for trained personnel, certified by Woodward · for trained personnel, certified by Woodward ... A certified experienced professional must also be trained by Woodward and certified

(Exemplary illustration)

Installation and operating instructions

EN GB

Document no.: 9943-1707 Revision: B

for trained personnel, certified by Woodward

- MP1 Frequency converter system

Original operation manual

This document is updated regularly.

► Always use the current version of the document.

You can find the current version of the document on the Woodward website:

www.woodward.com/publications

Document history

Woodward document revisions

• The first released version of a document has the revision acronym New.

• All further revisions are identified alphabetically from A to Z.

• After the revision Z, AA, AB, AC etc. follows.

General corrections

Date Version Modification carried out by

16.10.15 A Update document C. Aan de Brugh

16.10.15 B Update document C. Aan de Brugh

Product specific corrections

Date Version Modification carried out by

http://www.woodward.com/publications

Table of contents

9943-1707 - MANUAL - TD OPERATING INSTRUCTIONS - MP1 – ENGLISH 3 / 72

Table of contents

1 Safety .................................................................................................. 6

1.1 Classification of the warning notices with relation to actions ..................................... 6

1.2 Intended use ...................................................................................................................... 6

1.3 General safety instructions .............................................................................................. 7

1.3.1 Danger of electrocution ....................................................................................................... 7

1.3.2 Material damage by electrostatic discharge ........................................................................ 7

1.4 Foreseeable misuse .......................................................................................................... 8

1.5 Safety signs on the product ............................................................................................. 8

1.6 Behaviour in case of fire .................................................................................................. 9

1.7 Behaviour in case of accidents ....................................................................................... 9

1.8 Obligations of the operator .............................................................................................. 9

1.9 Qualification of personnel .............................................................................................. 10

1.9.1 Experienced professional certified by Woodward ............................................................. 10

1.10 Personal protective equipment ...................................................................................... 10

2 Information about the documentation ........................................... 11

2.1 Display conventions ....................................................................................................... 11

2.2 Applicable Documents ................................................................................................... 11

2.3 Keeping the documents ................................................................................................. 11

2.4 Validity of the instructions ............................................................................................. 12

2.5 Target groups .................................................................................................................. 12

3 Product and functional description ................................................ 13

3.1 Set-up ............................................................................................................................... 13

3.1.1 Frequency converter system ............................................................................................. 13

3.1.2 Mains cabinet (optional) .................................................................................................... 14

3.1.3 Power cabinet ................................................................................................................... 15

3.1.4 Control cabinet .................................................................................................................. 16

3.1.5 Low voltage cabinet (optional) .......................................................................................... 17

3.1.6 Filter cabinet (optional)...................................................................................................... 18

3.2 Functional principle ........................................................................................................ 19

3.2.1 Decentralised and central control unit ............................................................................... 20

3.2.2 DC-link .............................................................................................................................. 20

Table of contents

4 / 72 9943-1707 - MANUAL - TD OPERATING INSTRUCTIONS - MP1 – ENGLISH

3.3 Operating modes............................................................................................................. 21

3.3.1 Start sequence .................................................................................................................. 21

3.3.2 Standstill ........................................................................................................................... 22

3.3.3 Excitation .......................................................................................................................... 24

3.3.4 Standby ............................................................................................................................. 24

3.3.5 Mains-parallel .................................................................................................................... 24

3.4 Operating ranges ............................................................................................................ 25

3.4.1 Subsynchronous ............................................................................................................... 25

3.4.2 Synchronous ..................................................................................................................... 26

3.4.3 Supersynchronous ............................................................................................................ 26

3.5 Heating control ................................................................................................................ 27

3.5.1 Control sequence .............................................................................................................. 27

3.5.2 Subsequent heating time .................................................................................................. 30

3.5.3 Parameters of the heating control ..................................................................................... 31

3.5.4 Measured values of the climate control ............................................................................. 32

3.6 Name plate ....................................................................................................................... 33

3.7 CE marking ...................................................................................................................... 33

4 Assembly .......................................................................................... 34

4.1 Transporting the product and storage .......................................................................... 34

4.1.1 Symbols on the packaging ................................................................................................ 34

4.1.2 Safety instructions for transport ........................................................................................ 35

4.1.3 Safety instructions for storage ........................................................................................... 37

4.2 Unpacking the product ................................................................................................... 37

4.3 Check Scope of delivery ................................................................................................. 37

4.4 Positioning and installation of the product .................................................................. 38

4.4.1 Installation location............................................................................................................ 38

4.4.2 Minimum distances / free spaces ...................................................................................... 38

4.4.3 Tightening torques ............................................................................................................ 39

5 Electrical installation ....................................................................... 40

5.1 Connect rotor cable ........................................................................................................ 40

5.2 Connect stator cable ....................................................................................................... 41

5.3 Connect mains cable ...................................................................................................... 42

5.4 Connect control, measuring and bus cables ............................................................... 42

6 Hydraulic installation ....................................................................... 43

Table of contents


7 Commissioning ................................................................................ 44

7.1 Make a commissioning protocol ................................................................................... 44

7.2 Use coolant ...................................................................................................................... 44

7.3 Fill recooling system ...................................................................................................... 45

8 Operation .......................................................................................... 46

9 Troubleshooting ............................................................................... 47

10 Inspection, maintenance and repair ............................................... 48

11 Decommissioning ............................................................................ 49

11.1 Temporary shutdown ...................................................................................................... 49

11.2 Final decommissioning .................................................................................................. 49

11.2.1 Recycling and disposal ..................................................................................................... 49

12 Warranty............................................................................................ 50

13 Customer service ............................................................................. 51

14 Appendix ........................................................................................... 52

14.1 Environmental conditions .............................................................................................. 52

14.1.1 Environmental conditions for long-term storage (according to EN 60721-3-1) ................. 52

14.1.2 Environmental conditions for transport (according to EN 60721-3-2) ............................... 53

14.1.3 Environmental conditions for operation (according to EN 60721-3-3) .............................. 55

14.2 Error messages ............................................................................................................... 57

14.3 Warning messages ......................................................................................................... 64

14.4 Technical data ................................................................................................................. 67

14.5 Dimensions ...................................................................................................................... 67

14.6 Installing declaration ...................................................................................................... 67

15 List of terminology and abbreviations ........................................... 68

16 Index .................................................................................................. 70

1 Safety


1 Safety

1.1 Classification of the warning notices with relation to actions

D A N G E R Imminent danger to life or danger of severe injuries

W A R N I N G Danger of minor injuries

C A U T I O N Danger of material or environmental damage

N O T I C E Information and tips for easy handling of the product or the documentation

1.2 Intended use

Improper use may cause danger for life and limb and damage to the product and other material assets.

The frequency converters of the series CONCYCLE® CW 1000LD are intended for use in double fed asynchronous machines in wind turbines.

The intended use includes:

• observing all instructions for the product and all components of the system

• operation of the product without modifications to the product

• operation of the product within the relevant operating limits

• complying with all inspection and maintenance conditions

Any other use than the one described in these instructions or a use beyond the one described herein is regarded as improper use and is prohibited.

The manufacturer is not liable for damage resulting from improper use. Improper use invalidates the warranty of the manufacturer. The risk lies solely with the operator.

