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The ABB AC800PEC-PC-D235 is a high-performance embedded controller specifically engineered for real-time control of advanced power electronic systems. As part of ABB’s AC800PEC (Power Electronics Controller) platform, this module delivers deterministic, ultra-fast control capabilities essential for applications such as HVDC (High-Voltage Direct Current) transmission, STATCOMs (Static Synchronous Compensators), medium-voltage drives, wind turbine converters, and grid-scale battery energy storage systems (BESS).
Built around a dual-core Intel® processor combined with a powerful Xilinx® FPGA (Field-Programmable Gate Array), the ABB AC800PEC-PC-D235 achieves control cycle times as low as 100 nanoseconds—enabling precise switching synchronization, harmonic compensation, and fast fault ride-through responses that conventional PLCs cannot match. The system supports both IEC 61131-3 programming (via ABB’s Automation Builder) and direct C/C++ or Simulink® model deployment, offering unmatched flexibility for algorithm development and deployment in demanding power conversion environments.
Designed for integration into ABB’s PCS6000 and other power conversion platforms, the ABB AC800PEC-PC-D235 serves as the computational backbone for grid-stabilizing technologies, ensuring compliance with stringent grid codes (e.g., ENTSO-E, NERC, IEEE 1547) while maximizing system efficiency and reliability.
Technical Specifications
| Parameter Name | Parameter Value |
|---|---|
| Product Model | ABB AC800PEC-PC-D235 |
| Manufacturer | ABB |
| Product Type | Embedded Real-Time Power Electronics Controller |
| Processor | Dual-core Intel® Core™ i7 (or equivalent industrial-grade CPU) |
| FPGA | Xilinx® Kintex-7 or similar (high-speed logic fabric for parallel processing) |
| Control Cycle Time | Down to 100 nanoseconds (FPGA domain); ~10–100 µs (CPU domain) |
| Memory | 2 GB DDR3 RAM, 32 GB SSD (for OS and application storage) |
| Operating System | Real-time Linux or VxWorks (ABB-customized) |
| Programming Support | IEC 61131-3 (Structured Text, FBD), C/C++, MATLAB/Simulink (via Target for AC800PEC) |
| Communication Interfaces | PCIe, Gigabit Ethernet, CAN, RS485, Fiber Optic I/O (application-dependent) |
| I/O Capabilities | High-speed analog/digital I/O via daughterboards or backplane (e.g., AD/DA, encoder, PWM) |
| Compliance | IEC 61850 (Ed. 2), CE, IEC 61000-6 (EMC), IEC 60255 (protection relays) |
| Operating Temperature | 0°C to +55°C (industrial grade) |
| Form Factor | 3U CompactPCI or custom ABB rack-mounted module |
Main Features and Advantages
Unmatched speed for power electronics control: The ABB AC800PEC-PC-D235 leverages FPGA-based parallel processing to execute critical control loops—such as PWM generation, phase-locked loops (PLL), and current regulators—at sub-microsecond speeds. This enables precise management of semiconductor switches (IGBTs, IGCTs) in multi-level converters, minimizing switching losses and reducing harmonic distortion.
Hybrid programming environment: Engineers can develop high-level supervisory logic in IEC 61131-3 while implementing time-critical algorithms in C or HDL on the FPGA. With ABB’s Simulink integration, complex control strategies (e.g., virtual synchronous machines, adaptive droop control) can be modeled, simulated, and auto-deployed—dramatically accelerating R&D and commissioning cycles.
Seamless integration with ABB power systems: The ABB AC800PEC-PC-D235 is natively compatible with ABB’s PCS6000 converter platforms, MEGADYNE drives, and Ability™ digital ecosystem. It supports IEC 61850 GOOSE and Sampled Values for substation automation, enabling plug-and-play interoperability in modern smart grids and microgrids.
Robust architecture for mission-critical operations: Housed in a ruggedized enclosure with conformal coating and wide temperature tolerance, the ABB AC800PEC-PC-D235 operates reliably in electrically noisy environments such as HVDC converter stations or offshore wind farms. Redundant communication paths and watchdog timers ensure fail-safe behavior during grid disturbances.
Scalable and future-proof design: The modular architecture allows expansion via I/O daughterboards or PCIe peripherals. Firmware and control models can be updated remotely, supporting lifecycle extension and adaptation to evolving grid requirements—making the ABB AC800PEC-PC-D235 a long-term investment in grid resilience and decarbonization.
Application Field
The ABB AC800PEC-PC-D235 is deployed in some of the world’s most demanding power infrastructure projects. In HVDC interconnectors—such as those linking national grids across seas or continents—it controls voltage-source converters (VSCs) with millisecond-level response to maintain stability during faults. Within renewable energy plants, the ABB AC800PEC-PC-D235 manages grid-forming inverters for solar farms and wind turbines, providing synthetic inertia and black-start capability.
In industrial settings, it powers medium-voltage variable frequency drives (MV VFDs) for compressors, pumps, and mills, optimizing energy use while ensuring smooth torque control. For utility-scale battery storage, the ABB AC800PEC-PC-D235 executes fast frequency response (FFR) and ramp-rate control to support grid balancing under high renewable penetration. Its use in FACTS (Flexible AC Transmission Systems) like STATCOMs further enhances transmission capacity and voltage regulation—critical for aging grids undergoing modernization.
Research institutions and OEMs also utilize the ABB AC800PEC-PC-D235 for prototyping next-generation power electronics topologies, including solid-state transformers and DC microgrids, thanks to its open development environment and real-time fidelity.
Related Products
ABB AC800PEC Base Units (e.g., AC800PEC-BASE): Main chassis and power supply for the controller
ABB PCS6000: Power conversion system platform where AC800PEC-PC-D235 is commonly integrated
ABB Automation Builder: Engineering suite for IEC 61131-3 programming and system configuration
ABB Ability™ Edgenius: Edge computing platform for data analytics from AC800PEC systems
ABB REF615 / REL670: Protection relays often used alongside AC800PEC in substation schemes
MathWorks Simulink + ABB Target for AC800PEC: Toolchain for model-based design deployment
ABB Fiber Optic I/O Modules (e.g., FO800): High-noise-immunity interfaces for gate drive signals
Installation and Maintenance
Pre-installation preparation: The ABB AC800PEC-PC-D235 must be installed in a controlled environment within an ABB-certified control cabinet, with adequate EMI shielding and cooling. Ensure all fiber optic and high-speed electrical connections are clean and properly terminated. Verify compatibility with the host base unit firmware and I/O backplane revision before powering up. Use ABB’s diagnostic tools (e.g., PEC Diagnostics Suite) to validate FPGA bitstream loading and CPU boot sequence.
Maintenance recommendations: Although solid-state with no moving parts, the ABB AC800PEC-PC-D235 should undergo annual inspection of ventilation filters, connector integrity, and SSD health (if used for logging). Monitor system logs for FPGA timing violations or CPU load spikes, which may indicate control model inefficiencies. Keep firmware and control applications updated through ABB’s secure update channels. In redundant configurations, perform periodic switchover tests to validate failover performance. Always follow ESD handling procedures during replacement.
