Category: Company News

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 a 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 (nanoseconds for FPGA tasks)

• Fast tasks down to 100 μs (microseconds for Matlab/Simulink tasks)

• Slow tasks down to 1 ms (miliseconds forcontrol tasks)

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, process,write and transmit the signal Implementation of the AC 800PEC software on the three performance levels provides an exceptional range of control and communication functionality.

The following software packages have been developed to support each of our specific high power rectifier applications.

Aluminium applications

• AC 800PEC Unit controller ↔ AC 800PEC Master controller communication via PEC – PEC fiber optical link (100 μs)

• Units can be controlled independent from master

• Allows emergency operation (full smooth current control, in emergency mode, without AC 800PEC, available only in combination with DCS800 premagnetization)

• Predictive maintenance features can be included

• Open circuit-, over current-, under voltage-, over voltage protection packages included in software – A newly developed OPC (open circuit protection) stand-alone PLC (programmable logic controller), working in combination with the AC 800PEC Master controller functions or as standalone protection, in case of the master panel maintenance

• Controlled shutdown in an event, not needing an immediate trip → less disturbance for your processes

• Potline load swing detection and load shedding function integrated in application software

• On Load Tap Changer fast tapping function in order to prevent DC current overload during disturbances

• A special potline-to-earth resistance measurement system based on an AC 800PEC family available (PERMS)

• Maximum power regulation- To prevent over-shooting of power consumption and to support your power generators

• Maximum DC voltage regulation for stabilizing your process

Electrical arc furnace applications

• Stable arc detection

• Different control modes (constant current, constant power or constant resistance)

• Fast link to power quality system (PQS) ELREG (electrode regulation; anode hydraulicsystem control) features included:

• Electrode manual control (analog or digital)

• Electrode fast lift function (with or withoutseparate fast up valve)

• Automatic arc strike function

• Automatic arc restrike function

• Adaptive electrode control according to furnacebehavior or heat stage

• Superimposed integral control circuit

• Voltage fluctuation measurement (stabilityindex calculation)

• Arc-to-roof detection/protection

• Arc-to-roof protection during arc strikesequence

• Hydraulic oil pressure supervision andelectrode protection

• Cave-in detection

• High-voltage detection

• Counter pressure valve control logic

• Voltage-to-ground supervision

• Roof voltage monitoring

• Electrode auto raise function after furnace offcommand (distance or position selectable)

• Blocking valve control

• Electrode speed limitation for electrode andarm protection

• Future features

– Automatic proportional valve linearizationcheck

– Automatic proportional valve linearization

– Dynamic voltage setpoint control for a stablemelting process

Chemical applications: • OLTC step compensation for smooth process control – IDC current step compensation for smooth current change when stepping up

• Power factor compensation by OLTC • Predictive maintenance features can be included • Software protection packages including: – DC over current protection – AC over- and undervoltage protection – AC phase unbalance protection – System unbalance protection for 12 pulse systems

• DC earth fault detection available by 3 voltmeter method

• Process pulse block loop with SIL 3 level • Voltage ride-through in case of incoming voltage dips Electrowinning industries (copper & zinc): • IDC current step compensation for smooth current change when stepping up

• Power factor compensation by OLTC • Predictive maintenance features can be included • DC overcurrent protection • AC over- and undervoltage protection • AC phase unbalance protection • System unbalance protection for 12 pulse systems

• Master DC current control for parallel rectifier units

• DC open loop detection during start-up • DC open loop protection during operation DC power supplies for graphite electrode plants The graphitisation process demands a large variation of voltage and current from the DC power supply.

• Constant DC power suppy for the process irrespective of changing process resistance – Possible due to the very fast cycle times of AC 800PEC controller.

• Customer tailed process recipes can be added and modified from the operator panel in order to meet the specific customer requirements.

• After adding the corresponding recipes, the rectifier follows the predefined DC current, DC voltage and maximum allowed power set points, including all necessary graphitisation specific protection functions.
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Windows 2000 integrated, IEC 61131-3 compliant engineering tool. A special add-on includes AC 800PEC-specific functionality.

The AC 800PEC add-on provides full integration 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 features for analyzing, monitoring and maintaining Simulink applications running on an AC 800PEC system

OperateIT Process Panel Builder

The Process Panel Builder is the standard engineering tool for ABB’s Process Panel product line. It provides a wide choice of operator panels 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.

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 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 well-established programming tool, and

MATLAB®/ Simulink® with Real-Time Workshop®.

Key benefits

The AC 800PEC is a modular high-speed control system. The modules are arranged according to the required I/O configuration and the process.

The AC 800PEC I/O modules are connected via optional high-speed point-to-point connections.

The AC 800PEC supports up to 36 bi-directional fiber-optic PowerLinks.

• Hardware and communication modules ABB according to process needs

• Any combination of fast and slow I/Os, large and small topologies, installed locally and remotely.

Performance

The AC 800PEC excels with a very high processing speed. It provides

• Very fast analog and digital process I/Os with a typical cycle time of 25 µs

• Fast closed-loop control and regular process logic implemented in one controller

• Low-speed I/Os with a typical cycle time of 10 ms

• Very fast analog/digital conversion and nominal/actual value comparison, directly on the peripheral I/O module the Control Builder M programming tool and to the PECView service tool

• RS-232 / RS-422 serial ports for a local process panel and/or service terminal

• Up to two on-board AnyIO ports for ABB Communications Expansion bus (CEX) and AnyBus®-S modules for all common fieldbus types

• Up to 36 terminals for optical PowerLinks and ABB S800 optical ModuleBus for costeffective, noise-immune connections to I/O systems and power converters

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