ABB AC 800PEC High Performance Control System

ABB AC 800PEC High Performance Control System

Product positioning and core values

AC 800PEC is a high-performance industrial control system launched by ABB, developed specifically to meet model-based design and high-speed control algorithm requirements. Its core advantage lies in integrating traditional separated high-speed control (such as power electronics applications) and low-speed process control (PLC tasks) into a single processor unit, achieving full range cycle time coverage from 100 microseconds to several seconds. This system is based on ABB's ControlIT automation technology, combined with MATLAB ®/ Simulink ®  Model development tools significantly shorten the engineering cycle from simulation to implementation, suitable for scenarios such as traction, power generation, and industrial processing that require high real-time and reliability.

Hardware architecture and performance parameters

Processing Core and Architecture

Collaborative design of CPU and FPGA: The CPU is responsible for floating-point operations and complex logic, while the FPGA handles ultra high speed tasks (such as 25 nanosecond logic), forming a three-level performance hierarchy:

Ultra fast layer: 25 nanosecond task (VHDL programming, firmware module implementation);

Fast layer: 100 microsecond loop (MATLAB) ®/ Simulink ®  Control algorithm);

Slow layer: tasks lasting over 1 millisecond (programming in IEC 61131-3 language).

I/O system:

Fast I/O: Fiber optic connection, transmission time<10 microseconds (internal) to 25 microseconds (external), anti electromagnetic interference, no need to isolate transmitter;

Slow I/O: Compatible with ABB S800 module and supports millisecond level response.

Hardware scalability

Three architectural patterns:

Compact: Single processor integrated I/O, suitable for small devices or distributed subsystems;

Standard type: independent processor+fast I/O, suitable for central control scenarios;

Modularization: Multi processor+intelligent I/O, supporting redundant configuration of large systems.

Environmental adaptability:

Working temperature: -40 ℃ to+70 ℃ (traction field);

Anti vibration: Complies with traction industry standards and is designed with no moving parts.

Software Ecology and Programming System

Third level software architecture

Level 1: Systems Engineering

Tool: ABB Control Builder (Compact/Professional version);

Language: All 5 IEC 61131-3 languages (LD, FBD, ST, etc.);

Application: Non high speed logic (parameter configuration, system adaptation), can be integrated into 800xA automation systems.

Level 2: Control Algorithm Development

Tool: MATLAB ®/ Simulink ® +  Real-Time Workshop ®；

Process: Model simulation → Automatic generation of C code → One click download to controller;

Application: Core algorithms such as closed-loop control, protection logic, and state machines.

Level 3: Ultra High Speed Logic

Tools: VHDL+FPGA development framework;

Function: Communication protocol (such as Powerlink), pulse modulation, hardware level protection, firmware level packaging cannot be modified.

Model driven development process

Traditional vs Modern Workflow:

Traditional: specification definition → code handwriting → debugging (error prone, long cycle);

AC 800PEC：Simulink ®  Model → Automatic code generation → Real time debugging (online parameter optimization, direct deployment via Ethernet).

Communication and integration capabilities

Native protocol support

Industrial bus: Profibus DPV1 (master station), Modbus RTU/TCP, IEC 61850 (power system) CANopen；

ABB exclusive: Powerlink, Drivebus (DDCS), Modulabus (S800 fiber optic).

Expansion

Through the CEX module: Drivebus slave station ControlNet、DeviceNet；

Supports RS-232/422 serial port through Anybus modules such as Profinet, EtherCAT, Ethernet/IP, etc.

System integration

Deeply compatible with ABB 800xA automation platform, achieving unified monitoring from on-site equipment to factory level, supporting firewall and security authentication to prevent unauthorized access.

Typical application scenarios

Traction field (railway/rail transit)

Challenge: Wide temperature range, strong vibration, limited space;

Scheme: compact hardware+anti vibration design, stable operation from -40 ℃ to+70 ℃, integrated I/O and processor in the same module, meeting the space requirements of on-board equipment.

Power generation and excitation control

Requirement: High reliability, redundant and fault-tolerant;

Solution: Modular architecture+hot standby redundancy, automatically switches to the standby unit when the main controller fails, ensuring continuous operation of the generator excitation system, suitable for key equipment in power plants.

Industrial process control (such as cold rolling mill)

Challenge: Thickness control accuracy (MIMO multiple input multiple output system);

Solution: MATLAB ®/ Simulink ®  Develop model predictive control algorithm, combined with C code acceleration, to improve thickness deviation by 50%, surpassing traditional control schemes.

Engineering benefits and customer value

Performance improvement:

Control accuracy: The thickness deviation of the cold rolling mill is reduced by 50%;

Response speed: 100 microsecond cycle time, suitable for high-frequency switching requirements of power electronic devices.

Cost optimization:

Development cycle: The model automatically generates code, reducing manual programming workload by 50%;

Hardware investment: Integrating multitasking with a single processor to reduce the separate procurement cost of PLC and high-speed controller.

Sustainability:

Energy consumption: Efficient algorithms reduce device operating power consumption;

Lifecycle: Industrial grade hardware design, supports long-term upgrades, and protects user investments.

Service and Support System

Tool chain: AC 800PEC specialized tools cover the entire engineering cycle (design, commissioning, maintenance);

Training system: Provide courses such as model development and system integration to enhance user team skills;

Global service: 100+country offices, 24-hour technical support, combined with local experience and global resources.