STUDY OF ABB MAKE AC 800 PEC CONTROLLER IN PROCESS AND

PRODUCTION CONTROL SYSTEM IN WIRE ROD MILL OF VISAKHAPATNAM

STEEL PLANT

Training/project report submitted to
GITAM UNIVERSITY
In partial fulfillment for the Degree of
BACHELOR OF TECHNOLOGY




BRANCH EUREE

ELECTRICAL AND ELECTRONICS ENGINEERING

MAY, 2011




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ACKNOWLEDGEMENT

My sincere thanks to the Principal and Dean, Prof.D.Prasada Rao, Ph.d, Gitam University for his
permission to use the facilities of the institution.
Words seem inadequate to express my deep sense of gratitude to Dr.K.S.Lingam Murthy, M.E.,
Ph.D (IITD) , FIE, MISTE ,Professor and Head, Department of Electrical and Electronic
Engineering. Gitam University for his valuable guidance, constant support, encouragement, for
imparting knowledge and guiding me with patience.
I extend my sincere thanks to Sri.I.E.S.Naidu , Associate Professor, Department of Electrical and
Electronic Engineering , Gitam University for his guidance , support and help throughout the
training/ project work and for advice in completion of this work.
I am deeply indebted to Mr.Prabhakara Rao, AGM, Training and Development Center,
Visakhapatnam Steel Plant for granting me permission to carry on my training in the
Visakhapatnam Steel Plant.
I deeply thank Mr. Kunal Sarkar and Mr.Tushar Agarwal Wire Rod Mill Department,
Visakhapatnam Steel Plant for their constant help , support and guidance throughout the training.
I acknowledge gratefully to Mr.Abhayankar Banerjee and Mr.Yugandhar Yerneni for their
constant help and support throughout the training.
Last but not the least I specially thank my parents, family members and friends for their love,
understanding, support that has helped me during my work.
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CONTENTS

S.NO INDEX PAGE NO
1. INTRODUCTION 4
2. OVERVIEW OF VISAKHAPATNAM STEEL PLANT.. 6
3. WIRE ROD MILL. 10
4. PROCESS CONTROL BY COMPUTER IN WIRE ROD MILL. 16
5. PROGRAMMABLE LOGIC CONTROLLER.. 30
6. AC 800PEC AND ITS FEATURES.. 37
7. HARDWARE ASPECTS OF AC 800PEC 40
8. SOFTWARE ASPECTS OF AC 800PEC. 71
9. PROCESS CONTROL BY AC 800PEC IN WRM.. 87
10. CONCLUSION..... 89
11. TABLES. 91
12. BIBLIOGRAPHY..

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INTRODUCTION












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The AC 800PEC is ABB's high performance process control system and belongs to the Control
IT product line. Large-scale power converters and drives must be reliable, fast and precise. That
calls for a control system with outstanding performance. In order to meet this high performance
control requirements ABB provides two control platforms for power electronics systems.
The AC 800PEC is the optimum solution for combining the high-speed control requirements of
power electronics applications and low-speed process control tasks usually carried out by
separate PLC units. The AC 800PEC controller is configured and programmed using Control
Builder M, ABBs well-established programming tool complying with IEC 61131-3, and
MATLAB/ Simulinkwith Real-Time Workshop.
Ethernet is used as preferred medium for configuration and communication to upper control. The
AC 800PEC interfaces with ABBs I/O systems via the optical S800 Modulebus and with ABBs
communication modules via Communication Expansion Bus (CEX). It also supports 3rd party
AnyBus-S fieldbus modules.
This project mainly brings forth the rolling mill process done with the controls of the ABB make
800 PEC. It brings a contrast between the earlier technology of process control in rolling mill
with the process control done by the ABB 800 PEC. It also provides information regarding the
hardware and software aspects of the ABB 800PEC and also its process control diagram in the
Steel Plant wire rod mill.










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OVERVIEW OF VISAKHAPATNAM
STEEL PLANT








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Visakhapatnam steel plant is the first coast based integrated steel plant of India. Bestowed with
modern technologies, VSP has an installed capacity of 3 million tonnes per annum of liquid steel
and 2.656 million tones of saleable steel. At VSP, there is emphasis on total automation,
seamless integration and efficient up gradation, which result in wide range of long and structural
products to meet the stringent demands of discerning customers within India and abroad. VSP
products meet exalting international quality standards such as JIS, DIN, BIS, BS, etc.
VSP has become the first integrated steel plant in the country to be certified to all the three
international standards for quality ( ISO-9001 ), for Environment Management ( ISO -14001 )
and for Occupational Health and Safety ( OHSAS-18001 ) the certificate covers quality systems
of all operational, maintenance, service units besides purchase systems.
VSP exporst quality pig iron and steel products to Sri Lanka, Myanmar, Nepal, Middle East,
USA and South East Asia ( pig iron ). RINL VSP has awarded Star Trading House status
during 1997-2000.
The major steel products are angles, billets, channels, beams, squares, flats, rounds, re-bars, wire
rods. The by products are nut coke, coke dust, coal tar, anthracene, HP napthalence , benzene,
toluene, xylene, wash oil. The other products of VSP are granulated slag, lime fines, ammonium
sulphate. Recently in the year 2010 , the VSP has been awarded the Gold Award for Outstanding
Achievement in Training Excellence by Greentech Foundation, New Delhi and the Global
Human Resource Development Award of International Federation of Training and Development
Organization, London and many more.
VSP TECHNOLOGY :
v 7 meter tall coke oven batteries with coke dry quenching
v Biggest blast furnaces in the country
v Bell-less top charging system in Blast furnace
v 100% slag granulation at BF cast house
v Suppressed combustion LD gas recovery system
v 100% continuous casting of liquid steel
v Tempcore and Stelmor cooling processes in LMMM and WRM respectively.
v Extensive waste heat recovery systems
v Comprehensive pollution control measures

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Major units :
DEPARTMENT ANNUAL CAPACITY
( T )
UNITS ( 3.0 MT STAGE )
Coke ovens 2,261 3 batteries of 67 ovens and
7 mts height
Sinter plant 5,256 2 sinter machines of 312 sq.
mts grate area each
Blast furnace 3,400 2 furnaces of 3200 cu.mts
volume each
Steel Melt shop 3,000 3 LD converters each 133
cu.mtr volume and six 4
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strand bloom casters
LMMM 710 4 stand finishing mill
WRM 850 4*10 stand finishing mill
MMSM 850 6 stand finishing mill

Major sources of raw materials :
RAW MATERIAL SOURCE SOURCE
Iron ore lumps and fines Bailadilla , MP
BF lime stone Jaggayyapeta , AP
SMS limestone UAE
BF dolomite Madharam, AP
SMS dolomite Madharam, AP
Manganese ore Chipurupalli, AP
Boiler coal Talcher, Orissa
Coking coal Australia
Medium coking coal Gidi /Swang / Rajarappa / Kargali








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WIRE ROD MILL










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Wire rod mill ( WRM ) is a 4 strand, 25 stands fully automated and sophisticated mill. The mill
has a four zone combination type reheating furnace ( walking beam cum walking hearth ) of 200
TPH capacity for heating the billets received from billet mill of LMMM to rolling temperature of
1200 degree centigrade.
The heated billets are rolled in 4 strand, no twist continuous mill having a capacity of 8,50,000
tonnes of wire rod coils. The mill has the following configuration:
v 7 stand two high 4 strand horizontal roughing mill
v 6 stand two high 4 strand horizontal intermediate mill
v 2 stand 4 strand per finishing mill
v 10 stand 4 strand no twist finishing mill
The mill produces rounds in 5.5-12 mm range and rebars in 8-12 mm range. The mill is equipped
with standard and retarded stelmor lines for producing high quality wire rods in low, medium
and high carbon grade meeting the stringent National and International Standards viz, BIS , DIN,
JIS, BS, etc and having high ductility, uniform grain size and excellent surface finish. The wire
rod mill uses mainly two types of bearings : morgoil bearing and 2 row axial tapered roller
bearings.
PROCESS:
The raw material ( billets from the LMMM Department )is placed on the charging grid one (
controlled by ac motors ) i.e. in the billet yard by an overhead crane. From which it moves to the
charging grid two ( controlled by dc motors).Then through the cross transports, billet elevator,
billet transfer device and billet positioning device the billet is placed on the roller tables. The
billet now moves from the group 1 to group 2 ( four billets at a time). Then the billet enters the
walking beam furnace where it is heated to a temperature at around 1700 degrees centigrade.
When the billets reach the other end of the furnace they are hot enough to be rolled. Furnace is
the heart of this factory. Rolling is impossible without heating the billets. Heating reduces
residual stresses. Furnace is lined with several layers of refractory bricks.The red hot billets are
then pulled from the furnace on to the conveyor which transports it to the rolling stand. The billet
passes through the the peel bar and the billet withdrawing machine and passed through the
roughing mill stands( 1 to 7) for special rolls to attain desired sizes and thickness. The rolling
process is composed of stage wise rolling of steel. Then the rolled steel passes through the RM
sheers , intermediate mill stands, looper table, IB snap shell , intermediate block stand, FB sheer,
looper table 2 and finally reaches the finishing block. The sheering machines are used to cut
billets into pieces under various conditions such as : improper size, cobble, etc. Sheering
machines are pneumatically operated clutches. Finally it reaches the coil formation chamber
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from where it is hooked on the conveyor. These rolls are then placed on the compactor where is
it compressed and tied together. At last , the finished products are placed on the trucks with the
help of the special overhead travelling cranes.

