Alternative & Renewable Energy

HYDRAULIC PITCH HUB TRAINING SYSTEMMODEL 46124

Maintaining and operating wind turbines requires es-sential technical and troubleshooting skills. The Lab-Volt Wind Turbine Hub Training Systems offer hands-on training for real-world operation and maintenance situations, preparing students with the skills and training for jobs as wind turbine technicians. Lab-Volt offers two Wind Turbine Hub Training Systems: an Electrical Pitch Control Trainer and a Hydraulic Pitch Control Trainer. Both allow interconnection with Lab-Volt’s Nacelle Train-ing System, Model 46122.

The Lab-Volt Hydraulic Pitch Hub Trainer is a complete scaled-down version of a commercial wind turbine hub

and features all the components typically found in the hub of a commercial wind turbine. It includes a propor-tional hydraulic cylinder with its drive, a slewing bear-ing, and a representation of the wind turbine blade. A SIEMENS PLC controls the different functions of the Hydraulic Hub and is located in an electrical enclosure, with all the other electrical components. The enclosure features a transparent window to allow component iden-tifi cation, and transparent protective guards with electric interlocks ensure safe experimentation while working around the trainer.

A hydraulic unit is also installed on the trainer. A manual

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INTERNET: http://www.labvolt.com

GENERAL DESCRIPTION

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HYDRAULIC PITCH HUB TRAINING SYSTEMMODEL 46124

TABLE OF CONTENTS OF STUDENT MANUALS

• Introduction to Energy Production with Wind Power (88390-20)

– Energy Production with Wind

– Wind Turbine Overview

– Trainer Components

• Machine Safety (88391-20)

– Safety Aspects of a Wind Turbine

– Wind Turbine Operational Hazards

– Lab-Volt Hydraulic Pitch Hub Trainer Safety

– Lockout/Tagout procedure

• Introduction to SCADA (88392-20)

– The SCADA System Network

– The Hydraulic Pitch Hub Trainer HMI

• Rotor (88393-20)

– Blade Aerodynamics

– Aerodynamics Power Control

– Slewing Bearings

– Electric/Hydraulic Pitch Control

• Hydraulic System (88394-20)

– Introduction to Fluid Power

– Pressure and Flow Control

– Special Hydraulic Components

– Hydraulic Unit Components

– Hydraulic Unit Circuit

– Pitch Control

• Hydraulic Pitch Control Operation (88395-20)

– Control Overview

– Servo Control

– PLC

– Slip Rings

• Electrical System (88396-20)

– Electrical Panel Familiarization

– Safety Devices

– Power Supply

– Contactors

– Motor Drives

– Soft-Starting

– PLC and Remote I/O

• Troubleshooting (88397-20)

– Troubleshooting Basics

– Checking Safety Features

– Checking Motor and Solenoid Operation

– Checking Network Communication

hydraulic pump and an accumulator, as found in real-world wind turbines, are also included. The accumulator provides the back-up power required to insure the fail-safe operation of the pitch system.

Control modes are accessible using the full-color 6” touch screen operator panel, and a password protected

display allows the instructor to insert electrical faults for troubleshooting activities. Hands-on experiments cover lockout/tagout procedures while working on the equip-ment. General maintenance activities will also be car-ried out during the curriculum exercises.

TABLE OF CONTENTSGeneral Description ...................................................................................................................................................1

Table of Contents of the Student Manuals .................................................................................................................2

Specifi cations ............................................................................................................................................................9

Ordering Numbers ...................................................................................................................................................11

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MODULE DESCRIPTION

Rotor Blade

Mobile Workstation

On the hydraulic pitch hub trainer, one of three blades controlled by the software is represented by a silhouette stenciled onto a central plate. This allows the trainer to show a working blade in a scale large enough to display the actual workings of a full-scale wind turbine blade pitch control system. If an actual blade were present, it would extend from the back of the trainer.

The mobile workstation consists of a sturdy, welded steel frame painted using powder-coated paint for a du-rable surface. The unit is mounted on four swivelling casters with a lock mechanism to allow easy motion as well as stable operation.

Slewing Bearing

This component allows the blade to pivot relative to the hub or, in this case, the trainer. The trainer repre-sents a portion of a full-scale wind turbine rotor hub, and the slewing bearing is a scaled-down version of the component found in the full-scale wind turbine. Unlike the slewing bearing found in an electrical pitch control system, the slewing bearing of a hydraulic pitch control system has no internal teeth or meshing pinion gear.