1 Safety


1.3 General safety instructions

► Follow the safety instructions of the operator.

► Observe national regulations, standards, guidelines and laws.

► Only use suitable measuring instruments which are approved for the corresponding voltage levels.

► Only work on the cabinets when they are de-energized and when the wind turbine is not operating.

Ø Never stay alone in the wind turbine.

Ø Never operate the product with open cabinets.

Ø Do not remove, modify or disable any safety devices. Do not remove any protective covering.

Ø Do not reconstruct or modify the product.

1.3.1 Danger of electrocution

Touching live components causes danger to live by electrocution.

Before working on the product, observe the five safety rules:

► Isolate from power supply

► Protect against reclosing

► Verify the safe isolation from supply

► Connect to earth and short circuit

► Provide neighbouring parts under voltage with barriers

1.3.2 Material damage by electrostatic discharge

Electronic components can be destroyed by electrostatic discharge.

► Wear clothes made from pure cotton or with a high percentage of cotton.

Ø Do not wear clothes made from synthetic materials.

► Do not touch components with your hands or conducting tools.

1 Safety


1.4 Foreseeable misuse

► Do not commission the product if there is water condensation in the cabinet.

► Do not operate the product when water is leaking.

► Do not operate the product when large amounts of dust have accumulated.

1.5 Safety signs on the product

This symbol identifies danger to life due to high voltages in one area of the product. Only qualified personnel may work in that area of the product (→ Chap. 1.9).

This symbol identifies areas of the product with sensitive electronic components. The electronic components can be damaged by electrostatic discharge.

Ø Do not touch electronic components.

► If you work at open electronic components, wear an antistatic wrist strap for potential equalisation for electrostatic discharge.

1 Safety


1.6 Behaviour in case of fire

1. Report the fire:

• Call the local emergency number (→ Information sign emergency number in the WPP)

2. Bring yourself to safety:

• Take along persons at risk

• Close doors

• Follow marked escape route

• Do not use elevators

• Observe instructions (→ Escape and rescue plan in the WPP)

3. Try to extinguish the fire.

• Use the fire extinguisher

1.7 Behaviour in case of accidents

4. Report the accident:

• Call the local emergency number (→ Information sign emergency number in the WPP)

5. Administer first aid:

• Secure the accident location

• Care for the injured

• Observe the operating instructions

6. Take further measures:

• Instruct ambulance or fire brigade

• Remove curious bystanders

1.8 Obligations of the operator

The system operator has the following supervisory duties:

• Complementing the general safety information with local requirements

• Provisioning first-aid kit, fire extinguisher and rescue device for height rescue

• Make sure that only qualified personnel works on the product (→ Chap. 1.9)

• Make sure that the personnel is trained for height rescue and first aid

• Make sure that all safety devices are always present and operating

• Regular trainings for the personnel about the following:

o Observing and using all instructions

o Intended use of the product

o Knowledge of all safety devices

o Complying with legal provisions

o Observing operating instructions

1 Safety


1.9 Qualification of personnel

Technical knowledge is required for all work on the product. In order to guarantee safety, only a certified experienced professional may work on the product.

The operator has to make sure that the personnel is qualified.

1.9.1 Experienced professional certified by Woodward

Experienced professionals are persons who can assess the tasks assigned to them, identify potential hazards and take appropriate protective measures due to their technical training, knowledge and experience as well as their knowledge of the applicable regulations.

A certified experienced professional must also be trained by Woodward and certified for the work at the product.

1.10 Personal protective equipment

The personnel must wear appropriate personal protective equipment adapted to the dangers and working conditions. The protective equipment must protect but not restrain.

The following legal requirements apply for the personal protective equipment.

The personal protective equipment must be worn for all work on the product.

If special work requires additional protective equipment, this protective equipment is listed together with the corresponding work.

2 Information about the documentation



2.1 Display conventions

Describing text

► Single instruction

1. First of several instructions with defined order

2. Second of several instructions with defined order

Reaction of the product

Ø Prohibited action

• Bullet point, 1st category

o Bullet point, 2nd category

2.2 Applicable Documents

► Please observe all documents supplied with the system or components of the system, and

• documents which are supplied on request

o Specification for long term storage: 4930-1374 Long term storage of CONCYCLE® frequency converters – RPS-Wind

o Specification for storage, transport and operation: KP-46375_New Supplier_Specification_Storage_Transport_Operation_Concycle_MP1_gb_Rev_7

• Documents which are supplied after training and successful certification specifically for the individual person

o Technical Documentation CONCYCLE System Tool - GB

o Maintenance and repair instructions CONCYCLE® frequency converter system

2.3 Keeping the documents

► Keep these instructions and all documents supplied with the product in the system for further use.



2.4 Validity of the instructions

These instructions are only applicable for:

• CW1251LD-C02

• CW1331LD-C02

• CW1211LD-C04

2.5 Target groups

These instructions are intended for

• Park operators

• Experienced professionals

In order to guarantee safety, only a certified experienced professional may work on the product.

3 Product and functional description



3.1 Set-up

3.1.1 Frequency converter system

Fig. 3-1 Front view - frequency converter system

1 Mains cabinet (MC) (optional) 4 Low voltage cabinet (LVC) (optional) 2 Power cabinet (PC) 5 Filter cabinet (FC) (optional) 3 Control cabinet (CC)

The cabinets are identified with stickers on the cabinet doors:

• MC = Mains cabinet

• PC = Power cabinet

• CC = Control cabinet

• LVC = Low voltage cabinet

• FC = Filter cabinet



3.1.2 Mains cabinet (optional)

Fig. 3-2 Front view - mains cabinet

1 Cable entries, grid 5 Fuses for line side converter 2 Connections, grid 6 Contactor 3 Heat exchanger 7 Connections, stator 4 Circuit breaker 8 Cable entries, stator



3.1.3 Power cabinet

Fig. 3-3 Front view - power cabinet (left: with installed mounting plate, right: with swivelled out mounting plate)

1 Line contactor 7 Cable entries, rotor 2 Line choke 8 Mains supply 3 Heat exchanger 9 DC-link resistor 4 Line side converter

and DC-link limiter 10 dv/dt choke

5 Machine side converter 11 Overvoltage protector 6 Decentralised control unit



3.1.4 Control cabinet

Fig. 3-4 Front view - control cabinet

1 Batteries 6 Relay 2 Customer specific terminals 7 Heat exchanger 3 Auxiliary contactor 230 V 8 Breather 4 Terminals 9 Thermostat 5 Central control unit



3.1.5 Low voltage cabinet (optional)

Fig. 3-5 Front view - low voltage cabinet

1 Grid connection 7 Short circuit contactor 2 Fuse disconnector 8 Overvoltage protector 3 Motor circuit breaker line voltage measurement 9 Protection for additional measurement 4 Measuring terminals 10 Mains overvoltage protection 5 Auxiliary contactors 11 Customer specific terminals 6 Motor circuit breaker auxiliary drives



3.1.6 Filter cabinet (optional)

Fig. 3-6 Front view - filter cabinet

1 Heat exchanger 2 4 filter slots with protection



3.2 Functional principle

Fig. 3-7 Frequency converter to double fed asynchronous machine (schematic)

1 Decentralised control unit 8 Inverter (machine side converter) 2 Transformer for precharge of the DC-link 9 Mains 3 Rectifier for precharge of the DC-link 10 Mains switch 4 Line contactor 11 Stator contactor 5 Line choke 12 Stator 6 Rectifier (line side converter) 13 Rotor 7 DC-link

The CONCYCLE® frequency converter drives a double fed asynchronous machine in a wind turbine.