Fig : Wire rod mill products and applications






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CHARGING AREA
CHARGING GRID- 1 ( AC MOTORS )
CHARGING GRID -2 ( DC M0TORS )
CROSS TRANSPORTS
BILLET ELEVATOR
BILLET TRANSFER DEVICE
BILLET POSITIONING DEVICE
ROLLER TABLES
GROUP 1 TO GROUP 5
WALKING BEAM FURNACE
PEEL BAR
INTERMEDIATE MILL
STAND 8 TO STAND 13
INTERMEDIATE
BLOCK STAND 14
LOOPER
TABLE
FB SHEER
NO TWIST STAND
FINISHING BLOCK -16 TO 25
ROUGHING MILL STAND 1 TO 7
BILLET WITHDRAWING MACHINE
PINCH ROLL

RM SHEERS I TO 4
IB SNAP
SHELL
LOOPER
TABLE
LAYING
HEAD
TRACTOR
CHAIN
STELMORE
Coil formation chamber
Hook conveyor
Compactor and turnstile
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1 2
3 4
Fig: From left horizontally: 1-Digital crane electrical circuit. 2 and 3-Analog crane electrical
circuit. 4- Overhead travelling crane
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PROCESS CONTROL COMPUTER











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In computer process control, a digital computer is used to direct the operations of a
manufacturing process. Although other automated systems are typically controlled by computer,
the term computer process control is generally associated with continuous or semi continuous
production .
The computer process control generally includes the following:
1. Measurement of important process variables such as temperature, flow rate, pressure
2. Execution of some optimizing strategy
3. Actuation of such devices as valves, switches and furnaces that enable the process to
implement the optimal strategy
4. Generation of reports to management indicating equipment status, production
performance and product.
Organizational structure of the wire rod mill is of hierarchical type with three functional levels.
The first level functions are implemented on two computers viz., production control computer
and fault monitoring computer. The second level functions are realized by process control
computer. The PLCs are for level 3 functions.

Substantial economic advantages are obtained from this type of computer control in the process
industries. The computer hierarchy is capable of integrating all the data from the many individual
control loops far better than humans are able to do, thus permitting a higher level of
performance. Advanced control algorithms can be applied by the computer to optimize the
process. In addition, the computer is capable of sensing process conditions that indicate unsafe or
abnormal operation much more quickly than humans can. All these improvements increase
productivity, efficiency, and safety during process operation quality.
Computer process control in metals industry is the rolling of hot metals into final shapes. The
rolling process involves the forming of a large, hot metal billet by passing it through a rolling
mill consisting of one or more sets of large cylindrical rolls that squeeze the metal and reduce its
cross section. Several passes are required to reduce the ingot gradually to the desired thickness.
Sensors and automatic instruments measure the dimensions and temperature of the ingot after
each pass through the rolls, and the control computer calculates and regulates the roll settings for
the next pass.
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FUNCTIONS OF PROCESS CONTROL COMPUTER:

1. Control of main drives
2. Cascade control
3. Loop control
4. Bar tracking and cobble detection
5. Control of shears
6. Control of cooling water boxes & air blowers
7. Control of pinch roll and laying head
8. Control of stelmor conveyor and tractor chain
9. Control of dividing head and trimming in coil forming station
10. Static error rpm correction
11. Logging
12. Simulation of mill events
13. Communication with production control computer

Realization of above function is only possible with effective coherent coordination between
various field signals received by process control computer, its hardware and its software.

HARD WARE DETAILS:

1. System : Siemens 300 R30 E
2. Main Memory : 512 Kw (1 Mb)
3. Floppy Drive : Type 3944 8 Dsdd With Drives (Replaced With 3.5 Drives)
4. Terminals : 2 X Type 3974 B/W Monitors 44 Cm Standard Key Board
: 3 X Type 3974 Color Monitor 51 Cm : 1 X Type 3974
B/W Monitor 44cm
: 2 X Matif 128 Functional Key Board.
5. Oper.Console : 1 X Type 3914 I/O Printer 60 Cps.
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6. Printers : 1 X Type 3964 Dro29 160cps
7. Communication Ports : 1 X Typ3 3964-R For Prod.C.C
8. Input / Output
Cards : 19 X Type 3615-C For Digital Inputs& 32 Inputs Per Card.
: 22 X Type 3625 A / 3627-C For Digital Outputs & 32
Outputs Per Card.
: 17 X Ddc Pulse Counter Pulse Inputs &2 Per Card
: 2 X Type 3635c For Analog Inputs. 16 Inputs Per Card
16 X 3652-A Type For Analogue Outputs- 4 Per Card




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SIGNALS HANDLED:

1. Digital Inputs: 602
2. Digital Outputs: 547
3. Analog Inputs: 32
4. Analog Outputs: 68
5. Pulse Inputs: 32

CENTRAL PROCESSING UNIT OF R30 CPU OF PROCESS CONTROL

The central processing unit consists of:
1. Central processing module
2. Main memory
3. I/O interface
4. Operation, Test or Maintenance panel
5. Power supply unit

Central processing module consists of:
1. Central processor(CP)
2. Floating point processor
3. Integrated I/O processor
4. Interface channel for operation, test or maint.panel.

The central processor processes the specified operands in accordance with the instructions stored
in the main memory and reacts to internal and external (peripheral) interrupt request. The CPU is
extended by a floating point processor.This processor carries out arithmetic operations for 32 bit
fixed point and 32bit and 64 bit floating point operands.
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The integrated I/O processor handles data transfer to the peripheral units in time-divisional
multiplex operation with the central processor. Its data rate is maximum up to 400.2e10 words
per sec. Data traffic of fast peripheral units is made possible via. independent selector I/O
processor located directly between the corresponding peripheral unit and the main memory,
simultaneously to the execution in CP module at a rate of up to 1000.2e10 words per sec. The
selector I/O processor carries out this access to the memory in a cycle-stealing operation.

Hardware test devices such as maintenance panel, operating panel permits simple start up and
maintenance of CPU. The test panel and the virtual console permit direct testing of programs
near the hardware.


INTERNAL ORGANIZATION:

The core of the central processing module is formed by
the arithmetic unit and the control unit. The arithmetic unit consists of eight cascadable,
highly integrated, bipolar microprocessors for arithmetic and logic operations. They are
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combined in two 16-bit wide functional units of 16 hardware registers each.
Sixteen hardware registers of the central processor are available for arithmetic operations .They
can be used as intermediate storage units and can be incremented or decremented when the
instructions are executed. In addition to the 16 hardware general registers, the central processing
module has a number of additional registers, namely the special and auxiliary registers.
Some of these registers are housed in the hardware registers of the arithmetic unit, while some
are arranged as discrete components on the central processing module. The special registers are
addressable hardware registers. They control information which effect the execution of
instruction such as state of central processor and I/O processor and affect the state change.

The following are the special registers available:

1. Program status register (PZR) : influences program execution
2. Peripheral interrupt mask register (PUMR) : the causes of peripheral interrupts can lead
to a status change only if the mask is set.
3. Peripheral interrupt register (PUR) : used to buffer the peripheral interrupt requests.
4. Internal interrupt register (IUR) : used to buffer the internal interrupt register
5. Central processor status register (ZZR) : contains the binary coded number of the current
priority status.
6. Program runtime counter (PLZ) : used for program specific run-time monitoring and
measurement.
7. Request mask register (AMR) : a set bit enables peripheral requests of the corresponding
I/O interface channel in the I/O processor.
8. Table pointer register2 (TZR2) and Address control register (AWR):
enable access to a second virtual
address area in the case of R30 CPU.

Some special registers are program specific:
When a change of status occurs, they are written or read in to or from the parameter table by the
save-restore operation. The auxiliary registers have functions similar to those of special
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registers. However it is not possible to make changes to them by instructions. If program
interrupt occurs, however they are saved in to program specific parameter tables, from
which they can restore.

