ABB AC 800PEC The Ultimate High-Speed Controller for Power Electronics & Industrial Automation

Core Positioning & Design Philosophy of AC 800PEC

1. Single controller for dual tasks: Simultaneously meet high-speed power electronics control (converter drive, pulse modulation, fast protection) and low-speed process control (loop control, status monitoring, data acquisition), replacing the “high-speed controller + PLC” combination.
2. Strong anti-interference industrial-grade design: Full-fiber communication, fanless cooling, solid-state storage, suitable for strong electromagnetic, wide-temperature, and high-dust environments such as substations, wind turbine towers, locomotives, and industrial sites.
3. Seamless integration across the ecosystem: Compatible with ABB IndustrialIT software system, standard fieldbuses, and third-party upper systems, reducing engineering development and system docking costs.
4. Modular and flexible configuration: Supports local/remote distributed installation, and modules can be freely combined according to I/O points, control logic, and communication requirements, adapting to systems from small single machines to large multi-cabinet setups.

In-Depth Analysis of AC 800PEC Hardware Architecture

1. Core CPU Module

• Processor: 750 MHz PowerPC 750FX RISC processor with a 64-bit IEEE floating-point unit (FPU), optimized for high-speed control algorithms.
• Memory configuration: 64 MB SDRAM cache (running real-time programs) + 16 MB Flash solid-state storage (saving programs and data). No battery backup required, and data is retained after power failure.
• Hardware acceleration: Built-in FPGA (Field Programmable Gate Array) independently processes ultra-high-speed timing-critical tasks such as pulse width modulation, pulse logic, and fast protection without occupying CPU resources.

2. Interface & Communication Modules

• Optical fiber interface: Supports up to 36 bidirectional optical fiber PowerLinks. Full optical isolation between the controller and I/O modules completely eliminates electromagnetic interference, with long transmission distance and strong stability.
• Ethernet interface: 2 independent Ethernet TCP/IP ports for connecting to upper-level SCADA, engineer stations, and other controller modules.
• Serial interface: RS-232/RS-422 service serial port, suitable for local operation panels, commissioning terminals, and third-party serial devices.
• Expansion bus: 2 AnyIO ports supporting CEX bus expansion and AnyBus-S fieldbus modules, compatible with all mainstream industrial protocols.

3. Dedicated I/O Modules

1. Combi IO UA D149 (High-Speed Mixed I/O)
• Core purpose: Analog/digital acquisition and output for fast closed-loop control.
• Configuration: Base module UA D141 + up to 2 mixed IO boards UA D142.
• Single-point parameters: 16 high-speed digital inputs / 8 high-speed digital outputs, 6 high-speed analog inputs, 2 high-speed analog outputs.
• Adaptation: Can be equipped with low voltage divider (LVD, up to 1000 Vrms), high voltage divider (HVD, up to 6000 Vrms), CT/VT sub-boards to adapt to different voltage and current levels.
2. PECMI UA D140 (High-Speed Measurement Interface)
• Core purpose: High-precision fast acquisition of current and voltage, suitable for power electronics converters and reactive power compensation devices.
• Functions: Supports 4 active scalable current inputs, voltage divider/CT/VT sub-board access, with built-in protection circuits.
3. PINT DD C779 (Thyristor Pulse Interface)
• Core purpose: Direct drive of thyristor converter arms, suitable for rectification, reactive power compensation, and HVDC power transmission.
• Capacity: Single board controls 2 independent 6-pulse thyristor converter arms, with pulse logic implemented in hardware.
4. PEBB Interface Boards (GD D160/D165)
• GD D160: Directly drives 2 IGBT converters (2×6 pulses), expandable to 6 units.
• GD D165: Directly drives 4 IGBT arms (4×6 pulses), suitable for high-power PEBB (Power Electronic Building Block) converters.
5. AC 800PEC INT Interface System
• Core purpose: Direct control of IGCT converters, with 6 optical transmit/receive channels built-in, and full hardware pulse logic.
6. Standard ABB S800 I/O Compatibility
• Low-speed signals (temperature, pressure, liquid level, general switching values) can be directly connected to ABB S800 I/O modules via optical fiber or bus, maximizing compatibility with the existing ABB ecosystem.

4. Core Hardware Advantages

• Fanless design: Low-power circuits, natural cooling, no mechanical failure points, greatly improved MTBF (Mean Time Between Failures).
• Full optical isolation: No electrical connection between the controller and I/O/converters, stable operation in strong electromagnetic environments.
• Distributed installation: Modules can be installed locally centrally or remotely distributed, adapting to dispersed I/O requirements of large equipment.
• Wide-temperature stability: Industrial-grade wide-temperature design, meeting harsh environments such as rail transit, wind power, and field substations.

AC 800PEC Software System & Development Platform

1. Three-Level Software Architecture

1. Level 1: IndustrialIT Integration Layer (Conventional Control)
• Based on the international standard IEC 61131-3, programmed with ABB Control Builder M.
• Responsible for low-speed process control: cooling circuits, status monitoring, operation display, data recording, interlock protection.
• Seamlessly connects to ABB upper systems such as OperateIT and Process Portal, supporting custom operation panels.
2. Level 2: Fast Control Layer (Algorithm Core)
• Development tools: MATLAB/Simulink + Real-Time Workshop.
• Responsible for fast closed-loop control algorithms with a control cycle of 100 μs to several ms, suitable for converter closed-loop regulation, power control, voltage and current stabilization.
• The simulation model directly generates real-time code and downloads it to the controller, greatly shortening the commissioning cycle.
3. Level 3: High-Speed I/O Control Layer (Hardware-Level Logic)
• FPGA-based hardware programming, developed in VHDL language.
• Responsible for ultra-high-speed tasks: PWM pulse width modulation, pulse generation, hardware protection, fast I/O read/write, typical cycle 25 μs.
• Hardware-level execution with no software delay, response speed far exceeding conventional PLC and general controllers.