The frequency converter is a voltage converter in IGBT technology.

The frequency converter consists of

• Line side converter

• DC-link

• Machine side converter

A liquid cooling dissipates the heat losses of the IGBT power stacks. The coolant from the liquid cooling is a combination of water and antifreeze additive.

The incremental encoder (component of the generator) records rotation speed and rotor position.

The decentralised control unit controls the IGBT power stacks.



3.2.1 Decentralised and central control unit

Each power cabinet includes an individual decentralised control unit. The decentralised control units are connected to the central control unit.

3.2.2 DC-link

The DC-link couples the line side converter with the machine side converter.

DC-link voltage is generated after precharge by the decentralised control unit and after diode precharge by a boost converter (line choke). The line side converter pulses energy into the DC-link with the help of the line choke.

Due to undesired dynamic changes of the mains voltage, the voltage in the DC-link may increase.

The DC-link limiter protects the DC-link from critical voltage increases. The DC-link resistor of the DC-link limiter converts excessive electrical energy into heat when defined limit values are exceeded.

The energy meter and a temperature monitoring protect the DC-link limiter from overload.



3.3 Operating modes

3.3.1 Start sequence

Fig. 3-8 Start sequence of the wind turbine



3.3.2 Standstill

• The rotor of the generator is not in the operating range (minimum speed not achieved).

• The frequency converter is ready for operation or feeds reactive power via the line side converter into the mains.

D A N G E R Danger of electrocution

The frequency converter is energized even at standstill. Working at open cabinets can lead to life-threatening situations.

When the product is at standstill

Ø Do not open doors of the cabinets.

Ø Do not reach into the danger zones.

Ø Do not service or repair the product.

Fig. 3-9 Wind turbine at standstill – precharge of the DC-link (schematic)

The DC-link (2) is precharged by the signal “excitation release” via the rectifier for the precharge of the DC-link (1).



Fig. 3-10 Wind turbine at standstill - charge of the DC-link (schematic)

As soon as the threshold value for the DC-link voltage is reached

• the line contactor (1) is closed

• the line side converter (2) is enabled and regulated to a rated voltage

• the DC-link (3) is charged further via the line side converter (2)

Option reactive power supply / operating status “precharge”

N O T I C E The option reactive power supply is only activated by Woodward on request.

At standstill and with active line side converter, the reactive power can be fed into the mains.

The amount of the fed reactive power is determined by the wind turbine control.

Reactive power supply:

• The operating status “precharge” is activated with the signal “excitation release”.

• The line contactor is closed.

• The DC-link is charged to a DC-link voltage of at least 1.4•mains voltage.

The rotation speed of the generator is below the min. rotation speed.

The converter of the mains side feeds reactive power into the mains.



3.3.3 Excitation

Fig. 3-11 Wind turbine in excitation (schematic)

The line side converter (1) regulates the DC-link voltage to the nominal value. If the nominal value of the DC-link voltage is reached and is within the operating range, the machine side converter (2) is enabled and excites the rotor of the generator (3).

The machine side converter (2) generates rated voltage and rated frequency.

3.3.4 Standby

The following applies for standby

• The excitation of the rotor is completed.

• The machine side converter regulates the generator voltage in the operating range to the nominal value, independently of the rotor speed.

• As soon as the signal “load requirement” is active, the control synchronises the generator voltage with the mains voltage.

3.3.5 Mains-parallel

As soon as generator voltage and mains voltage are synchronized, the stator contactor is closed and connects the generator with the mains. The wind turbine is in mains-parallel (parallel operation).

The line side converter regulates the DC-link voltage.

Operating ranges (→ Chap. 3.4):

• Subsynchronous operation: Power is taken from the mains.

• Supersynchronous operation: Power is fed into the mains.

The machine side converter regulates the grid capacity according to the specification of the wind turbine control.



3.4 Operating ranges

The operating ranges of the wind turbine are determined by the specified slip limits.

Synchronous rotation speed: 𝑛𝑛𝑠𝑠 = 𝑓𝑓𝑝𝑝

· 60 𝑠𝑠𝑚𝑚𝑚𝑚𝑚𝑚

f = Frequency of the stator voltage

p = Pole pairs of the generator

Slip: 𝑠𝑠 = 𝑚𝑚𝑠𝑠− 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚ℎ𝑚𝑚𝑠𝑠

• s > 0: Subsynchronous operating range

• s = 0: Synchronous operating range

• s < 0: Supersynchronous operating range

3.4.1 Subsynchronous

Fig. 3-12 Wind turbine in subsynchronous operation (schematic)

The rotor is driven below the synchronous rotation speed.

The machine side converter provides the excitation of the rotor and feeds current with a slip frequency into the rotor.

The generator feeds

• energy via the stator into the mains

• a small part of the energy via the frequency converter into the rotor



3.4.2 Synchronous

Fig. 3-13 Wind turbine in synchronous operation (schematic)

The rotor operates with synchronous rotation speed.

The rotor is fed with a direct current by the machine side converter.

The generator provides 100% of the energy via the stator into the mains.

The wind turbine reaches approx. 2/3 of its rated power in synchronous operation.

3.4.3 Supersynchronous

Fig. 3-14 Wind turbine in supersynchronous operation (schematic)

The rotor is driven above the synchronous rotation speed.

A voltage is induced in the rotor. The DC-link voltage increases. The line side converter reduces the energy of the DC-link and feeds current via the line choke into the mains.

The generator feeds

• approx. 80% of the energy via the stator into the mains

• approx. 20% of the energy via the rotor and the frequency converter into the mains



3.5 Heating control

Validity: from software version 2.5 (CSC4).

The heating control of the central control unit secures the heating of the power cabinet. The heating of the other cabinets is controlled via separate thermostats.

3.5.1 Control sequence

Fig. 3-15 Control sequence of the heating control



Initialisation

The heating control is initialized at system start:

• The central control unit calculates the subsequent heating time (→ Chap. 3.5.2).

• The commissioning counter is scanned.

• The heating control is switched over to the central control unit.

• As soon as the relay for the heating operation is switched on, the warning “W12: Heating operation active” appears.

N O T I C E As long as the heating operation is active (warning message W12), the system cannot switch into the operating status “heating”.

• Heating control switches into the operating status “preheating”.

Preheating

Preheating includes cooling liquid heating.

• The following applies for the operating status “preheating”:

o The dew points of the heat sink and the mains cabinet and the temperatures of the cooling liquid and the mains cabinet are checked.

o The relay “ready for operation” is switched off, the wind turbine is not started by an excitation release.

o The relay for the heating operation remains switched on, the warning “W12: Heating operation active” stays.