The following auxiliary registers are available:
1. Interrupt flag register : used to provide further details on internal interrupt cause from
program traps.
2. Table pointer register 1 (TZR1) : used for addressing the current parameter table in the
respective priority status and, only in the case of R30 CPU, for addressing the UTI
memory page table.
3. Instruction address buffer (BAP) : for storing the last instruction address to allow errors
and interrupt causes to be established.

INSTRUCTION EXECUTION:

The execution of instructions is controlled by the instruction scheduler.
The instructions are executed in micro program steps. Depending on the operations to be
performed, a micro program cycle may have a duration which varies and is typically 200ns. The
R1 general purpose register always contains the address of the instruction to be performed next.
Simultaneously with the last micro program steps of the preceding section , the central processor
switches this instruction address to the data and address bus (DAB) and reads the coding from
main memory. The new instruction is first decoded in the first micro program steps the operand
address is calculated if necessary, and the operands draw from the main memory. The operands
are processed by subsequent sequence of micro programs.
During the last microprogramming steps of the current instruction, the next instruction is
obtained simultaneously from main memory for instruction processing.
This (above) point omitted only in instructions which change the R1 general purpose register and
in store instructions. In these instances the time required for next instructions extended by at least
400ns. If there are one or several requests to the integrated I/O processor (IEAP) the processing
of the instruction in CP is interrupted before the first micro program step of the new instruction.
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A micro program sequence of IEAP is first executed. After all requests applied to IEAP have
been processed, the CP continues its instruction execution.

PROGRAM STATUS REGISTER:

The program status register (PZR) contains information for controlling instruction and program
execution. In the event of a status change (and therefore at each program change as well), the
contents of PZR, the program status word, is deposited in the parameter table of the current
status or program. The PZR is then loaded with the program status of the new status or new
program.

INTERRUPT SYSTEM:

The central processor is available to the current user program during the normal program run and
executes this program.
A change in CP status must occur if
1. traps are reported during the program run, and
2. Errors, malfunctions or alarms occur.

To ensure that these interrupt events are processed quickly and rationally the central processor
recognizes 16 priority statuses (PZT 0-15). Each priority is subdivided in to a normal mode and a
special mode. The maintenance panel, operation and test panel, virtual console and start up
programs run in a special CP status (Z0) with the maintenance panel having highest priority. The
priority status of the central processor is determined by three special registers of 16 bits each.
1. IUR : internal interrupt register
2. PUR : peripheral interrupt register
3. PUMR : peripheral interrupt mask register

The IUR requests a priority status under program control with the bit no. Corresponding to the
priority status requested. A bit in the PUR is by the IEAP specifically for the interface to inform
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the central processor that there is an interrupt request from a peripheral device. The peripheral
units signal to the CPU by means of peripheral request (PA) that they wish to have a transfer of
information. Two basic functions are distinguished.

Data between the central processing unit and the peripheral unit (PU) are exchanged by means of
a peripheral data request (PDA).

The I/O processors execute this data transfer directly with main memory. A peripheral
organization request (POA) leads to a status change in central processor via the I/O
processors by setting of the interface specific bit in the PUR (errors of the I/O processors
are also signaled in this manner).

The bit no. in the PUR corresponds to the no. of I/O interface. PUR bit is set by the micro
program if a voltage failure has been recognized. In general with the operating systems,
ORG300, in operation the priority states are:

Z0 : SPECIAL STATUS FOR MAINTENANCE
PANEL OPERATION PANEL, TEST PANEL AND
VIRTUAL CONSOLE.
PTZ0 : ERROR HANDLING
PTZ (1-11) : PERIPHERAL INTERRUPT HANDLING (IF
NECESSARY USES HIGH-SPEED REACTION AREA)
PTZ (1-13) : IF NECESSARY USES HIGH SPEED REACTION AREA
PTZ14 : OPERATING SYSTEM
PTZ15 : USER PROGRAM

ADDRESSING:

In the R30 CPU (maximum address range 1024.2e10 words), the main memory locations 0-
64.2e10 words can be addressed with physical addressing. For addressing the other main
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memory areas the main memory (physical address area) is subdivided in to partial areas of
64.2e10 words (virtual address area). 20 bit address in main memory locations within a virtual
address area can be accessed with a 16 bit virtual address which is carried out with the aid of
memory page tables which are filled in main memory. In the R30 CPU, physical memory is
substantially reserved for the operating system, ORG, while virtual addressing is normally used
by the user programs running under ORG administration.

Since an individual memory page table can be allocated to each program, a continuous virtual
address area of 64.2e10 words is always available to the program. The PZR bits 14 and 15
determine whether the 16bit address to be interpreted as a virtual or physical address. If bit 14 is
set, virtual addressing is carried out (addressing through register R1). If 15 bit is set the address
of the operand must be interpreted as virtual address.

BUFFER STORE:

For a further increase in system power especially with larger main memory configurations the
R30 CPU uses buffer storage. Since access time to the buffer stores is shorter (1000ms) than the
access time to memory, the mean instruction executing times is reduced and the limiting data
areas in I/O traffic are improved. The buffer store has a capacity of 64 words divided in to 4
sectors of 16 words each. Each sector has an address register. When a memory request occurs the
address switched through is compared associatively with four sector addresses. if equity is
detected with a sector address the buffer controller selects one of the four lines of sector based on
least significant address bits. If data are already entered in this line the desired data word is
passed to the processor. Otherwise the four data words are loaded in to the line with a
main memory access and are declared valid. If the buffer controller can not detect equality with
any sector address, the sector address which has not been used for longest time is erased , the
new address is adopted as the sector address and the corresponding line is loaded with a main
memory access .

The buffer store has thus has two distinctive advantages:
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1. Instruction and data look ahead because of 4 word wide main memory access.
2. Working out of small to medium sized program loops with optimum speed.

TECHNICAL DATA:

Word length : 16 bits
Registers : general purpose registers -16
: Special registers - 9
: Auxiliary registers - 4
Instructions : matrix instructions list (234 instructions without floating processor)
(301 are standard instructions
Out of which:
61 load instructions
23 store instructions
98 arithmetic instructions
15 Boolean instructions
43 comparison instructions
28 bit test instructions
15 branch instructions
15 shift instructions
3 field instructions)

For 16 bit fixed point instructions, 32 bit fixed point and floating point instructions, 64 bit
floating point instructions, bit instructions, byte instructions and field instructions:
-12 are internal instructions
- 6 are I/O instructions.
Instruction format : 16,32 and 48 bits
Parallel processing : 16 bit, 32 bits with floating point processor

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Address volume: 512.2e10 words
(Per program): 2 x 64.2e10 words (Virtual addressing with R30 CPU)

Interrupt structure: 16 priority statuses each with normal and special Modes

Status change time: 19.3 micro sec. to 22 micro sec. with the R30 CPU

Logic : TTL, S-TTL, LS-TTL in MSI & LSI

I/O SYSTEM : Integrated I/O processor for controlling block transfer to all I/O interface
channels via 8 separate EAP instructions.

I/O interface channel: 11 I/O interface channels for word serial (16 bitsparallel) and byte serial (8
bits parallel) data transfer.

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Connection of process peripherals: each I/O interface can be extended with additional basic and
expansion controllers for a maximum of 6246 process I/O devices.

Connection of standard peripherals: each I/O channel can be extended with additional
multiplexer controllers for max 256 peripheral units or with PROMEA programmed multiple
interfaces for max. 16 peripheral units working in serial mode.

MAIN MEMORY:
Addressing : max 512.2e10 words
RAM
Type Of Store: Dynamic Nmos Semiconductor Memory.
Configuration: max. 8 memory modules
Module capacity: 32, 64, 96& 128.2e10 words
Access time per cycle: 300 to 450 nano sec ; 700 nano sec. with error correction
Access width: 16 bits parallel
In a large plant, several orders for rolled products with different specifications may be in the mill
at any given time. Control programs have been developed to schedule the sequence and rate at
which the hot metal ingots are fed through the rolling mills. The production control task of
scheduling and keeping track of the different orders requires rapid, massive data gathering and
analysis. In modern plants this task has been effectively integrated with the computer control of
the rolling mill operations to achieve a highly automated production system.







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PROGRAMMABLE LOGIC CONTROLLERS














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The term programmable logic controller is defined as follows by :
A digitally operating electronic system, designed for use in an industrial environment, which
uses a programmable memory for the internal storage of user-oriented instructions for
implementing specific functions such as logic, sequencing, timing, counting and arithmetic, to
control, through digital or analogue inputs and outputs, various types of machines or processes.
Both the PC and its associated peripherals are designed so that they can be easily integrated into
an industrial control system and easily used in all their intended functions."
A Programmable Logic Controller is an industrial computer control system that continuously
monitors the state of input devices and makes decisions based upon a custom program , to
control the state of devices connected as outputs. Based upon a user written program, stored in its
memory, it controls the status of devices connected as outputs.




