AC 800PEC High Performance controller application
High-performance applications with extremely fast control algorithms – cycle times that range from 100 μs (microseconds) for fast control loops to seconds for long-term operational transients – require specialized control devices.
The AC 800PEC has a unique combination of features for demanding applications:
- Short cycle times, down to 100 μs
- High processing power
- Fast communication and I/O via optical links
- Programming tools:
– System engineering with IEC61131-3 languages using ABB’s Control Builder, both Compact and Professional versions available
– Product and control development using MATLAB®/Simulink® for model-based design, easily bridging the gap from simulation to implementation
- Full integration into ABB Ability™ 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
- Robust reliance file system, insusceptible post power loss
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 for control 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
PCD230A101 3BHE022291R0101 UNITROL 6000 X-power controller
ABB AC 800PEC PP D113 High-performance controller
PPD113B01-10-150000/3BHE023784R1023
PPD113B03-26-100110/3BHE023584R2634
PPD113-B03-23-111615/3BHE023584R2365
PPD113B03-26-100100/3BHE023584R2625
PPD115A102/3BHE017628R0102
PPD512 A10-15000/3BHE040375R1023
UNITROL 6000 PCD232A 3BHE022293R0101
PCD235A101 3BHE032025R0101
UNITROL 6000 PCD530A102 3BHE041343R0102
PCD231B101 3BHE025541R0101
PCD230A101 3BHE022291R0101
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 hydraulic system control) features included:
• Electrode manual control (analog or digital)
• Electrode fast lift function (with or without separate fast up valve)
• Automatic arc strike function
• Automatic arc restrike function
• Adaptive electrode control according to furnace behavior or heat stage
• Superimposed integral control circuit
• Voltage fluctuation measurement (stability index calculation)
• Arc-to-roof detection/protection
• Arc-to-roof protection during arc strike sequence
• Hydraulic oil pressure supervision and electrode 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 off command (distance or position selectable)
• Blocking valve control
• Electrode speed limitation for electrode and arm protection
• Future features
– Automatic proportional valve linearization check
– Automatic proportional valve linearization
– Dynamic voltage setpoint control for a stable melting process