• Changeover into the next operating status

The heating control switches from the operating status “preheating” into the next operating status when the following conditions are met:

o Cooling liquid temperature > 25 C

o Cabinet temperature > 5 C

o The dew point of the heat sink matches the required value

o The dew point of the cabinet matches the required value

• What is the next operating status?

o Subsequent heating switched on: Change to the operating status “subsequent heating” (→ Chap. Subsequent heating)

o Subsequent heating switched off: Change to the operating status “heating” (→ Chap. Heating)



• Cooling liquid heating

If one or more conditions are not fulfilled, the heating control influences the measured variables by enabling and disabling the cooling liquid heating.

The heating control switches the cooling liquid heating on if

o the cooling liquid temperature is below the parametrised minimum temperature

o the dew point of the heat sink does not match the required value (cooling liquid too cold)

The heating control switches the cooling liquid heating off if

o the cooling liquid temperature is above the parametrised minimum temperature

o the dew point of the heat sink matches the required value

The heating control switches the cooling liquid heating on if

o the cabinet temperature is below the parametrised minimum temperature

o the dew point of the cabinet does not match the required value (cabinet too cold)

• The heating control switches the cooling liquid heating off if

o the cabinet temperature is above the parametrised minimum temperature

o the dew point of the cabinet matches the required value

Premature cancelling of the preheating in the case of a fault (e.g. heating malfunction): If a heating is switched on, the heating control checks if the temperature of the heating has risen within 10 subsequent heating cycles. If the temperature of the heating has not risen, the warning “Climate Control” is set and the heating control switches to the following operating status.

Subsequent heating

• If the subsequent heating time is 0, the heating control switches to the operating status “heating”.

• If the subsequent heating time is bigger than 0, the dew points of the heat sink and the mains cabinet will be increased by offsets (parameterisable) and met during the subsequent heating time.

o During subsequent heating, the heating control meets all temperatures and dew points. The cycle time of the subsequent heating is 1 minute. The cycle counter is only reduced if all conditions (temperature and humidity) are met.

o In the end of the subsequent heating time, the heating control switches to the operating status “heating”.

o Premature cancelling of the subsequent heating in the case of a fault: The heating control counts the amount of time in which the system does not meet the conditions for temperature and dew point. If this fault time exceeds an limit value (parameterisable), the warning “Climate Control“ is set and the heating control switches immediately into the operating status “heating”.



Heating

The following applies for the change into the operating status “heating”:

• The relay “ready for operation” is released.

• The relay for heating operation is switched off.

• The warning “W12: Heating operation active” is confirmed.

In the operating status “heating”, the wind turbine is ready for operation. An excitation release starts the wind turbine.

In operating status “heating”, the heating control operates as in operating status “preheating”. However, the dew points are checked twice per cycle with changeable values (parameterisable).

3.5.2 Subsequent heating time

The subsequent heating time depends on the off duration of the control computer.

• For an off duration of less than 3 hours, no subsequent heating is required.

• For an off duration of more than 3 hours, the subsequent heating time is 1 hour per started off day. The maximum subsequent heating time is 8 hours.

• If the wind turbine is not yet commissioned, the subsequent heating time is 8 hours.



3.5.3 Parameters of the heating control

4640*: Subsequent heating

The parameter determines which operating status the heating control switches to after preheating:

• Subsequent heating switched on (standard): Change to the operating status “subsequent heating”

• Subsequent heating switched off: Change to the operating status “heating”

4644*: Minimum cooling liquid temperature

The minimum temperature of the cooling liquid in °C. If the cooling liquid temperature falls below the parameterised value, a warning is set.

4645*: Minimum cabinet temperature

The minimum temperature of the cabinet in °C. If the cabinet temperature falls below the parameterised value, a warning is set.

4646*: Offset for the heat sink dew point in operating status “subsequent heating”

In operating status “subsequent heating”, the heat sink dew point is increased by the offset. As soon as the cooling liquid temperature falls below the value of the dew point plus offset, the cooling liquid heating is controlled.

4647*: Offset for the cabinet dew point in operating status “subsequent heating”

In operating status “subsequent heating”, the cabinet dew point is increased by the offset. As soon as the cabinet temperature falls below the value of the dew point plus offset, the cooling liquid heating is controlled.

4648*: Offset for the heat sink dew point in operating status “heating”

In operating status “heating”, the heat sink dew point is increased by the offset. As soon as the cooling liquid temperature falls below the value of the dew point plus offset, the cooling liquid heating is controlled.

4649*: Offset for the cabinet dew point in operating status “heating”

In operating status “heating”, the cabinet dew point is increased by the offset. As soon as the cabinet temperature falls below the value of the dew point plus offset, the cooling liquid heating is controlled.

4657*: Maximum fault time in operating status “subsequent heating”

The maximum amount of time the system is in the operating status “subsequent heating” without meeting the conditions for temperature and dew point.

* Number of the parameter in the System Tool



3.5.4 Measured values of the climate control

4638*, 4639*: Switching states of the heating

Heating is switched on or off.

4641*: Cabinet temperature

The central control unit receives the cabinet temperature via a 0-10-V-signal.

4642*: Outside temperature

The central control unit receives the outside temperature via a 0-10-V-signal.

4643*: Cabinet humidity

The central control unit receives the cabinet humidity via a 0-10-V-signal.

4651*: Cooling liquid temperature

The central control unit receives the cooling liquid temperature via an mA-signal.

4652*: Operating status of the climate control

The central control unit outputs the operating status of the climate control.

4653*: Subsequent heating time

The subsequent heating time calculated by the central control unit during the initialisation.

4654*: Remaining operating time

The remaining time in the operating status “subsequent heating” until the central control unit changes the operating status.

4655*: Heat sink dew point temperature

The dew point temperature of the heat sink calculated by the central control unit.

4656*: Cabinet dew point temperature

The dew point temperature of the cabinet calculated by the central control unit.

* Number of the measured value in the System Tool



3.6 Name plate

The name plate is in the cabinet of the control cabinet.

3.7 CE marking

The CE marking documents that the products comply with the basic requirements of the relevant regulations.

The declaration of conformity can be accessed at the manufacturer’s premises.

4 Assembly


4 Assembly

4.1 Transporting the product and storage

1. Please observe the following documents for transport and storage of the product:

• Specification for long term storage: 4930-1374 Long term storage of CONCYCLE® frequency converters – RPS-Wind

• Specification for storage, transport and operation: KP-46375_New Supplier_Specification_Storage_Transport_Operation_Concycle_MP1_gb_Rev_7

4.1.1 Symbols on the packaging

The components and the accessories of the product are packed ready for transportation and then shipped.

The packages display the following transport and shipping information symbols:

Up

Handle with care

Keep dry

Keep away from heat

Do not use hand hooks

Centre of gravity

Sling here

Do not use hand trucks

Clamp as indicated

Maximum

stacking load

Do not cut packaging

Admissible

temperature range

No forklifts

2. Observe all transport and shipping information on the packages.

4 Assembly


4.1.2 Safety instructions for transport

3. Observe the environmental conditions defined in the appendix (→ Chap. 14.1.2).

4. Observe the technical data of the product, especially the weight (→ Chap. 14.4).

5. Observe the following safety instructions:

• Cabinets must only be transported upright. Tilted transport is not permitted.

• All load handling attachments (lifting tools, ropes, and chains etc.) must have a sufficient capacity.

• All load handling attachments must be equipped with safety hooks.

• Load handling attachments must only be attached to the provided load handling points.