Fig: Programmable controller
With the coming of microcontrollers, associated peripheral chips and developments in the field
of software technology, the whole scenario related to process of control and automation
underwent a radical change. Instead of achieving the desired control or automation through
physical wiring of control devices, in plc it is achieved through a program or say software. As
the desired logic control is achieved through a program, these controllers are referred to as
Programmable Logic Controllers. The PLC have in recent years experienced an unprecedented
growth as universal element in industrial automation. It can be effectively used in applications
ranging from simple control like replacing small number of relays to complex automation
problems.
INPUTS
PROGRAMMABLE
CONTROLLER
OUTPUTS
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What are the advantages of using PLC ?
v Reduced space: PLCS are fully solid state and hence extremely compact as compared to
hard-wired controller wherein electromechanical devices are used. The wiring involved is
straight, simple and less.
v Energy saving : average power consumption is just 1/10
th
of power consumed by an
equivalent relay logic control.
v Ease of maintenance: Modular replacement, easy trouble shooting , error diagnostics with
programmer supported by software.
v Economical: considering one time investment is most economical system. The benefits
like reduced space, less wiring, low power requirement, lower project time, less down
time being fully solid state, highly reliable, etc. need to be considered when talking about
economy. Cost of PLC is recovered within a short period ( low pay back period).
v Greater life and reliability: Static devices hence lesser number of moving parts, reduces
wear and tear. In the case of hard wired logic the control, hardware is either
electromechanical or pneumatic and therefore it is more prone to faults due to wear and
tear of moving parts resulting in lesser ON TIME of the system.
v Tremendous flexibility: To implement changes in control logic, considerable time is
saved. PLC can carry out complex functions such as generation of time delays, counting,
comparing, arithmetic operations, real time control, analog value processing etc. On line
as wells as Off line programming is possible. High processing speed and great flexibility
in the processing of both analog and digital signals. Suitability for closed loop tasks with
several loops and high sampling frequencies.
v Shorter project time: The hard wired control system can be constructed only after the task
is fully defined. In the PLC, however, the construction of the controller and wiring are
independent of control program definition. This means that the total hardware is standard
and desired control is achieved through program.
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v Communication capabilities: The PLC can communicate with other PLCS , auxiliary
devices like PC, printer, etc. or other compatible devices like drives. In todays working
environments, the communication capabilities is a prerequisite for a any control and
automation task.
v Rugged and designed to withstand vibrations, temperature, humidity, and noise.
v Have interfacing for inputs and outputs already inside the controller.
v Easily programmed and have an easily understood programming language.




Page 34 of 91

CONSTITUTION OF A PLC
The PLC is basically a programmed interface between the field input elements like limit
switches, sensors,transducers, push-buttons, etc and the final control elements like actuators,
solenoid valves, dampers, drives, LEDs, hooters, etc. This interface called as Programmable
Logic Controller. It consists of :
1. Input modules
2. CPU with processor and program memory
3. Output modules
4. Bus system
5. Power supply
INPUT DEVICES:
The input devices used are push buttons, selector switches, limit switches, level switches,
photoelectric sensors, proximity sensors, motor starter contacts, relay contacts, thumbwheel
switches ( 220 V AC, 24V DC ).
OUTPUT DEVICES :
The various output devices used are valves-relays, motor starters, solenoids, control relays,
alarms, lights, fans, horns.
INPUT PROCESSING AND INPUT MODULE:
During input scan the PLC reads the on/off status of inputs and stores them in the input image
memory before execution of program. This information is stored and held valid till the next scan
of the input module. No change in status is acknowledged in between scan sequence.
The input module actually acts as an interface between the field control inputs and the CPU. The
voltage or current signals generated by the sensors, transducers, limit switches, push buttons , etc
are applied to the terminals of the input module. The input module converts the field signal into
Page 35 of 91

standard control signal for processing by PLC. The standard control signal delivered by the input
module could be 5V or 9V whereas the field signal received by it could be say 24V DC or 230V
AC. If required, the input module isolates the field signal from the CPU. It sends one input at a
time to the CPU by multiplexing action thus helping in serial communication. Depending upon
the nature of the input signal coming from the field, the input module could be analog input
module or digital input module.
CENTRAL PROCESSING UNIT OR PROGRAM PROCESSING:
The user executes the user program taking into consideration the status from image memories
and not that of the actual physical elements. Depending upon the logic, the output image memory
is updated as the program execution progresses and results is conveyed to the CPU memory for
intermediate storage.
The central processing unit consists of the :
v Arithmetic logic unit
v Program memory
v Process image memory
v Internal timers and counters
v Flags
The heart of CPU is its microprocessor/microcontroller chip. The working of CPU is fully
controlled by the instructions/programs stored in user program memory. The user program
directs and controls the CPU working. This program is prepared by the user based on the control
logic required for the control and automation tasks. ALU is the organizer of the PLC. The ALU
organizes the input of the external signals and data, performs logic operations with the data,
performs calculations, takes account of the value of the internal timers and counters, takes
account of the signal states of stored in the flags, stores the signal
Disadvantages of PLC control
- Too much work required in connecting wires.
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- Difficulty with changes or replacements.
- Difficulty in finding errors; requiring skillful work force.
- When a problem occurs, hold-up time is indefinite, usually long.
Advantages of PLC control
* Rugged and designed to withstand vibrations, temperature, humidity, and noise.
* Have interfacing for inputs and outputs already inside the controller.
* Easily programmed and have an easily understood programming language.















Page 37 of 91









AC 800PEC AND ITS FEATURES









Page 38 of 91


We are surrounded by electronic devices of all types and descriptions, and expect these to
perform autonomously and correctly. In power electronics, the demands on such devices are
especially tough. The time domain, which must be handled, ranges from nanoseconds for the
triggering and monitoring of the individual switching actions to seconds for long term
operational transients. Designing a single, slim and efficient controller to handle all this is no
easy task.

ABBs AC 800PEC controller was designed specifically with such applications in mind. The
model can flexibly be adapted to handle different time domains and code can efficiently be
crfeated from Matlab/Simulink model.

The processing unit inside the early AC 800PEC controllers was the PP D102. However,
specifically targeting smaller systems where both space and costs are critical, ABB has produced
a new controller based on the PP D104 rocessor-an ultra-compact device taking up less space
than a credit card.

The AC 800PEC provides the optimum solution for the high-speed control reqirements of power
converters. The AC 800PEC is a high-end controller belonging to ABBs AC 800product line. It
is configured and programmed with control builder and MATLAB/Simulink with Real-Time
Workshop. The controller combines a very powerful CPU and a large Field-Programmable Gate
Array, which suits AC 800PEC to control demanding power electronics systems.

Two controller types are available;
The AC 800PEC 800, the standard controller. The AC 800PEC is mounted on a DIN rail.
Page 39 of 91

The AC 800PEC 80, an OEM type controller with reduced performance, e.g. for
embedded system applications requiring a fast controller.

Ethernet is used as preferred medium for configuration and communication to upper control. The
AC 800PEC interfaces with ABBs I/O systems via the optical S800 Modulebus and with ABBs
communication modules via communication expansion bus ( CEX, AC 800PEC only ). It also
supports 3
rd
party AnyBus-S fieldbus modules. The AC 800PEC I/O modules are connected via
high-speed point-to-point connections. AC 800PEC supports up to 36 bi-directional fiber optic
power-links.


