Steel Plant Report

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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, ABB’s well-established programming tool complying with IEC 61131-3, and

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

Ethernet is used as preferred medium for configuration and communication to upper control. The

AC 800PEC interfaces with ABB’s I/O systems via the optical S800 Modulebus and with ABB’s

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 ( 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 8,50,000tonnes 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

INTERMEDIAT

BLOCK STAND

LOOPER

TABLE

FB SHEERNO TWIST STAND

FINISHING BLOCK -16 TO 25

ROUGHING MILL STAND 1 TO 7

BILLET WITHDRAWING MACHINE

PINCH ROLL

RM SHEERS I TO 4IB 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 PLC’s 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 , tocontrol 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: PLC’S 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 1/10th 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 PLC’S , auxiliary

devices like PC, printer, etc. or other compatible devices like drives. In today’s 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.



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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



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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.



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AC 800PEC AND ITS FEATURES



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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.

ABB’s 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 ABB’s 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.



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· 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 ABB’s I/O systems via the optical S800 Modulebus and with ABB’s

communication modules via communication expansion bus ( CEX, AC 800PEC only ). It also

supports 3rd

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.



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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 800PEC’S 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



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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.



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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



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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.



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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 PCB’s 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



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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 :



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· 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.



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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.



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· 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 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



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· 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.



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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.



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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



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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



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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



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· 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



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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 IGCT’s is also possible.

Features:

· Upto six optical modules with 6 transmitter/receiver channels

· FPGA for configuration of I/O’s 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



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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 ABB’s 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



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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.



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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:



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· 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:



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· 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.



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· 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.



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· 3 phase AC output voltages with nominal voltages at input: Vout = 2.652 .

· 2rms outputs 0….20mA.

· 1rms output0….0…10V.

· 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 efficientdesign, 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:



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· 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



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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.



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EXAMPLES FOR TYPICAL CONFIGURATION



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SOFTWARE ASPECTS OF AC 800PEC



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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 ABB’S 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, AAB’s

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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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 ABB’s Control Network, Electrical ModuleBus, and

OPTICAL ModuleBus AS WELL AS Profibus DP and RS-232

8. Support for ABB’s 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,

ABB’s 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 ABB’S 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

Steel Plant Report

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