• Load handling points of single components must not be used to transport other components.

• Use only intact ropes as load handling attachment.

• Ropes and chains must not have any knots.

• Ropes and chains must not touch any sharp edges.

• Loads must not be lifted over persons.

• Components must not be mechanically damaged or destroyed.

• Electronic components and their contacts must not be touched.

4 Assembly


Fig. 4-1 Load handling points (exemplary illustration)

6. Refer to the transport drawing for:

• further transport information

• Position of the centres of gravity

4 Assembly


4.1.3 Safety instructions for storage



During storage, the product must be protected from dust, wetness and humidity.

4.2 Unpacking the product

Generally, the packaging material stays with the customer. The customer is responsible for an environmentally friendly disposal of the packaging material according to local requirements.

4.3 Check Scope of delivery

► Check scope of delivery for completeness.

Quantity Denomination

1 Frequency converter system

1 Circuit diagram

1 Transport drawing

1 Customer-specific accessories

1 Customer-specific commissioning protocol

1 Installation and operating instructions

1 Installing declaration

4 Assembly


4.4 Positioning and installation of the product

4.4.1 Installation location

1. Please observe the requirements from the project planning of the wind turbine (→ Technical data sheet).


3. Make sure to align the door hinges of the product with the defined escape direction of the installation location.

4. If the admissible environmental temperatures for operation cannot be guaranteed, install air-conditioning or convection cooling at the installation location.


4.4.2 Minimum distances / free spaces

6. Observe the dimensions defined in the appendix (→ Chap. 14.5).

7. Please note: Minimum room height = product height + 1 m for discharge of hot air.

8. Observe the minimum distances to the walls and other systems and machines (→ Engineering drawing)

4 Assembly


4.4.3 Tightening torques

The tightening torques for screwing the floor frame of the frequency converter into the platform of the wind turbine are defined by the wind turbine manufacturer.

Standard tightening torque for screw connections

Thread Tightening torque [Nm]

M4 2.3

M5 4.6

M6 7.9

M8 19

M10 38

M12 66

M16 162

5 Electrical installation



5.1 Connect rotor cable

Fig. 5-1 Rotor connection

► Connect the rotor cable to the terminals (K), (L) and (M) (observe circuit diagram!).



5.2 Connect stator cable

Fig. 5-2 Stator connection

► Connect the stator cable to the terminals (U), (V) and (W) (observe circuit diagram!).



5.3 Connect mains cable

Fig. 5-3 Grid connection

► Connect the mains cable to the terminals (L1), (L2) and (L3) (observe circuit diagram!).

5.4 Connect control, measuring and bus cables

► Connect the control, measuring and bus cables to the customer specific terminals (observe circuit diagram!).

6 Hydraulic installation


6 Hydraulic installation

Fig. 6-1 Coolant connections

► Connect the coolant lines with:

• Coolant supply (1)

• Coolant return (2)

7 Commissioning


7 Commissioning

D A N G E R Danger to life due to wind turbine in operation

If you have to work on open cabinets during commissioning of the product while the wind turbine is operating, it can cause life-threatening situations.

► Only commission the product when all cabinets are closed.

► Observe the technical documentation CONCYCLE System Tool - GB.

7.1 Make a commissioning protocol

1. Commission the product with the corresponding commissioning protocol.

2. After completing commissioning, send the completely and correctly filled in commissioning protocol to the Woodward-Service within the contractually defined period.

7.2 Use coolant

IGBT power stacks are liquid-cooled. Antifreeze additive must be added to the coolant.

1. Only use a mixture approved by Woodward as coolant.

C A U T I O N Risk of material damage due to incorrect preparation of the coolant

Due to an incorrect mixing ratio of water and antifreeze additive, components can be damaged.

Ø Never use only water to prepare the coolant.

► Always use the mixture to prepare the coolant.

2. Make sure to follow the manufacturer instructions of the coolant.

7 Commissioning


7.3 Fill recooling system

1. Use a suitable filling pump to fill the recooling system.

Fig. 7-1 Water inlet of the recooling system (exemplary illustration)

Ø Do not open the ball valves of the recooling system.

2. Use the filling pump to pressurise the recooling system.

3. Check all hydraulic connections for tightness.

4. If all hydraulic connections are tight, then open the ball valves of the recooling system.

5. Fill the recooling system

• Coolant quantity → Manufacturer manual Recooling system

• Nominal system pressure: 2.5 - 3.5 bar

8 Operation


8 Operation

D A N G E R Danger of electrocution

If the product is in operation, working at open cabinets can lead to life-threatening situations.

When the product is in operation

Ø Do not open doors of the cabinets.

Ø Do not reach into the danger zones.

Ø Do not service or repair the product.

► Observe the technical documentation CONCYCLE System Tool - GB.

9 Troubleshooting


9 Troubleshooting

If faults occur at the product, the event recorder of the central control unit records these faults. You can analyse the recorded data with the System Tool.

1. Please observe the technical documentation CONCYCLE System Tool - GB.

2. Observe the fault message and warning message tables in the appendix (→ Chap. 14.2 and 14.3).

10 Inspection, maintenance and repair


10 Inspection, maintenance and repair

► Please observe the Maintenance and repair instructions CONCYCLE® frequency converter system.

11 Decommissioning


11 Decommissioning

11.1 Temporary shutdown

For maintenance and repair work, the product can be shut down temporarily.

► Please observe the Maintenance and repair instructions CONCYCLE® frequency converter system.

11.2 Final decommissioning

► Contact the Woodward service.

11.2.1 Recycling and disposal

The product contains batteries, accumulators, condensers as well as electronic components and circuit boards which must be disposed of as special waste in compliance with local requirements.

All components with the crossed-out wheeled bin symbol are reusable economic goods and must be recycled after replacement.

12 Warranty


12 Warranty

As manufacturer of the frequency converter system, Woodward extends the warranty agreed upon in the framework supply agreement.

The warranty comes into effect with delivering and commissioning the frequency converter system.

Woodward acknowledges the warranty only with a completely and correctly filled in commissioning protocol.

13 Customer service


13 Customer service

► You can find the contact information on the back side of this document.

14 Appendix


14 Appendix

14.1 Environmental conditions

C A U T I O N Material damage due to unsuitable environmental conditions

Unsuitable environmental conditions may damage the product.

► Store, transport and operate the product only in the defined environmental conditions.

14.1.1 Environmental conditions for long-term storage (according to EN 60721-3-1)

Environmental parameters Unit Value

Climatic environmental conditions (according to class 1K2)

Low air temperature °C +5

High air temperature °C +40

Low relative air humidity % 5

High relative air humidity % 95 *

Low absolute air humidity g/m3 1

High absolute air humidity g/m3 25

Temperature changing speed °C/min 0.5

Sunlight W/m2 700

Thermal radiation — No

Condensation — No

Precipitation (rain, snow, hail, etc.)