Page 40 of 91











HARDWARE ASPECTS OF AC 800PEC












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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. The AC 800PEC is the
optimum solution for combining
The high-speed control requirements of power electronics applications
Low speed tasks usually carried out by separate PLC units.
The AC 800PEC hardware is optimized for power electronics control:
Optical connection between controller and process I/O
Fast peripheral I/O devices for control and measurement
Program and data stored in Flash memory, no battery backup needed.
Compatible with standard ABB S800 I/O devices
Suitable for field installation
The different I/O modules can be connected to the AC 800PEC controller to cover most
automation requirements in process industry, power generation and distribution, transportation
and traction. The modular energy-efficient design of the AC 800PEC allows operation without
forced cooling.
The modules are mounted on standard DIN rails and can easily be installed in distributed
processes. The number of directly connectable I/O systems is limited only by the maximum
available fiber-optic links to the processor ( 36 bidirectional links ) . Depending on the required
performance, single, multiple or redundant bidirectional links are used between modules. Each
module comprises a mechanical carrier, a base module and a configurable set of sub-modules
which provide the required I/O terminals or communication interfaces. The controller comprises
a low power circuit with high reliability. The hardware can be configured freely, depending on
the process requirements and the selected communication with the upper control.
Key hardware features are :
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Modular and flexible concept, DIN rail mounted
One powerful CPU : IBM PowerPC 750FX, 600MHz, 128 Mbyte RAM, 16 MByte Flash
Memory
Built in RS232, ModuleBus and redundant Ethernet
Fast optical link between AC 800PECS and Data acquisition PC
Optical communication cables
Hot swap I/O modules
Local and remote I/O options
Very low power consumption
Industry quality hardware with excellent EMC and MTBF properties
The AC 800PEC controller module contains the processor, the optical interfaces to the peripheral
I/O, the fieldbus and interfaces to the upper control :
Base unit AC 800PEC BP ( back plane with slots for mounting the processor, the power
supply, and the optical and communication modules )
Processor module AC800PEC CPU mounted on the AC 800PEC BP. The CPU is a
fully-featured 600MHz RISC processor with a 64-bit IEEE Floating-Point-Unit ( FPU ).
It is optimized for applications with very fast control cycles.
Two AnyIO interfaces, each consisting of an AnyBus-S slot, an additional AnyIO
extension slot for an AC 800PEC CEX interface or special applications.
Upto 6 AC 800PEC optical modules for fiber-optic links to various I/O modules.
Programs and data are stored in a robust solid-state 16 MB Flash memory, whish is formatted as
a file disk. Active programs are operating out of the cached 64 MB SDRAM. The AC 800PEC
Page 43 of 91

control system is a set of modules. The modules are arranged according to the required I/O
configuration and process needs.

Fig
The AC 800PEC arrangement consists of :
AC 800PEC controller module PP D113
AC 800PEC Combi IO modules UA D149
AC 800PEC INT interface modules PV D164
S800 I/O Modules
CEX-bus extension modules
AC 800PEC PEBB interface boards
AC 800PEC Measurement interface.
Each module consists of a mechanical carrier, a base module and a configurable set of
submodules which provide the required I/O terminals or communication interfaces. The modules
are mounted on standard DIN rails. Three types of controllers are available. They only differ in
the size of the application logic which is implemented inside the FPGA.
Page 44 of 91


Fig: Controller Module Identification
PP D113 CONTROLLER MODULE:


The controller module contains the main controller and the following sub boards:
One or two AnyIO communication modules
Upto six AC 800PEC optical modules
One LED display module
One power supply module
Page 45 of 91


Fig: AC 800PEC Controller system overview
The AC 800PEC Controller module contains the processor, the optical interfaces to the
peripheral I/O , the fieldbus interfaces to the upper control and some ancillary components:
Base unit AC 800PEC BP ( backplane with slots for mounting the processor, the power
supply, as well as optical and communication modules).
Processor module AC 800PEC CPU mounted on the AC 800PEC BP ( processor type:
Power PC 750FX).
Power supply module AC 800PEC PS to provide the various supply voltage levels.
Upto two AnyIO communication modules: AnyBus-S fieldbus interfaces to connect with
all common fieldbus types and /or one AC 800PEC CEX interface.
Upto 6 AC 800PEC optical modules for fiber optic links to various I/O modules.
The hardware is designed for control applications requiring high I/O and control performance.
The controller consists of a low power circuit with high hardware and system reliability. The
hardware can be configured freely depending on the process requirements and the selected
communication with upper control. The units are mounted on a horizontal DIN rail.


Page 46 of 91

AC 800PEC BACKPLANE XX D129
The AC 800PEC backplane acts as mechanical support for the AC 800PEC controller and for the
communication and supply modules. The modules are mounted onto the backplane PCB with
spacer bolts. The AC 800PEC BP backplane is responsible for the 5V and 3.3V power
distribution to all PCBs and for the signal distribution between the AC 800PEC CPU and the
interface modules.
The backplane provides interface slots for the following processor equipments:
One interface for the AC 800PEC CPU
Two interfaces for the AC 800PEC optical modules
Two AnyIO interfaces
One interface for the power supply module
One interface for the LED modules.

Fig: AC 800PEC Controller module component assembly
Page 47 of 91


Fig: AC 800PEC backplane : general view from top
The backplane is also responsible for distribution of all signals to and from the AC 800PEC
CPU, level conversion, debug and development interfaces and manufacturing test adapter.
AC 800PEC PROCESSOR MODULE PPD103
The processor module AC 800PEC CPU contains the main processor, the memories and the
interfaces for the communication and I/O equipment.

Fig: Processor Module AC 800PEC Overall view and Block Diagram
The processor is divided into four main functional units :
Page 48 of 91

CPU : The PowerPC 750FX is a high performance CPU for low power operation. The
CPU is a fully featured RISC processor with 64 bit IEEE Floating point unit, optimized
for applications with very fast control cycles. The CPU is well suited for automatically
generated code. The controller is operating as a stand alone device.
Memory: Programs and data are stored in a robust solid state 16 MB Flash memory,
which is formatted as a file disk. Active programs are operating out of the cached 64 MB
SDRAM. The SDRAM controller operates at 100 MHz and is equipped with an error
correction circuit for save soft error recovery. There is sufficient external memory to run
coincidentally several complex application programs.
Communication: The controller provides two integrated Ethernet interfaces used for
interfacing with the Control environment, i.e. for accessing applications running on the
CPU. Two universal Asynchronous Receiver/Transmitter ( UART ) circuits are provided.
One is equipped with an RS 232-C interface and is used for service purposes, such as
device configuration, IP- address configuration and boot recovery. The second is used for
the serial interface on the optional CEX interface.
Programmable Logic : The interface to the I/O circuits are implemented in a FPGA. The
CPU and the configurable FPGA exchange data via two independent PCI buses. One bus
is used for random I/O access and the second bus is dedicated for high speed burst
transfers. The CPU configures the FPGA after booting. The FPGA has generic logic
resources, as well as dedicated memory, loop up table, multipliers, clock managers and
advanced I/O circuits. The FPGA is connected to the backplane connectors by means of
the backplane interface.
Page 49 of 91


Fig: AC 800PEC CPU : FPGA Functional Block Diagram
AnyIO COMMUNICATION MODULES
The AC 800PEC backplane can host one or two AnyIO communication modules. Typically, the
AnyIO communication module is an AnyBus-S module or an application specific AnyIO board.
Upto two AnyBus-S modules or one AnyBus-S and one AC 800PEC CEX interface.
The CEX ( Communication Expansion ) interface provides the physical connection between the
AC 800PEC controller platform to the ABB specific CEX bus system. The CEX bus is used for
connection of various types of communication interfaces. the CEX module allows the connection
of upto 12 external slave units to the CEX bus. The CEX module board consists of the following
functional devices:
CEX I/O Driver: is the physical connection to the CEX Bus system. All signals from the
AC 800PEC system FPGA are converted from the LVTTL level to the LVDS level used
by the CEX bus.
Page 50 of 91

Serial interface : Several full duplex UART signal are available via the AnyIO connector
to implement a serial RS-422 or RS-232. The serial inte4rface is used to communicate
with a control panel.

Fig: CEX Module : Block diagram and Communication interfaces.
I/O MODULES
The combination of a huge variety of I/O modules is another specific advantage of the AC
800PEC. The AC 800PEC is an open system that provides standard interfaces even for modules
with customized design and functionality. All internal communication between the controller and
I/O modules is achieved entirely by means of optical links. There are no electric connections
between the controller and any I/O device.
There are several methods of connecting I/O systems to the AC 800PEC Controller.
S100 I/O via CI856
S800 I/O units via the ModuleBus.
S800 I/O units via CI854/CI854A and CI840, PROFIBUS DP.
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S800 I/O units via CI854/CI854A and CI1801, PROFIBUS DP.
S900 I/O units can be connected to PROFIBUS DP
Genius remote I/O (TRIO) via the CI862 Interface
Satt I/O on ControlNet via the CI865












Depending on the process requirements, several types of I/O modules are provided:
I/O modules ( AC 800PEC Combi IO) for fast signal exchange, e.g. CT and VT inputs,
fast trip logic, safety relays, encoder signals. A Combi IO can carry up to two add on
terminal modules.
Page 52 of 91