2. Dedicated Engineering & Commissioning Tools

1. Control Builder M: IEC 61131-3 standard programming tool supporting ladder diagram, function block, structured text, easy for conventional automation engineers to get started.
2. PECView: PC-based dedicated commissioning tool for monitoring, analyzing, fault diagnosis, and parameter tuning of Simulink applications, supporting online debugging and offline analysis.
3. Process Panel Builder: Operation panel configuration tool with a rich built-in graphics library, quickly customizing human-machine interfaces, and standardized panels reducing configuration time.
4. AC 800PEC dedicated add-on: Licensed with hardware, fully integrated into the ControlIT engineering environment for unified project management.

AC 800PEC Communication & Bus Capabilities

1. Mainstream Fieldbus Support

• Slave protocols: Profibus-DP, Modbus-RTU, CANopen, Interbus, LonWorks
• Master protocols: Profibus-DP, MB300, Ethernet
• Extended communication: CEX bus, compatible with all ABB AC 800 series communication modules, suitable for rail transit and traction drive applications.

2. Upper-Level Communication

• Dual Ethernet TCP/IP: Connect to factory SCADA, MES systems, engineer stations, and redundant controllers.
• Remote service: Local debugging via RS-232 serial port, supporting remote diagnosis and maintenance.

3. Core Communication Advantages

• Multi-protocol parallel operation: High-speed control bus + conventional fieldbus + upper-level Ethernet run independently without interference.
• Optical fiber communication anti-interference: Zero packet loss and zero delay in strong electromagnetic environments (near converters and high-voltage equipment).
• Distributed expansion: Supports multi-controller networking, adapting to collaborative control of large multi-unit equipment.

5. Typical Application Scenarios of AC 800PEC

1. High-power power electronics converters
   Rectifiers, inverters, active power filters (APF), static synchronous compensators (STATCOM), SVC dynamic reactive power compensation.
2. New Energy Power Generation & Energy Storage
   Wind power grid-connected converters, photovoltaic inverters, energy storage converters (PCS), micro-turbine control systems.
3. Rail Transit & Traction Drives
   Light rail/subway traction control systems, locomotive converter control, EMU auxiliary converter control.
4. High-Voltage Direct Current (HVDC) Transmission
   IGCT/IGBT HVDC control, thyristor converter valve control.
5. Industrial Heavy-Duty Drives
   Rolling mill main drives, hoist drives, high-precision drives for large fans/pumps, synchronous drive systems.
6. Special Power Equipment
   Series voltage restorers, pulse power supplies, industrial test platforms, high-precision power experimental devices.

6. Full Series AC 800PEC Product Model Recommendations

1. Core Controller Models

(1) AC 800PEC PP D113

• Order No.: 3BHS201058E01 (document standard model)
• Positioning: Standard universal type, first choice for medium and small power converters, wind power, energy storage, rail transit.
• Adaptation: Single-cabinet systems, conventional I/O points, non-redundant high-speed control scenarios.
• Highlights: Complete CPU + optical fiber interface + CEX expansion, compatible with all dedicated I/O modules.

(2) AC 800PEC BP Backplane

• Positioning: Basic installation carrier of the system, used to install CPU, power supply, optical interface, and communication modules.
• Advantages: Standardized slots, modular flexible configuration, supporting redundant configuration.

2. Dedicated I/O & Interface Modules

Required for High-Speed Control

• Combi IO UA D149: High-speed analog/digital mixed I/O, core module for fast closed-loop control.
• PECMI UA D140: High-speed current and voltage measurement, essential for converter sampling.

Required for Converter Drive

• PINT DD C779: Special pulse interface for thyristor converters.
• PEBB GD D160: 2-arm drive for IGBT converters.
• PEBB GD D165: 4-arm drive for IGBT converters.
• AC 800PEC INT: Special interface for high-power IGCT converters.

Low-Speed Signal Expansion

• Full series of ABB S800 I/O: Suitable for low-speed signals such as temperature, pressure, and general switching values.

3. Quick Selection Guide

• Medium and small power converters / energy storage PCS → PP D113 + Combi IO UA D149 + PECMI UA D140
• Thyristor rectification / reactive power compensation → PP D113 + PINT DD C779
• High-power IGBT/IGCT converters → PP D113 + PEBB GD D165 + INT interface
• Rail transit traction → PP D113 + Traction DA D143 module + S800 I/O

Core Value of Choosing ABB AC 800PEC

1. Cost reduction by more than 30%
   Single controller replaces high-speed controller + PLC, reducing hardware, wiring, cabinet space, and maintenance costs, and lowering system failure points.
2. Leap in control performance
   Fastest 25 μs control cycle, hardware-level FPGA protection, dynamic response far exceeding conventional PLC, improving product accuracy and stability.
3. Development cycle shortened by 50%
   IEC 61131-3 + Simulink dual platform, simulation direct download, no repeated coding, more efficient commissioning.
4. Industrial-grade high reliability
   Full optical isolation, fanless, Flash battery-free storage, long-term stable operation in strong electromagnetic and wide-temperature environments.
5. Ecosystem compatibility without barriers
   Compatible with ABB’s full range of products and mainstream fieldbuses, zero obstacles to connecting upper systems and third-party devices.

Conclusion