— No

Build-up of ice and icing — No

Biological environmental conditions (according to class 1B1)

Chemically active substances (according to class 1C1L)

Sea salt and thawing salt — No

14 Appendix


Mechanically active substances (according to class 1S1)

Sand in air — No

Mechanical environmental conditions (according to class 1M2)

* Deviating from the standard

14.1.2 Environmental conditions for transport (according to EN 60721-3-2)



Low air temperature °C -20 *

High air temperature

in unventilated containers

in ventilated containers or outdoors

°C

°C

+60

+40

Temperature change

Air/air

Air/water

°C

—

-25/+25

No

Relative air humidity

not combined with quick temperature change

combined with quick temperature change: Air/air at high relative air humidity

% / °C

— / —

75 / +30

No / No

Absolute air humidity

combined with quick temperature change: Air/air at high water content

— No

Precipitation, rain — No

Sunlight W/m2 700

Water (excluding rain) — No

Wetness — No

14 Appendix




Chemically active substances (according to class 2C1)

Sea salt — No


Sand in air — No

Mechanical environmental conditions (according to classes 2M1, 2M2 **)

Sinusoidal vibrations (frequency range)

Amplitude of the deflection

Amplitude of the acceleration

Hz

mm

m/s2

2-9 / 9–200 / 200-500

3.5

10 / 15

Noise vibrations (frequency range)

Acceleration Spectral Density

Hz

m2/s3

10–200 / 200-2000

1 / 0.3

Shocks (total shock response spectrum: type I)

Peak acceleration â m/s2 100

Shocks (total shock response spectrum: type II)

Peak acceleration â — No

Free fall

Weight: > 100 kg m 0.1

Overturning

Weight: > 100 kg — No

Roll, pitch

Angle

Period

°

s

±35 **

8 **


** Class 2M2

14 Appendix


14.1.3 Environmental conditions for operation (according to EN 60721-3-3)



Low air temperature °C -25 *

(-40 **)

High air temperature °C +45 *

(+50 ***)

High relative air humidity % 90 *

Temperature changing speed °C/min 0.5

Low air pressure kPa 84 *

High air pressure kPa 106

Thermal radiation W/m2 No

Condensation — No

Water (excluding rain) — No

Built-up of ice — No


Chemically active substances (according to class 3C1)

Sea salt — No *


Sand in air — No

14 Appendix



Mechanical environmental conditions (according to class 3M2)

Sinusoidal vibrations, stationary (frequency range)

Amplitude of the deflection

Amplitude of the acceleration

Hz

mm

m/s2

2-9 / 9-200

1.5

5

Shocks, non-stationary (Total shock response spectrum: type L)

Peak acceleration â m/s2 40

Shocks, non-stationary (Total shock response spectrum: type I)


Shocks, non-stationary (Total shock response spectrum: type II)



** applicable for cold climate version

*** applicable for hot climate variant

14 Appendix


14.2 Error messages

Generally, errors can be corrected by

• Woodward or an authorised Woodward partner

• personnel certified by Woodward

* Corrective measures marked with an asterisk may only be carried out by Woodward or an authorised Woodward partner.

If you are unable to correct one of the listed errors, please contact Woodward service.

Error text Meaning Correction

Fxx: Unknown Fault without error text. Not possible.

F1: Hardware protection

FPGA reported watchdog trip. ► Check hardware. *

F2: IGBT over-load LSC

Report of an electric line from the IGBT power stack of the line side converter.

► Check if the error persists. ► Check hardware control. ► Check overload of the IGBT power

stack. Check electric connection for short-circuits.

► Measure insulation of the stator (with disconnected IGBT power stack).

► Measure insulation of the power stack (with disconnected stator).

► Check IGBT.

F3: DC-Link volt. too high

DC-link voltage exceeded critical value. Message via DCU.

► Check if the error persists. ► Check hardware control. ► Check electric connection for short-

circuits. ► Check IGBT.

F4: Default-parameter active

Booting of system with default parameters.

► Load valid set of parameters. *

F5: Commissioning missing

Commissioning of system not completed or commissioning counter reset.

► If rotary stator field is incorrect, connect correctly.

► If rotary field rotor is incorrect, connect correctly.

► If generator current transformer is incorrectly connected, connect correctly.

► Fully complete commissioning.

F6: Emergency stop

Message via digital input that safety chain is interrupted. Emergency stop activated.

► Close safety chain.

14 Appendix



F7: CB Gen. I> | I>>

Message via digital input that overcurrent tripping of the circuit breaker activated.

► In case of overload, check power curve of the WPP.

► In case of short-circuit: Check overload of the IGBT power stack. Check electric connection for short-circuits.

► Observe maintenance instructions of the circuit breaker.

F8: U phase sequence check

Voltage for checking of the rotating field not reached.

► Check encoder. *

F9: Synchronizing Fault

Synchronization failed. Angular difference or amplitude difference too big.

► Check stator capacitors, symmetry and load.

► Check IGBT current wave form and hardware of the driver.

► Check IGBT. ► Generator pointer angle and

parameter for vector check. *

F10: C.B. Gen. Fault

The set feedback time of the circuit breaker on the stator/grid is exceeded or feedback although no command has been given.

► Check wiring and driver. ► Record switching cycles.

F11: CB LSC fault

The set feedback time of the contactor on the line side converter is exceeded or there is feedback although no command has been given.


F12: C.B. Fault (contactor)

The set feedback time of the contactor on the stator/grid (parallel to circuit breaker) is exceeded or there is feedback although no command has been given.


F13: DC link precharge

Set precharge voltage of the DC-link is not reached in the time frame.

► Check fuse in the precharging circuit. ► Measure charging voltage.

F14: DC link B6 charge

Set B6 charging voltage of the DC-link is not reached in the time frame.

► Check fuse in the precharging circuit. ► Measure charging voltage.

F15: Gen. voltage low

Tripping on DSP. Minimum stator voltage undercut.

► Check hardware and parameter. *

F16: Gen. voltage high

Tripping on DSP. Minimum stator voltage exceeded.


F17: Gen. current fault

Tripping on DSP. Maximum stator current exceeded.


F18: Mains current fault

Tripping on DSP. Maximum mains current exceeded.

► In case of overload, check power curve of the WPP.

F19: WTC release missing

Message via digital input that feedback of the superordinate wind turbine control is missing.

► Check WTC output of the WPP. ► Check wiring up to CSC. ► Check CSC-input.

14 Appendix



F20: Heat-sink overtemp.

Message via digital input that overtemperature of external device was detected.

► Check cooling system. ► Check environmental conditions. ► In case of overload, check power

curve of the WPP.

F21: DC link rated voltage

Rated voltage of the DC-link not reached. ► Check hardware and parameter. *

F22: Stator rated voltage

Rated voltage of the stator not reached. ► Check hardware and parameter. *

F23: Stator rated frequency

Rated frequency of the stator not reached. ► Check hardware and parameter. *

F24: Ringline shut down 1

Message via digital input that ringline 1 is interrupted.

► Check fuses and circuit breaker according to circuit diagram.

► Check CSC-input. ► Measure voltage. ► Check settings.

F25: Ringline shut down 2

Message via digital input that ringline 2 is interrupted.



F27: Rotary field rotor

The rotary field rotor is incorrect. ► Check connection of the rotor cables.

F28: Shaft encoder

Position encoder reports failure of bars. Safe operation not guaranteed.

► Check true running (→ Technical data).

► Check measurement of the traces (A/B/N).

► Check wiring between encoder and CSC.

F29: Mains fault Tripping on DSP or message via digital input. Detailed information: see event recorder.