S800 I/O modules for signal exchange without high speed requirements e.g. control and
status signals for process, plant and ancillary equipment, general measurement quantities.
AC 800PEC INT interface system for fiber optic links to external devices e.g.
transmission of firing pulses to converters, time critical measurement.
AC 800PEC PEBB Interface board and PEBB Int Quad board for direct IGBT converter
control.
AC 800PEC PINT ( Pulse INTerface) for the transmission of firing pulses to thyristor
modules.
AC 800PEC Measurement interface for current and voltage measurements.
The I/O devices are linked with the AC 800PEC controller via fiber optic links. All I/O devices
have a common interface technology. The communication protocol is based on the PowerLINK
technology which is designed for high speed signal transmission. The S800 I/O modules use
DDCS.
POWER SUPPLY KU D181
The power supply provides the supply voltages needed by the system. It is located on the
backplane on top of the AnyIO modules.two redundant 24V inputs are connected via diodes and
an EMC filter to the DC/DC converter. Input varistors protect the devices against overvotages.
The DC/DC converter supplies the galvanically isolated 5 VDC and 3.3 VDC needed by the
backplane. A 24VDC output is delivered to supply the CEX bus. This output is not isolated. An
EMC filter suppresses the reflected distortion of the DC/DC converter. The output is protected
against overcurrent and power feedback by means of a diode and a fuse.
Its main features are :
Nominal input voltage -24 VDC
Redundant input
+/- 3% output accuracy
Page 53 of 91

2 ms power after an input power failure at 40 W

Fig: AC 800PEC PS


COMMUNICATION MODULES
Communication with external systems ( i.e. the upper control via fieldbus) is via CEX or
AnyBus-S fieldbus interface module, or via Ethernet ports on the processor module.
The CEX interface provides optimum connectivity with complete ABB AC 800 CEX program
such as MB300, Profibus master, Ethernet. The supported AnyBus-S fieldbus types are profibus
slave , CANopen slave, Lon Works slave, Interbus slave, Modbus slave, etc.
All internal communication between controller and I/O modules is achieved exclusively by
means of optical links via the optical Modulebus. There are no electric connections between the
controller and any I/O device.


Page 54 of 91

AC 800PEC COMBI IO UA D149



The Combi IO UA D149 is a universal remote I/O device for high-speed applications and is part
of the AC 800PEC control system. It is mainly used for sensing actual values in fast closed-loop
control and protection circuits. The Combi IO comprises the basic module UA D141 which can
be equipped with stackable I/O boards such as :
Upto 2 mixed IO boards UA D142, each providing 16 fast digital inputs 8 fast digital
outputs, 6 fast analog inputs, 2 fast analog outputs
Alternatively: 1 traction module DA D143 providing 13 analog inputs with various
predetermined characteristics, 18 digital inputs allocated to specific monitoring tasks.
The Combi IO basic module consists of a backplane with a built in power supply. The module
provides three interfaces, a digital and an analog data interface and one for supply purpose.
Standard and application specific I/O modules can be connected directly to these interfaces. This
allows the adaption to a wide range of application requirements. Upto 128 digital I/Os, inputs or
outputs in blocks of 8 can be configured on the digital interface, 8 analog outputs and 12 analog
inputs are supported by the analog interface part. An optical module provides the link to the AC
800PEC controller.

Page 55 of 91



Features:
Redundant supply- A redundant 24 V power supply generates all the required electronic
supplies internally. An EMC protection is provided.
6 fast optical links to AC 800PEC controller
Digital interface for I/O module adaption
Analog interface with 12 input and 8 output channels
Programmable logic device
Status visualization
Hardwired trip relay

Page 56 of 91

COMBI IO MIXED MODULE UA D142

Fig: Mixed I/O Module
The Combi IO mixed module is an universal I/O device with direct customer interface and
belongs to the AC 800PEC control system. The module is a sub-module of the Combi IO basic
module and can be combined with other I/O modules. It serves as a simple signal conditioner, all
functions are controlled by the FPGA on the Combi IO basic module.
Features:
16 digital inputs
8 digital outputs
SW independent tripping circuit with relay circuit
6 fast analog inputs with interface to CT/VT and LVD module
2 galvanically isolated analog outputs with +/- 10 volts and +/- 20 Ma
Page 57 of 91


Fig: Basic circuit of Mixed I/O and block diagram
COMBI IO TRACTION MODULE UA D143
The Combi IO traction module is a specially designed submodule for traction purpose. One
traction module can be stacked on a basic module.

Features:
3 analog inputs for PT100 temperatures
2 analog inputs for NTC temperatures
3 fast analog inputs for control and protection
Page 58 of 91

1 fast analog input
4 fast analog inputs from the intermediate circuit
7 digital outputs for control
6 digital inputs for isolator positions
2 digital inputs for supply supervision
2 digital input for speed encoder
Control signals for battery charger

Fig: Traction module: Block diagram and basic circuit


Page 59 of 91

AC 800PEC MEASURING INTERFACE PECMI UA D140
The measuring Interface PECMI provides a high speed current and voltage measurement device
wich supplements the Combi IO module.active scalable inputs for upto 4 current sensors ( e.g.
LEM) are provided. Inputs for voltage divider boards and CT/VT sub-boards are available.
AC 800PEC INT INTERFACE SYSTEM PV D164
The PEC INT OV D164 interface module provides up to 36 optical transmitter and receiver
channels to interface with the AC 800PEC control system and various converter measurement
boards. In addition, direct firing pulse transmission for IGCTs is also possible.

Features:
Upto six optical modules with 6 transmitter/receiver channels
FPGA for configuration of I/Os and fast logic and is clocked with 40 MHz allows a wide
range of high speed applications such as gate control in power electronic systems.
Interface to other boards via PowerLINK
Optical redundant remote download of PEC INT firmware
Power supply for on board components
SW independent tripping circuit
6 status LEDs, visible with mounted casing
Page 60 of 91


Fig: PEC INT : Basic circuit and Block diagram

AC 800PEC PEBB Interface Boards GD D160 and GD D165

Fig: Typical PEBB Board
The PEBB Interface Board is a universal remote I/O device for the direct drive of two IGBT
converters with up to 2*6 pulses within ABBs Power Electronic Building Block (PEBB). It also
measures and monitors all analog and digital signals from the two IGBT converters. Six
additional parallel IGBT converters can be driven via extension interfaces. A measuring interface
PECMI can be connected for current and voltage sensing devices. The PEBB Interface Quad GD
Page 61 of 91

D165 can be used as an alternative universal remote I/O device to drive up to four IGBT bridges
with up to 4*6 pulses within a Power Electronic Building Block.
Features:
Optical communication to the AC 800PEC controller
Control of 2 independent IGBT converters
Traction safe input: For safe blocking of all switching pulses an extra 24 V input signal
TSS is provided.
Current inputs: Three differential analog current inputs are converted to +/- 10V signals
are added in analog summing circuits.
DC voltage inputs: Each IGBT converter interface supplies one actual DC voltage
measurement.
Temperature measurement: Each IGBT converter interface supplies one temperature
signal. The 12 temperatures are sensed with 2 multiplexed 10 bit AD converters.
Fast overcurrent detection with settable reference : 2 x 3 analog comparators are
implemented to achieve the necessary reaction time
20 to 28 volt supply with supervision and safe power down
In order to precisely a defective halfbridge, each of the 4 error signals per IGBT
converter are monitored by the FPGA. The signals are transmitted directly from the IGBT
converter interface to the FPGA via Schmitt triggers.
Page 62 of 91


Fig: PEBB Interface: Basic circuit and block diagram
AC 800PEC PEBB INTERFACE QUAD GD D165

The PEBB interface Quad is an universal remote I/O device to drive up to four IGBT bridges
with up to 4*6 pulses within a power electronic building block. It also measures and monitors all
analog and digital signals of the four IGBT converters. Each of the four channels is equipped
with 3 halfbridge or one full bridge interface. The module is connected to the AC 800PEC
controller via up to four serial optical links. The communication protocol is implemented in a
configurable logic device.
Features:
Page 63 of 91

The communication with the AC 800PEC controller board is accomplished via four
optical interfaces.
Control of four independent IGBT converters.
For safe blocking of all switching pulses an extra 24 volt input signal TSS is provided.
Earth fault detection.


