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Top reliability is a must – the AC 800PEC in power generation

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concepts are no longer applicable.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 thanks to

redundant subsystems also provides increased reliability. In

the case of a problem 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.

Precision for optimum quality – the AC 800PEC for industrial processes

The most demanding function in a rolling mill is thickness

control. By using the powerful AC 800PEC controller and its

ability to implement C-Code beside the standard IEC 61131-3

program level, a new thickness control solution for cold

rolling mills has been developed based on an MIMO (Multi

Input Multi-Output) control concept. The benefit to the

customer is an improvement in thickness deviation by up to 50 percent.

Well suited to a harsh environment – the AC 800PEC for traction

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/Os in the same

compact hardware device.

Top reliability is a must – the AC 800PEC in power generation

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concepts are no longer applicable.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 thanks to

redundant subsystems also provides increased reliability. In

the case of a problem 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.

Native (depending on the configuration):

−MMS

− Modbus TCP Slave

− IEC61850

− ABB Powerlink

− ABB Drivebus (DDCS)

− Iba-PDA

− Optical Modulebus (S800)

− CANopen

− 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

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 down 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. Strict security procedures and effective

firewalls prohibit unauthorized intrusions and ensure per

manent system safety.

The AC 800PEC provides connectivity, using either native

(built-in) or add-on functionality.

Scalability in performance – you and your process define what you need

Your process defines the required performance level. Several

pre-configured 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

− 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.

Whereas the fast I/O system covers read and write operations

requiring less than 1 ms, 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.

Three system architectures provide scalability from small and

compact to large and modular systems:

Compact

One processor module with integrated, fast I/O devices. This

configuration is ideally suited for:

− Smaller applications

− Limited-space applications

− Intelligent field devices, e.g. subsystems in distributed applications

Standard

One processor module with separate, fast logical I/O

devices. This configuration is ideally suited for:

− Standard industrial applications with central processing

− Small applications with detached, fast I/O Modular

One or several central processor modules with separate, fast,

intelligent I/O and fast logical I/O devices.

Full and trouble-free integration into higher-level plant control

systems as well as future expansions and reconfigurations

are easy thanks to the fully modular architecture.

Modularity and connectivity for any size and performance

Scalability in size – from small and compact to large and modular

For any application size, the optimum hardware configuration

is easily achieved: the processing power can either be

centralized at one location with distributed logical I/O devices,

or intelligent I/O devices can carry out specific tasks in

the field to enhance performance and relieve the central processor.

Three system architectures provide scalability from small and

compact to large and modular systems:

Compact

One processor module with integrated, fast I/O devices. This

configuration is ideally suited for:

− Smaller applications

− Limited-space applications

− Intelligent field devices, e.g. subsystems in distributed applications

Standard

One processor module with separate, fast logical I/O

devices. This configuration is ideally suited for:

− Standard industrial applications with central processing

− Small applications with detached, fast I/O Modular

One or several central processor modules with separate, fast,

intelligent I/O and fast logical I/O devices.

Full and trouble-free integration into higher-level plant control

systems as well as future expansions and reconfigurations

are easy thanks to the fully modular architecture.

Implementation of the AC 800PEC software on the three

performance levels provides an exceptional range of control

and communication functionality:

Level 1: System engineering (ControlIT)

ABB’s ControlIT supports all 5 IEC61131-3 programming

languages and uses ABB’s Control Builder as the program

ming tool. This is the level on which system engineers

implement functions that do not require high-speed perform

ance but demand quick and easy adaptation to a specific project.

AC 800PEC controllers can also be fully integrated into

ABB’s 800xA automation systems.

Level 2: Product & control development (MATLAB / Simulink™)

Fast closed-loop control applications are designed using

MATLAB® / Simulink®. C-code is automatically generated and

downloaded to the embedded device using Real-Time

Workshop® from MathWorks®.

Typically, it is on this level that control developers will

implement the control, the protection, the state machine and other functions.

Level 3: Communication & very fast logic (VHDL)

Extremely fast processes are programmed in VHDL. Proto

cols and some control logic requiring extremely short cycle

times are implemented on this level. The standardized tasks

are available as firmware modules and are not accessible to

the application developers.

Transparent software structure and easy programming

The AC 800PEC is the perfect way to unite the system design

capabilities of ABB’s ControlIT with the control and simulation

capabilities of MATLAB® / Simulink®. Quick implementation of

complex control algorithms (e.g. model predictive control)

reduces development cycles and costs. Furthermore, the

system is open to future technologies.

Implementation of the AC 800PEC software on the three

performance levels provides an exceptional range of control

and communication functionality:

Level 1: System engineering (ControlIT)

ABB’s ControlIT supports all 5 IEC61131-3 programming

languages and uses ABB’s Control Builder as the program

ming tool. This is the level on which system engineers

implement functions that do not require high-speed perform

ance but demand quick and easy adaptation to a specific project.

AC 800PEC controllers can also be fully integrated into

ABB’s 800xA automation systems.

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.