ControlIT AC 800PEC Control System

The modular controller for high-speed performance

Windows 2000 integrated, IEC 61131-3 compli-
ant engineering tool. A special add-on includes
AC 800PEC-specific functionality.
The AC 800PEC add-on provides full integra-
tion of the AC 800PEC into the ControlIT
engineering environment.
The license for the add-on is issued with the
AC 800PEC hardware.

PECView
The PECView is a PC-based commissioning and
service tool. It provides a complete set of fea-
tures for analyzing, monitoring and maintaining
Simulink applications running on an
AC 800PEC system.

OperateIT Process Panel Builder

The Process Panel Builder is the standard engi-
neering tool for ABB’s Process Panel product
line. It provides a wide choice of operator pan-
els for all requirements that can be integrated
easily into an AC 800PEC control system, such
as:
• Easy customization of operator graphics
using a comprehensive library
• Standardized faceplate concept to minimize
configuration time.

3BHS201058 ZAB E01 / 04.2004 © Copyright 2004 ABB. All rights reserved.
Dokman AG

ABB Switzerland Ltd

Power Electronics Systems, Turgi
CH-5300 Turgi / Switzerland
Tel: +41 58 589 38 09
Fax: +41 58 589 20 90
E-mail: pes@ch.abb.com
www.abb.com/powerelectronics

12 ABB
 Large-scale power converters and drives
must be reliable, fast and precise. That
calls for a control system with outstanding
performance, such as the AC 800PEC.
But why should the same controller not
cope with slow processes, too, such as
cooling circuits, monitoring and balance
of plant?
The AC 800PEC does it all: when it comes
to high-speed processes in an industrial
environment with all related ancillary
tasks, it is the ideal controller.

The AC 800PEC is ABBs high-end process

control system, and belongs to the ControlIT
product line.
The AC 800PEC is the optimum solution for
High Power Converter
Drives combining
• the high-speed control requirements of
power electronics applications
• low-speed process control tasks usually
carried out by separate PLC units.

The AC 800PEC controller is configured and

programmed using Control Builder M, ABB’s
Wind Turbine well-established programming tool, and
MATLAB®/ Simulink® with Real-Time
Workshop®.

Series Voltage Restorer

Micro Turbine

Light Rail Propulsion

ABB 3
 Key benefits
The AC 800PEC is a modular high-speed
control system. The modules are arranged • Hardware and communication modules IndustrialIT integration
according to the according to process needs The AC 800PEC is fully integrated into ABB’s
required I/O config- • Any combination of fast and slow I/Os, large ControlIT software environment.
uration and the and small topologies, installed locally and
CEX Bus IndustrialIT Enabled products from ABB will
process. remotely.
Fieldbus Ethernet TCP/IP set the standard for productivity and profits in
(AnyBus-S) (Com 1/Com 2)
The AC 800PEC I/O future power, automation and information
modules are Hardware solutions.
connected RS-232
Service Port AC 800PEC hardware is optimized for power
via optional (Com 4)
RS-232/RS-422 electronics control:
(Com 3)
high-speed
Optical links • Optical connection between controller and
point-to-point
PowerLink
Optical ModuleBus
process I/O
connections.
• Fast peripheral I/O devices for control and
The AC 800PEC supports up to
measurement Plant Network
36 bi-directional fiber-optic
• Program and data stored in Flash memory,
PowerLinks.
no battery backup needed
• Compatible with standard ABB S800 I/O OptimizeIT
Performance Ethernet TCP/IP
Enterprise Systems
devices
The AC 800PEC excels with a very high the Control Builder M programming tool and • Suitable for field installation. OperateIT Process Portal Operator Consoles
processing speed. It provides to the PECView service tool
• RS-232 / RS-422 serial ports for a local Software
• Very fast analog and digital process I/Os with
a typical cycle time of 25 µs process panel and/or service terminal The AC 800PEC is programmed with:
• Fast closed-loop control and regular process • Up to two on-board AnyIO ports for • ABB Control Builder M programming envi-
logic implemented in one controller ABB Communications Expansion bus (CEX) ronment based on the IEC 61131-3 standard
Ethernet TCP/IP
• Low-speed I/Os with a typical cycle time of and AnyBus®-S modules for all common • Optimized fast application code development
10 ms fieldbus types based on MATLAB®/Simulink® with Real
• Very fast analog/digital conversion and • Up to 36 terminals for optical PowerLinks Time Workshop®.
nominal/actual value comparison, directly on and ABB S800 optical ModuleBus for cost- OperateIT Server

the peripheral I/O module. effective, noise-immune connections to

Control Network
I/O systems and power converters. Ethernet TCP/IP
Connectivity
Process Panel ControlIT
CEX Bus Extension
The AC 800PEC features outstanding ability to Modular configuration CEX AC 800M
RS-422
communicate with other control devices: The modular-design AC 800PEC comes with:
• Two Ethernet ports for connection to a plant • Units mounted onto a DIN rail or equipped
control network, other processor modules, for direct wall mounting Fieldbus ControlIT AC 800PEC
FieldIT EngineerIT ControlIT
Fieldbus Solutions Host Terminal