AC800PEC MEASUREMENT INTERFACE UA D144
The AC800PEC Measurement Interface is an universal remote I/O device and part of the
AC800PEC Control system. The Measurement Interface provides 3 differential bipolar voltage
inputs and 5 active current sensor interfaces.The module is connected to the AC800PEC control
system via upto four optical serial links (POF 10 MBit/s)The communication firmware is
implanted in a Programmable Logic Device (FPGA).Voltage divider boards and CT/VT modules
are available. For voltages up to 1000 V a Low voltage Divider (LVD) is needed. For higher
voltages the High Voltage Divider (HVD) is needed.
Features:
Page 64 of 91

Optical Links(upto 4 links) TO AC AC800PEC controller
3 differential voltage inputs
The three phase voltages and the voltage of the neutral point are measured with individual HVD
or LV boards ( XV C770 AE or XV C775, respectively). Three voltages are generated from these
measurements and are applied to the ADC of the Measurement Interface.All ADC inputs are
spike filtered with first order passive filters. The filters on the Measurement Interface are located
close to the signal input of the ADC.Fast overcurrent detection (analog detection with
comparator t <1microsecond; signal to AC800PEC board; time <2).Because of different
overcurrent levels, a DAC is used to set an individual trip level for each of the 5 current
channels. The positive and negative trip levels are identical for one channel. It can be set to
max.100% of the ADC voltage. Four overcurrent signals are generated and connected to four
FPGA inputs. Therefore it is possible to determine on which channel an overcurrent occurs.High
resolution A/D conversion is used.Firmware start up is possible from the local Flash memory or
via remote download from the AC800PEC controller.
AC800PEC PINT Pulse Interface DD C779
The DD C779 PINT( Pulse transformer Interface) board is an interface device which is inserted
between the AC800PEC controller and the firing pulse transmitters of a thyristor convertor.Two
6 pulse thyristor convertor bridges can be controlled independently by one PINT board.
Communication with the AC800PEC controller takes place via fast optical links.
Features:
2 channel thyristor control logic with 2 x 6 pulse pulse transformers
Serial reception of the conducting windows for each channel via two redundant plastic
optical fibre cables (POF)
Conversion of the conducting windows into 8 micro second/ 10 microsecond pulse train.
Monitoring of the firing channels including driver transistor.
Page 65 of 91

Feedback of individual errors and status via serial links
Fast feedback of collective errors for each channel via redundant fiber optic links
Supply buffer
Power supply:
The supply input of the module is connected to the 24 volt DC supply. All required
electronic supplies are generated on board. The board is equipped with power supply
monitoring.
AC 800 CT/VT MODULE UU D148
The AC 800 CT/VT convertor Module is used for the potential isolated measurement of
alternating voltages and alternating currents.A module consists of 3 measuring channels. The
associated amplifiers are adapted to the different nominal input voltages, or to the different
nominal output voltages, for the current inputs, by means of jumpers.For voltage measurement
the input side convertors transform the input voltages to the electronic level. A measuring
amplifier scales the value and passes it on to the output as an analogue voltage value, providing
galvanic isolation and decoupling.For current measurement the input side convertors transform
the input currents to the electronic level. The resulting current produces a voltage drop across a
burden resistor which is amplified and passed on to the output as an analogue voltage value,
providing galvanic isolation and decoupling. A 4 bit identification code informs the connected
device about the module type.
Features:
Convertor module for potential isolated measurement of analogue input values voltage
and current.
50/60 Hz version with 3 channels.
Nominal input voltages (rms): 100 V/3, 100 V, 200V/3 and 200 V selectable on board.
Nominal input current.
Page 66 of 91

3 phase AC output voltages with nominal voltages at input: Vout =2.652 .
2rms outputs 0.20mA.
1rms output0.010V.
Available versions:
UU D148 AE 01: 3 voltage measurements
UU D148 AE 02: 3 current measurements
UU D148 AE 03: 3 current measurement
4 bit device identification.
Measuring accuracy: amplitude error max. 0.5% Phase error max. 0.5
Supply voltages 15 VDC
Test voltage: 2.5 kVeff/ 1 min (50 Hz)
S800 I/O
The S800 I/O is a distributed, highly modularized and flexible I/O system with eco efficient
design, providing easy installation of the I/O modules, process cabling and connection to power
convertor systems.The S800 I/O modules and termination units can be mounted and combined in
many different configurations to fit with your space requirements and to suit many types of
applications. As it is using DDCC module bus or profibus, S800 I/O system should be used for
slower applications. The system has a minimal cycle time of 1 ms for digital and 4 ms for analog
data.All S800 I/O modules are supported by the AC 800PEC.
The communication with the AC 800PEC controller is carried out with the optical DDCS module
Bus for distances upto 15m or 200m and with the profibus via CEX bus module for distances
upto 1000 m.
Features:
Page 67 of 91

Other communications options via PROFIBUS DP or Advant Fieldbus 100
Quick fault finding with the help of the LEDs of each module and analog input/output
modules.
An extensive scope of digital input/output modules and analog input/output modules
digital input/output modules and analog input/output modules with intrinsic safety
interfaces.
mounted on DIN rails
support of dual redundancy in power supply
support of fieldbus media supervision, bumpless change over and failure reporting
all outputs can be individually set to freeze or to take on predefined values
easy connection to power convertor systems minimizing communication delays and cost
all modules have plastic injection molded enclosures which provide safety protection
degree IP20 according to IEC 529. The plastic used is halogen free.
I/O modules are protected from destruction by a mechanical keying arrangement if an
attempt is made to insert a module type in a position with different key code than the
factory set code of the I/O module. Terminal units have keys which are set to key code of
its I/O modules key code.
An electrical ID is checked at start up if this does not match the configured type, the I/O
module is not taken into operation
Hot swap of S800 I/O allowing replacement of faulty modules without disconnecting
field power or system power to the I/O station


Page 68 of 91

POWER SUPPLY CONCEPT
Under normal circumstances, the 24 VDC power supply required by the AC 800EPC system and
associated field equipment can be obtained from the plants standard mains supply.







Page 69 of 91

EXAMPLES FOR TYPICAL CONFIGURATION


Page 70 of 91












Page 71 of 91











SOFTWARE ASPECTS OF AC 800PEC








Page 72 of 91

The AC 800PEC application software is object- oriented in a structured way, which means that
changes made to an object type of instance thereof only affects that type or that instance only.
For this reason, subsequent bug fixes, updates, improvements, expansions etc can be performed
quickly and easily. It also means that the different program sections can be assigned their own
priorities and cycle times with a large measure of freedom.
All solutions run in a common language runtime environment (CLR ) in the controller, making it
possible to access information between solutions in a different languages seamlessly. So each
contributing project engineer can develop solutions in the preferred language for each task
without having to consider which languages related modules are written in.
Control Functionality:
From binary logic to advanced closed loop control
Pre-defined advanced process objects
User defined function blocks
Very fast execution cycle
Pick your choice fieldbuses
Open communication standards
IEC 61131-3 compatible
Simulink/ C-Code via RTW

The key AC 800PEC capability is high-speed control application processing, as required in
power electronics for integration into ABBS standard control environment. Implementation of
the AC 800PEC software on three performance levels provides a superb range of control and
communication functionality:
Level 1: Industrial integration
This level is based on the industry standard IEC 61131-3 and contains the slow-control,
monitoring, operating, displaying and registering functions. The development of programs in
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accordance with the IEC 61131-3 standard is carried out in the Control Builder M, AABs
Industrial compatible engineering tool.
Level 2 : Fast control software
This level contains fast control and protective functions with cycle times from less than 100
micro seconds to a few milliseconds.
Fast, time-critical and I/O tasks are programmed by means of MATLAB/Simulink and integrated
into the Control environment as a Simulink I/O unit. This allows perfect interaction between the
high-speed AC 800PEC core functions and the standard Control software.
Level 3: High speed I/O control
This level contains highly time-critical, hardware- specific functions such as pulse-width
modulators, pulse logic with associated protective functions, fast analog and binary inputs and
outputs, etc. it is implemented in the FPGA ( Field Programmable Gate Array ) and programmed
in VHDL ( Very High Speed Integrated Circuit Hardware Description Language).
The software for the AC 800PEC is structured as shown in Figure 2-1. It comprises three levels:
The top level (or application engineering level) is based on the industry standard IEC
61131-3 and contains the higher-level, slow control, monitoring, operating, display and
registering functions. The development of programs in accordance with the IEC 61131-3
standard takes place in the Control Builder, the IndustrialIT compatible engineering tool
by ABB.
The medium level contains the fast control and protective functions with cycle times
within the range of below 100micro seconds to a few milliseconds. It is programmed in
MATLAB/Simulink.
The lowest level contains the very fast hardware specific functions such as pulse width
modulators, pulse logic with associated protective functions, fast analog and binary
inputs and outputs, etc. This level is implemented in FPGA and is programmed in
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VHDL. All access to the peripheral hardware by the other two levels takes place via this
level.

TECHNICAL DATA AND PERFORMANCE OF AC 800PEC:
Available RAM Memory:
The available RAM memory is measured after loading the firmware and an empty project. The
total available RAM in the AC 800PEC is 64 Mbytes. The available memory for Control
application is 8Mbytes by default. The maximum size of the Control program must not exceed
50% of the available memory, because sufficient memory must be available for online software
updating.
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Available flash memory: The total flash memory in the AC 800PEC is 16 Mbytes. 1 Mbyte is
used for the bootimage. The remaining 15 Mbytes are disposable for firmware, Simulink and
system tasks for the Control application, the cold retain and for the Simulink transient recorder
dara.
Memory Consumption and execution times:


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ENGINEERING WORKFLOW : OVERVIEW
The application engineering has access only to the top level i.e. the Control applications and the
standard I/O interfaces of the AC 800M platform as well as to the AC 800PEC specific hardware
libraries. The project specific high speed control tasks and configuration of the AC 800PEC
specific fast I/O are programmed by means of MATLAB/Simulink and the Real Time
Workshop. This requires special skills that can be acquired by suitable training.alternatively, this
part of a project can be assigned to ABB specialists, provided that all tasks are specific at the
beginning of the engineering phase. The resulting program code is then downloaded to the
controller by the application engineer using an installer package. The corresponding I/O
specification is imported into the Control Builder M by means of standard commands. The
application engineer only needs to access the Control level to define the standard control tasks
and interfaces ( fieldbus and S800 modules). Applications are created using Control Builder M
and are then downloaded to the controllers.
The control environment programming and service tools are connected directly to the controller
via Ethernet and RS-232 serial links.