► Check for mains fault. ► Check parameter of the grid

protection relay. ► Check CSC-input.

F30: Can-bus-error

CAN bus connection faulty. CSC → CSK. Connection to display not monitored.

► Check CAN bus connection (internal/external).

F31: Cooling-system error

Message via digital input that pressure switch has reported fault and fan has switched off.

► Check CSC-input. ► Check cooling system.

F32: Rotary field stator

The rotary stator field is incorrect. ► Check connection of the stator cables.

F33: Shaft encoder (90° Error)

Encoder adjustment has not been carried out correctly. Deviation = 90°.

► Check alignment of encoder. ► Check fixing of encoder.

F34: I stator current transformer

Stator current transformer connected incorrectly.

► Check installation direction. ► Check connections. ► Check connection between the

cabinets.

14 Appendix



F35: I grid current transformer

Current transformer connected incorrectly. ► Check installation direction. ► Check connections. ► Check connection between the

cabinets.

F37: HW & SW incompatible

Hardware and software not compatible. ► Install correct Hardware. *

F38: LSC AC Voltage

Tripping on DSP. Admissible LSC voltage exceeded or undercut.


F39: DC link over voltage

Tripping on DSP. Maximum DC-link voltage exceeded.


F40: DC link under voltage

Tripping on DSP. Minimum DC-link voltage undercut.


F41: duzk/dt Increase or decrease of the DC-link voltage too high.


F42: LSC current

Tripping on DSP. Maximum LSC current exceeded (I2t protection).


F43: Rotor earth fault

Current sum supervision of the rotor currents detected sum not equal to zero.

► Measure insulation at rotor.

F44: LSC line to earth

Current sum supervision of the line side converter currents detected sum not equal to zero.

► Measure insulation at the choke.

F45: LSC DC current Offset

Offset in the measuring chain (to be aligned at system start) exceeded admissible value.

► Check LSC current measurement in Data visualizer.

► Check offset of the measuring section.

F46: MSC DC current Offset

Offset in the measuring chain (to be aligned at system start) exceeded admissible value.

► Check MSC current measurement in Data visualizer.

► Check offset of the measuring section.

F47: IGBT over-load MSC

Report via fibre optics of the IGBT power stack of the MSC.

► Check if the error persists. ► Check hardware control. ► Check overload of the IGBT power

stack. Check electric connection for short-circuits.

► Measure insulation of the rotor (with disconnected IGBT power stack).

► Measure insulation of the power stack (with disconnected rotor).

► Check IGBT.

F48: Preliminary CB tripped

Circuit breaker (upstream of the stator contactor) is open.

► Check stator contactor for burnt-in contacts.

F49: INI file Faulty INI file input. System has booted with backup file.

► Input correct INI file and boot. *

14 Appendix



F50: Coolant temperature

Cooling liquid temperature exceeded maximum admissible value.

► Check cooling liquid pump. ► Check coolant level. ► Check temperature detection.

F51: Chopper DC-link limiter IGBT reports error. ► Check if the error persists. ► Check hardware control. ► Check DC-link limiter IGBT.

F53: Parameter value overflow

Overflow at calculation of the DSP parameters.

► Adhere to value range during parameter setting. *

► Set to default parameter.

F55: External Comm. supervision

No communication via Anybus module. ► Check communication connection between CSC and bus master. *

► Check if Anybus module is present in CSC. *

► Measure with communication tool, e.g. CANanlyzer.

► Connect Anybus module if Anybus module is missing.

F56: CB failure protec. Step 1

Failure protection of the circuit breaker has tripped on the 1st level. Current is flowing although stator switch should be open.

► Check stator contactor for welded contacts.

F57: CB failure protec. Step 2

Failure protection of the circuit breaker has tripped on the 2nd level. Signal should act on the medium voltage breaker.

► Check circuit breaker and contactor in the stator section for welded contacts.

F58: Chopper Counter shutdown

DC-link limiter is about to shut-off. Converter is separated from the grid.

► Check hardware control. ► Check electric connection for short-

circuits. ► Check IGBT.

F59: IGBT driver voltage supply

Power supply of the IGBT driver stage is not in the specified range.

► Check power supply at the driver stages. *

F60: Wrong FPGA version

Product detected during start-up that the currently active FPGA design cannot be used with active firmware version.

► Input software again with Device Installer.

F67: LSC IGBT L1

Error from IGBT (no overcurrent). ► Check cooling system. ► Check IGBT.

F68: LSC IGBT L2


F69: LSC IGBT L3


F70: MSC IGBT K


F71: MSC IGBT L


14 Appendix



F72: MSC IGBT M


F73: Chopper IGBT

If DCU is connected: IGBT error at the DC-link limiter.

► Check IGBT.

F74: Power Supply IGBT Driver

Power supply of the PPA boards faulty.

F75: Power Supply IGBT Adapter

Power supply of the DCU adapter board faulty.

► Check power supply at the DCU adapter board.

F76: Cabinet-Temperature

Cabinet inside temperature too high.

F77: Battery failure

Battery voltage drops too much. ► Replace battery. *

F78: UPS missing (24V)

Uninterrupted power supply is missing. ► Measure UPS voltage.

F79: LSC Over Voltage

Voltage at the line side converter exceeded critical value.

F80: App0 VHDL/FW in DCU

DCU contains incorrect revision of the FPGA configuration of the DCU (bootloader).

► Update bootloader. *

F81: App1 VHDL/FW in DCU

Device Installer contains incorrect revision of the FPGA configuration of the DCU (application).

► Update Device Installer. *

F82: Adapt. VHDL/FW in DCU

Device Installer contains incorrect revision of the FPGA configuration of the DCU adapter board (application).

► Update Device Installer. *

F83: Main CB closing failed

Automatic restart, insertion of switch failed.

F84: Stator short circuit contactor failed

Insertion of short circuit contactor for positioning mode failed.

F85: Mains surge arrestor

Surge arrestors at grid connection have tripped.

F86: Stator surge arrestor

Surge arrestors at stator connection have tripped.

F87: Rotor surge arrestor

Surge arrestors at rotor connection have tripped.

F88: Aux. Surge arrestor

Surge arrestors have tripped.

F89: Over-Frequency

Overfrequency detected. Parametrised limits have been left.

14 Appendix



F90: Under-Frequency

Underfrequency detected. Parametrised limits have been left.

F91: df/dt Error Frequency change too big.

F92: Chopper path failure

DC-link limiter discharged DC-link in non-parametrised time (start or stop of the converter).

F93: Grid over voltage

F94: Filter 1

F95: Filter 2

F96: Filter 3

F97: Filter contactor fault

F98: Filter test skip fault

F99: Excitation Error during excitation phase (stator voltage control).

► Check stator voltage measurement. ► Check MSC current measurement. ► Check stator for short-circuit/line to

earth. ► Check if correct generator is selected. ► Check generator parameter. ► Check driver of the MSC IGBT.

F100: Power cabinet: Door open

F101: Chopper (B - common)

F102: Chopper (A - common)

F103: Chopper (B - OCP)

F104: Chopper (A - OCP)

F105: Leakage current in Chopper B

F106: Leakage current in Chopper A

14 Appendix


14.3 Warning messages

The following people are authorised to act on warnings

• Woodward or an authorised Woodward partner

• personnel certified by Woodward

If you are unable to correct one of the listed warnings, please contact Woodward service.

