance levels covering different cycle times. Control tasks are allocated depending on their speed requirements:

− Very fast tasks down to 25 ns

− Fast tasks down to 100 μs

− Slow tasks down to 1 ms

The hardware architecture of the AC 800PEC is an ideal match to the three-level software structure.

To support the short processing cycle times, the AC 800PEC provides a fast I/O system. Depending on the speed of the I/O connection, it is possible to achieve data throughput times below 100 μs – including the time required to read, transmit, process, transmit and write the signal.
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AC800PEC Controller GFD563A102 3BHE046836R0102 Scalability in Performance

Your process defines the required performance level. Several preconfigured software packages are available for easy and straightforward engineering.

DCS (Distributed Control System)

• Processing cycle times down to 1 ms

• Use of slow I/O

• Programming in Control Builder HMI (Human Machine Interface)

• Processing cycle times down to 1 ms

• Use of slow and fast I/O

• Programming of interface in Control Builder

• Nearly all common field busses supported

• Hardware time stamping available upon request PLC (Programmable Logic Controller)

• Processing cycle times down to 1 ms

• Use of fast and slow I/O

• Programming in Control Builder PAC (Programmable Automation Controller)

• Cycle times down to 100 μs

• Use of fast and slow I/O

• Programming in MATLAB®/Simulink® and

Control Builder

Process interfaces for any speed The AC 800PEC provides two kinds of I/O – fast and slow. The fast I/O system covers read and write operations requiring less than 1 ms, and the slow I/O system covers speeds above 1 ms.

The fast I/O system is AC 800PEC specific, using devices connected exclusively via fiber optic links, and brings substantial advantages compared to electric concepts:

• Fast communication between controller and I/O devices

• High immunity to electromagnetic interference

• Potential-free connections, making isolating transmitters obsolete

The slow I/O modules from ABB’s S800 system can be added to any configuration, depending on project needs.

Versatile and reliable The AC 800PEC adapts to any application

Seamless integration into plant control In today’s demanding market, a controller must not only deliver maximum performance but also provide transparency. In this respect, the

AC 800PEC provides a large range of possibilities. Integrated communication ensures transparent, plant-wide data exchange and control – from overall plant control to separate processes. Use of ABB’s System 800xA with the powerful AC 800PEC controller permits uniform automation throughout the plant, seamlessly integrating advanced solutions into the process control system. The AC 800PEC provides connectivity, using either native (built-in) or add-on functionality. Native (depending on the configuration):

• MMS

• Modbus TCP Slave

• IEC61850

• ABB Fast Fiber Optic Link

• ABB Drivebus (DDCS)

• IbaPDA

• Optical Modulebus (S800)

• CANopen

Add-on

Using ABB CEX Modules:

• ABB Drivebus (DDCS)

• Profibus Master DPV1

• Modbus RTU

• S100 I/O

• Masterbus 300

Using Anybus modules

• CANopen

• ControlNet

• DeviceNet

• Profibus Slave

• Profibus Slave DPV1

• Profibus Master DPV1

• Profinet I/O

• EtherCAT Slave

• Ethernet/IP

Well-suited to a harsh environment – the AC 800PEC

Since the AC 800PEC controller is used in different ABB solutions, there is a huge installed base, which enables the extraction of long-term lifecycle experiences.

Traction, with its particularly harsh environmental conditions, is one of the most important applications of the AC 800PEC.

The controller operates through a wide temperature range (-40 to +70 °C), with vibrations according to traction standards. The compact solution is the ideal response to the demands of restricted spaces and allows integration of the processing unit together with all the I/O’s in the same compact hardware device.

Reliability is a must – the AC 800PEC in powergeneration

Typically, excitation systems are used for generator control in power plants where high reliability is the no. 1 requirement. Due to the very short process cycles, traditional redundancy concepts are no longer applicable.

The modular architecture of the AC 800PEC not only greatly reduces the complexity of the overall system, but redundant subsystems also provide increased reliability. Should a problem occur in one subsystem, the main controller switches over to the remaining subsystems, which are scaled in such a way that the overall task can still be fulfilled. Should the main controller fail, a second controller is available in hot-standby.The modular architecture of the AC 800PEC not

only greatly reduces the complexity of the overall system, but redundant subsystems also provide increased reliability. Should a problem occur in one subsystem, the main controller switches over to the remaining subsystems, which are scaled in such a way that the overall task can still be fulfilled. Should the main controller fail, a second controller is available in hot-standby.
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