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APPLICATION STRUCTURE:
The Control and Simulink applications are treated as two independent program blocks in the
controller. The program execution is coordinated by means of interrupt control. A pre-defined set
of data of the Simulink application is accessible on Control level by means of a Simulink I/O
unit in the Control Builder Application. Therefore the application engineer cannot modify the
Simulink part of the program code. But he has the option to select and scale the set of
parameters among the available data in the Simulink I/O unit. Furthermore he can customize the
I/O configuration of the controller.

CONTROL BUILDER:
The AC 800PEC software is managed with Control Builder M Professional, ABBs Windows
2000 Integrated, IEC 61131-3 compliant engineering tool. A special add-on includes AC
800PEC specific functionality. The AC 800PEC add-on package provides full integration of the
AC 800PEC into the Control engineering environment. The Control Builder is a programming
tool used by the application engineer to create control applications for AC 800PEC systems and
to download the software to controllers. The Control Builder is also used to configure I/OSs and
the controller communication.
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Compact control builder builds on the firmware of the AC 800PEC controller which offers
functionality such as:
1. Data scanning
2. Data type management
3. Logical, mathematical and time-based data processing
4. Fuzzy logic control
5. Process object handling
6. Output updating
7. Support for communication by ABBs Control Network, Electrical ModuleBus, and
OPTICAL ModuleBus AS WELL AS Profibus DP and RS-232
8. Support for ABBs Process portal, Compact HMI 800 and Process Panel human machine
communication systems.
Hardware requirements of Control builder:

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CONTROL LEVEL:
The Control level (or application engineering level) software is based on the industry standard
IEC 61131-3 and contains the slow control, monitoring, operating, display and registering
functions as well as the standard I/O interfaces of the AC 800M platform. The development of
programs in accordance with the IEC 61131-3 standard takes place in the Control Builder,
ABBs Industrial compatible engineering tool.The Control Builder programming tool is used to
generate and download the above mentioned slower control applications. Control Builder is a
fully integrated Windows application and is available in 2 versions:
Compact Control Builder for standard control application forWindows XP Professional
and Windows 2003 Server
Control Builder Professional with extended functionality, such as batch handlings,
Industrial 800XA integration, DCS and high integrity applications, for Microsoft XP
Professional.


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FAST CONTROL SOFTWARE: PROGRAMMING WITH MATLAB/SIMULINK AND
CONTROL FUNCTIONS:
The fast control application is designed and programmed in MATLAB/Simulink by means of
the OPCoDe workflow. The MATLAB/Simulink environment for the AC 800PEC consists of
the standard Simulink function block library, supplemented with a PEC specific function block
library containing blocks that were adapted or built additionally. The Real-Time Workshop
allows to parametrize and test the MATLAB/Simulink application directly on the target system.
Standard Simulink Function Block Library : The standard library contains the basic function
blocks needed for control and data handling tasks.
AC 800PEC Function Block Library: It contains several blocks from the Simulink and the
Simulink extra library ( sources, sinks, signals and systems, discrete, math, flip flops, functions
and tables ). The AC 800PEC function block library contains the functions that have been
specially designed for the fast closed loop control applications.

FAST CONTROL SOFTWARE: PRINCIPLE OF OPERATION:
I/O HANDLING :
The interfaces to the I/O devices are implemented in Field Programmable Gate Array( FPGA
).The data exchange between the AC 800PEC CPU and the FPGA takes place via a Dual Port
RAM to provide asynchronous and independent access to the transferred data.

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TASK COORDINATION AND INTERRUPT HANDLING
The AC 800PEC is capable to process several independent program blocks at different speeds by
means of preemptive multitasking. Switch over between the blocks takes places in very short
time.only a small part of the program usually needs to be executed with very high speed.
Therefore the control tasks are distributed on three different priority levels. The highest priority
level which contains the very fast tasks is processed with a typical cycle time of 100 to 200
micro seconds. Typically, this level performs tasks such as :
Fast controllers like current control
Reference generation for the valve pulse modulatorsm which are located in the FPGA
Fats protection tasks
The second level is processed with a typical cycle time of approximately 10ms and contains
slower processes :
Slower control functions, such as power or torque control
Slower time critical tasks, such as setpoint generation
Process image update
Slower protection tasks.
The task coordination is organized on the Simulink level.
INTERACTION WITH CONTROL LEVEL:
Data, which are to be exchanged between Control and Simulink applications are introduced as a
Simulink hardware library into the Control Builder Application. The channel definition consists
of two parts:
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The code for the interface definition which is to be downloaded to the AC 800PEC
processor
The Simulink I/O definition which is used for interfacing with the Control Builder
platform and for the specifications of the I/O devices.
Access to the parameters, signals and events of the Simulink project is provided with the
definition of the I/O devices. This means that no additional functions are needed on Control level
to access the fast control and the physical I/O data. All data can be read directly by the software
drivers of the interfaces.
The data are stored in a memory area reserved by the Simulink application.In sequence A, the
Simulink application reads and writes the data for the external devices/software interfaces in this
memory area. In sequence B, an external device (e.g. a ControlIT function block) accesses the
same memory area. The device has read and write access to the data.
Since the fast and slow control applications can run independently, there.is no synchronized
access to data. This fact must be considered when programming the MATLAB/Simulink level of
the application: fast changing signals in the Simulink application should not be used directly for
transfer to external interfaces.
AC 800PEC SPECIFIC FEATURES IN CONTROL BUILDER
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The above figure lists the communication and I/O devices that can be used with AC 800PEC.
The last column indicates whether a device is configured on Control level with Control Builder
or on Simulink level:
The S800 low speed interfaces are directly addressed and configured on Control level.
The fieldbus and communication modules are directly addressed and configured on
Control level
The fast interfaces are programmed with MATLAB/Simulink. They cannot be configured
on Control level.
OVERLOAD COMPENSATION
Overload compensation, a standard Control Builder function, is configurable with the AC
800PEC:
The limit for time critical tasks is set by default to 50%.
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The limit for other tasks is set by default to 80%.
SYSTEM CLOCK HANDLING
Both application levels operate with independent system clocks:
The AC 800PEC features a propriety platform time for the operating system and the
Simulink application.
Control defines its own time, independently of the AC 800PEC system time.

PECView
The PECView is a PC-based commission and service tool. It provides a complete set of features
for analyzing, monitoring and maintain Simulink applications running on an AC 800PEC system.
OPERATE PROCESS PANEL BUILDER
The Process Panel Builder is a standard engineering tool for ABBS Process Panel product line.
It provides a wide choise of operator panels for all requirements that can be integrated easily into
an AC 800PEC control system, such as :
1. Easy customization of operator graphics using a comprehensive library
2. Standardized faceplate concept to minimize configuration time.
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PLATFORM SOFTWARE
Operating system: The operating system used in the AC 800PEC processor is VxWorks from
Wind River Systems Inc. The VxWorks operating system is a real time multitasking operating
system with a very short cycle time. In addition to the basic operating system functions ( task
scheduling, flash memory management) it also offers standardized interfaces and services such
as the I/O communication, diagnostics and more.
Web Server: A Web server is implemented in the AC 800PEC processor. It is used for
communication with special service tool.
SOAP Server: A Simple Object Access Protocol server is implemented in the AC 800PEC
processor. It is used for communication with the control panel.
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When the hardware is switched on, the so-called "Bootimage" operating system is first loaded
from the protected area of the Flash memory and started. The VxWorks operating system is then
loaded from the formatted Flash memory area and started. The operating system checks the Flash
file system for errors. if any errors (like lost chains) exist the system tries to rectify them
automatically. All software drivers, communication drivers and configuration software modules
(e.g. FPGA configuration software) required for the operation of the hardware are loaded from
the Flash memory by startup scripts. The startup process for the Simulink application now
begins. The previously-loaded software drivers, communication drivers and configuration
software modules, and finally the Simulink and ControlIT applications, are then started.



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PROCESS CONTROL OF WRM BY AC 800PEC










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CONCLUSION











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BIBLIOGRAPHY