Error text Meaning Reaction

Wxx: Unknown warning

Warning or warning message. Not possible.

W1: Ringline alarm

Notice of a warning via digital input warnings.



W2: Line interruption 20mA Channel 0

Line break in channel 0 of the mA-inputs. ► Check mA-output of the WPP. ► Check wiring up to CSC. ► Check CSC-input.

W3: Position encoder warning

Position encoder reports failure of bars. Safe operation guaranteed.

► Check true running (→ Technical data).

W5: Coolant temperature

Cooling liquid temperature (measured via 4-20-mA-channel) exceeded limit for warning.

► Check cooling liquid pump. ► Check coolant level. ► Check temperature detection.







W9: Encoder Offset-Warning

Automatic encoder adjustment reports high deviation of the offset compared to the last start.

► Check if encoder has been changed (warning will not occur at next start).

► Check if encoder has turned on the shaft.

W10: Climate Control

No temperature increase despite active heating. (Power cabinet and/or cooling liquid).

► Check cooling liquid pump. ► Check coolant level. ► Check temperature detection. ► Check fan heater.

14 Appendix



W11: CB Release

On systems without LSC contactor, the mains side circuit breaker opens at open cabinet door.

► Close cabinet doors.

W12: Heating operation active

System is in operating status “preheating” or “subsequent heating”.

► Wait until temperature has been reached.

W13: Converter-Off timer runs

Time delayed shut-off of the CSC at faulty uninterrupted power supply:

• Warning W13 • After a few seconds without

voltage, the system shuts down with error message F78

• After approx. 2 minutes without voltage, the CSC switches off via the relay “converter off”

W14: Ambient temperature

Outside temperature (measurement value 4642) exceeds the value set in parameter 5136.

► Wait until outside temperature drops below the value set in parameter 5136.

W15: Cabinet temperature

Cabinet temperature (measurement value 4641) exceeds the value set in parameter 5137. After defined period of time (parameter 5135) with excessive temperature (T > parameter 5137-parameter 5138), the system shuts down with error message F76.

► Wait until the cabinet temperature drops below the value set in parameter 5137.

W16: Coolant system pressure

Coolant pressure (measurement value 4658) is below the value set in parameter 4623.

► Wait until coolant pressure has increased again: p > parameter 4623+parameter 4624.

W17: Mains surge arrestor

Surge arrestors at grid connection have tripped.

W18: Stator surge arrestor

Surge arrestors at stator connection have tripped.

W19: Rotor surge arrestor

Surge arrestors at rotor connection have tripped.

W20: Aux. Surge arrestor

Surge arrestors have tripped.

W21: Over-Frequency

Overfrequency detected. Parametrised limits left.

W22: Under-Frequency

Underfrequency detected. Parametrised limits left.

14 Appendix



W23: df/dt (positive)

Excessive positive frequency deviation within a certain period of time. The system shuts down with error message F29.

W24: df/dt (negative)

Excessive negative frequency deviation within a certain period of time. The system shuts down with error message F29.

W25: UPS failure

Subordinate wind turbine control reports outage of the USV (display in System Tool only).

W26: Filter supervision skip

Filter test skipped, if:

• Excessive deviation of mains frequency from rated frequency (Δf > parameter 5151)

• Excessive negative sequence component of the mains voltage (U > parameter 5153)

• System in voltage dip

14 Appendix


14.4 Technical data

► For technical data, please refer to the technical data sheet.

14.5 Dimensions

► For dimensions, please refer to the technical data sheet.

14.6 Installing declaration

The installing declaration documents that the products fulfil the basic requirements of the applicable directives for incomplete machinery.

The installing declaration is part of the delivery documentation.

15 List of terminology and abbreviations



B6

Three-phase bridge rectifier

CB (Circuit breaker)

Circuit breaker

Chopper (DC-link limiter)

The DC-link limiter protects the DC-link from critical voltage increases.

CSC (Control System CONCYCLE)

Central control unit

The central control unit is connected to the decentralised control units. Among others, the central control unit controls the DC-link.

DFIG (Double fed induction machine)

Asynchronous machine which is driven as motor or generator.

DCU (Digital Control Unit)

Decentralised control unit

The decentralised control unit controls the IGBT power stacks. Each power cabinet includes an individual DCU. The decentralised control units are connected to the central control unit.

IGBT (Insulated-gate bipolar Transistor)

Bipolar transistor with insulated gate electrode

The IGBT are highly robust power transistors with nearly powerless driver.

Encoder

Electromagnetic measuring transducer for conversion of the angular position of a rotor into a electronic dimension.

Power Stack

Assembly with IGBT

LSC (Line Side Converter)

Mains side converter



Fibre optics

Cable and lines to transfer light.

MSC (Machine Side Converter)

Machine side converter

OCP (Over Current Protection)

Overcurrent protection device

PLC (Programmable logic controller)

The PLC is a device that is used to control a machine or system.

DC-link voltage

Voltage of the DC-link

WPP (Wind turbine)

A wind turbine includes:

• Rotor blades

• Drive train (hub, rotor shaft, gear box, brake, etc.)

• Generator (rotor & stator)

• Nacelle

• Tower

• Frequency converter system

• Basement

• Electrical supply

WTC (Wind turbine controller)

Controlling computer of the wind turbine

WW (Woodward)

Woodward Kempen GmbH

DC-link

Energy storage for electrical coupling of two converters

DC-link resistor

Resistor of the DC-link

16 Index


16 Index

A

Antifreeze additive .................................................... 44

C

CE marking ................................................................. 33 Central control unit .................................................... 20 Commissioning........................................................... 44 Commissioning protocol ............................................ 44 Coolant ...................................................................... 44 Customer service ....................................................... 51

D

DC-link ........................................................................ 20 Decentralised control unit ......................................... 20 Decommissioning ....................................................... 49 Dimensions ................................................................ 67 Disposal ...................................................................... 49

E

Electrical installation .................................................. 40 Environmental conditions .......................................... 52 Error messages .......................................................... 57

F

Functional principle ................................................... 19

G

General safety instructions .......................................... 7

H

Hydraulic installation ................................................. 43

I

Inspection .................................................................. 48 Installation location ................................................... 38 Intended use ................................................................ 6

M

Maintenance .............................................................. 48

N

Name plate ................................................................. 33

O

Obligations of the operator ......................................... 9 Operating modes ....................................................... 21 Operating ranges ....................................................... 25 Operation ................................................................... 46 Option reactive power supply .................................... 23

Q

Qualification of personnel ......................................... 10

R

Recooling system ....................................................... 45 Recycling .................................................................... 49 Repair ......................................................................... 48 Revisions ...................................................................... 2

S

Safety instructions ....................................................... 7 Scope of delivery ........................................................ 37 Set-up ......................................................................... 13 Storage ....................................................................... 34

T

Target groups ............................................................. 12 Technical data ............................................................ 67 Tightening torques ..................................................... 39 Transport.................................................................... 34 Troubleshooting ......................................................... 47

W

Warning messages ..................................................... 64 Warning notices ........................................................... 6 Warranty .................................................................... 50

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October 2015

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