4 ABB ABB 5
 The AC 800PEC hardware AC 800PEC Combi IO
The AC 800PEC system incorporates for fast signal exchange
AC 800PEC PINT
equipment that meets the most challenging for the control of thyristor modules
– and also contradictory – requirements in Communication modules
process control. It includes a wide range of
Communication with external systems (i.e. the
I/O modules to cover all power electronics
upper control via fieldbus) is via CEX or
control requirements. S800 I/O modules for low AnyBus®-S fieldbus interface module, or via
speed signal exchange
The different I/O modules can be connected Ethernet ports on the processor module.
to the AC 800PEC controller to cover most AC 800PEC Measurement
automation requirements in: Interface PECMI for current The CEX interface provides optimum connec-
and voltage measurements tivity with the complete ABB AC 800 CEX pro-
• Process industry AC 800PEC INT interface gram, such as:
• Power generation and distribution system for direct IGCT
converter contol • MB300
• Transportation and traction.
AC 800PEC PEBB
Interface board for direct • Profibus master
The modular, energy-efficient design of the IGBT converter control • Ethernet
AC 800PEC allows operation without forced requirements and the selected communication The supported AnyBus®-S fieldbus types are:
cooling. with the upper control. Programs and data are stored in a robust solid- • Profibus slave • CANopen slave
The modules are mounted on standard DIN The AC 800PEC controller module contains the state 16 MB Flash memory, which is formatted • Lon Works slave • Interbus slave
rails and can easily be installed in distributed processor, the optical interfaces to the periph- as a file disk. Active programs are operating • Modbus slave • etc.
processes. eral I/O, the fieldbus, and interfaces to the out of the cached 64 MB SDRAM.
The number of directly connectable I/O sys- upper control:
tems is limited only by the maximum available • Base unit AC 800PEC BP (backplane with
fiber-optic links to the processor (36 bidirec- slots for mounting the processor, the power
AC 800PEC CPU
tional links). supply, and the optical and communication Com 1
Ethernet 1
Depending on the required performance, modules)
single, multiple or redundant bidirectional links • Processor module AC 800PEC CPU Com 2
CPU Ethernet 2
are used between modules. mounted on the AC 800PEC BP. The CPU is (PowerPC ® 750FX)
a fully-featured 750 MHz RISC processor with Com 4
Each module comprises a mechanical carrier, RS-232
AnylO AC 800PEC Optical Modules
a 64-bit IEEE Floating-Point-Unit (FPU). It is Slot 2 CPU Slots 4 ... 6
a base module and a configurable set of sub-
optimized for applications with very fast
modules which provide the required I/O Memory
control cycles PCI 1
terminals or communication interfaces. (64 MB SDRAM)
• Two AnyIO interfaces, each consisting of Back-
– an AnyBus®-S slot plane
AC 800PEC Controller PP D113 – an additional AnyIO extension slot for an
FPGA

Disk
The controller comprises a low power circuit AC 800PEC CEX interface or special (16 MB Flash PCI 2
CEX Bus Module Optical Modules
Backplane interface

with high reliability. The hardware can be applications memory)

(programmable logic)

(AnylO Slot 1) Slots 1 ... 3

configured freely, depending on the process • Up to 6 AC 800PEC optical modules for
fiber-optic links to various I/O modules.

6 ABB ABB 7
 I/O modules AC 800PEC PEBB Interface Boards
GD D160 and GD D165
The combination of a huge variety of I/O • Alternatively: 1 Traction Module DA D143,
modules is another specific advantage of the providing The PEBB Interface Board is a universal remote
AC 800PEC. – 13 analog inputs with various predeter I/O device for the direct drive of two IGBT
Standard ABB S800
mined characteristics converters with up to 2 x 6 pulses within
The AC 800PEC is an open system that pro- I/O System
– 18 digital inputs allocated to specific moni ABB’s “Power Electronic Building Block
vides standard interfaces even for modules with For slow process signals,
toring tasks. (PEBB)”.
customized design and functionality. the standard ABB S800
In order to adapt to various voltage and current It also measures and monitors all analog and
All internal communication between the con- I/Os provides a large
levels, the Combi IO can be combined with digital signals from the two IGBT converters.
troller and I/O modules is achieved entirely by and flexible interface
low voltage divider boards (up to 1000 Vrms) Six additional parallel IGBT converters can be
means of optical links. with a virtually unlimited
and CT/VT sub-boards. driven via extension
There are no electric connections between the number of analog and interfaces.
S800 I/O digital I/Os.
controller and any I/O device.
A measuring interface Optical link
Process PECMI can be connect-
AC 800PEC
Measuring Interface ed for current and voltage
AC 800PEC sensing devices.
PECMI UA D140 Optical link
Combi IO UA D149
The PEBB Interface Quad
Combi IO UA D149
The Combi IO AC 800PEC INT Interface System GD D165 can be used as an
Optical module The Measuring
UA D149 is a uni- PV D164 alternative universal remote
versal, remote I/O Interface PECMI pro-
Submodule Submodule I/O device to drive up to
1 2 vides a high-speed cur- The PEC INT board comprises up to six optical
(Mixed IO or
device for high-speed four IGBT bridges
Traction Module)
rent- and voltage-meas- modules with 6 transmitter/receiver
applications, and is or
Process
HVD with up to 4 x 6
urement device which channels to interface PEBB
part of the AC 800PEC LVD
pulses within a IGBT
or
with the AC 800PEC modules
LVD supplements the Combi
control system. It is Process “Power Electronic
CT/VT control system
IO module. Optical link
mainly used for sens- Building Block (PEBB)”.
and various Optical module

Voltage

Current
Process ing actual values in • Active scalable inputs
converter
fast closed-loop for up to 4 current

Current
Voltage
types, e.g. for
control and protec- sensors (e.g. LEM) are provided
direct-firing module
AC 800PEC PINT Pulse Interface DD C779
tion circuits. • Inputs for voltage divider boards and CT/VT Optical module
pulse trans- Optical module The board is used to control two independent
The Combi IO comprises the basic module sub-boards are available.
mission to 6-pulse thyristor converter bridges.
UA D141, which can be equipped with In order to adapt to various voltage and
IGCT converters.
stackable I/O boards such as: current levels, the PECMI can be combined
The complete pulse Process
with voltage divider boards:
IGCT
• Up to 2 Mixed IO boards UA D142, each logic is implemented modules
– Voltages up to 1000 Vrms require a Low
providing in a programmable
Voltage Divider (LVD)
– 16 fast digital inputs / 8 fast digital outputs logic (FPGA) on the
– Higher voltages up to 6000 Vrms require the
– 6 fast analog inputs PEC INT board.
High Voltage Divider (HVD).
– 2 fast analog outputs.

8 ABB ABB 9
 Communication
Process

IT environment
Industrial 31-3 control software
– IEC 611

> 1ms
Slow process I/O

Level 1
Software /Simu link Tools
tion MATLAB
Fast applica

Simulink
I/O Uniit
ps

Simulink
I/O Uniit
– control loochine
The key AC 800PEC capability is high-speed – sta te ma ABB IndustrialIT provides a complete suite
– protection
control application processing, as required in of AC 800PEC engineering tools for all

100 µs - 1 ms
power electronics, for integration into ABB's phases of your automation project – from

Typical cycle time

Level 2
standard ControlIT environment. engineering, installation and commission-
Implementation of the AC 800PEC software on program
ing to operation and maintenance.
lication VHDL

DPRAM
DPRAM
Very fast app ing
three performance levels provides a superb – fast task tim rs
ic and modulato

Configuration access with Control Builder

– pul se log are The ControlIT environment programming
to I/O hardw Fast process I/O

range of control and communication func-
tionality:
Level 1: IndustrialIT integration
This level is based on the industry standard
IEC 61131-3 and contains the slow-control,
monitoring, operating, displaying and regis-
tering functions.
The development of programs in accordance
with the IEC 61131-3 standard is carried out in
the Control Builder M, ABB’s IndustrialIT
compatible engineering tool.
Level 2: Fast control software
This level contains the fast control and protec-
> 25ns
– powerLinkt protection
– very fas and service tools are connected directly to
the controller via Ethernet and RS-232
Level 3
serial links.
OperateIT Process Panel Builder
modulators, pulse logic with associated protec-
tive functions, fast analog and binary inputs MATLAB®/ Simulink® and the Real Time
and outputs, etc. It is implemented in the Workshop® (RTW). This requires special skills
FPGA (Field Programmable Gate Array) and that can be acquired by suitable training. ControlIT Control Builder
programmed in VHDL (Very High Speed Alternatively, this part of a project can be
Integrated Circuit Hardware Description assigned to ABB specialists, provided that all
Language). tasks are specified at the beginning of the
engineering phase.
Engineering workflow The resulting program code is then down- I/O specification

tive functions with cycle times from less than The project-specific high-speed control tasks loaded to the controller by the application MATLAB/Simulink

100 µs to a few milliseconds. and configuration of the AC 800PEC-specific engineer using an Installer Package. The
Fast, time-critical control and I/O tasks are pro- fast I/O are programmed by means of corresponding I/O specification is imported
grammed by means of MATLAB®/Simulink® into the Control Builder M by means of
Software developer Application engineer standard commands.
and integrated into the ControlIT environment
as a Simulink I/O unit. This allows perfect Requirements The application engineer only needs to access PECView
specification
interaction between the high-speed AC 800PEC the ControlIT level to define the standard
Fast control application
core functions and the standard ControlIT programming ControlIT tasks and interfaces (i.e. fieldbus and
(MATLAB/Simulink, FPGA)
software. S800 modules). Applications are created using
Control Builder M, and are then downloaded
Installation Fast control
Level 3: High-speed I/O control package application to the controllers.
(fast control specification
appl. firmware)
This level contains highly time-critical, hard-
ware-specific functions such as pulse-width
Control IT application
ControlIT Control Builder M
programming
(Control Builder M) The AC 800PEC software is managed with
Control Builder M Professional, ABB’s

10 ABB ABB 11