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HYDRAULIC PITCH HUB TRAINING SYSTEMMODEL 46124

Hydraulic Cylinder

Hydraulic Power Unit

Hydraulic Pressure Gauges

Human Machine Interface (HMI)

The hydraulic cylinder’s piston converts the energy of the hydraulic fl uid under pressure into mechanical en-ergy. With one end fi xed to the hub and the other end fi xed to the rotating core of the slewing bearing, the linear translations of the hydraulic cylinder are trans-formed into a rotational motion used to adjust the blade pitch position. An electrical transducer integrated into the cylinder (located on the lower end of the cylinder) transmits piston position data back to the PLC.

The Hydraulic Power Unit supplies and controls the fl u-id power pressure required to reposition the blade angle by actuating a hydraulic cylinder.

The Hydraulic Pressure Gauges provide a reading of the pressure on a scale graduated in units of bars and pounds per square inch (psi). The gauge shown on the left (GP1) is used to monitor the pressure on the hy-draulic cylinder section of the hydraulic system. The gauge on the right (GP2) monitors the hydraulic pres-sure in the accumulator. Normal system operating pres-sure is between 600 and 900 psi.

The HMI is a touch screen that is used to operate and monitor the hydraulic pitch hub trainer. The HMI uses a system called supervisory control and data acquisition (SCADA) to provide control and data monitoring.

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Main Power Switch

This component is used to power the hub training sys-tem on and off as needed. It also provides a mecha-nism to attach a padlock for lockout/tagout procedures.

Emergency Stop Switch (ESS)

Electrical Panel

The ESS opens an electrical contactor on the trainer so that all electrical energy to the hydraulic unit ceases when the button is pressed.

The Electrical Panel contains the electrical supply, dis-tribution, and control functionality for the hub trainer be-hind a clear, lockable door.

Start Push-Button Switch

This green push-button switch closes the contactors that power on the hydraulic motor after the main power switch is set to the on (|) position

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HYDRAULIC PITCH HUB TRAINING SYSTEMMODEL 46124

24 Vdc Power Supply Circuit Breaker

AC Motor Drive

This part of the electrical control panel provides 24 volts direct current to the hub trainer for control purposes.

The Circuit Breaker is a switch that opens (discon-nects) the electrical circuit when a certain current (am-perage) is exceeded, cutting power to the trainer or a specifi c device. When the cause of the overcurrent is determined and addressed, the circuit can be closed (energized) by fl ipping the “tripped” switch.

The AC Motor Drive is used to control the speed of the hydraulic pump motor.

Fuse Holder

The Fuse Holder holds fuses that burn out when a certain line current is exceeded, protecting devices on the trainer. When the cause of the overcurrent is deter-mined and addressed, the burned out fuse needs to be replaced.

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Motor Starter Protector

Contactor

Proportional Valve Control Amplifi er

Media Converter

The Motor Starter Protector is a circuit breaker (also called overload relay) which protects the hub trainer motor from overcurrent. These devices have thermal and magnetic trip mechanisms, as well as an adjust-able trip set point.

The Contactor is a relay (remote-controlled switch) that provides high-current switching capabilities in electri-cal circuits. This device provides on/off control of the trainer’s motor.

The Proportional Valve Control Amplifi er is a digital electronic module used to drive the system’s propor-tional directional control valve. This device provides im-proved control of the hub hydraulic proportional control valve which controls the hydraulic cylinder.

The Media Converter is an optical and digital electronic transceiver module used to remotely communicate with the PLC.

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HYDRAULIC PITCH HUB TRAINING SYSTEMMODEL 46124

Courseware

The courseware supplied with this training system con-sists of student manuals and instructor guides. The stu-dent manuals consist of a series of job sheets. Each job sheet includes an information sheet which presents the theory involved and a hands-on section where the users are instructed to carry out a series of tasks. The student manuals are fully illustrated and color printed. Refer to the Table of Contents of the Student Manuals section of this datasheet to see the list of topics covered.

The instructor guide provides the results of measure-ments carried out under similar operating conditions and the answers to all questions.

Programmable Logic Controller (PLC) and Clock

Distributed I/O System

This digital electronic controller module runs the system programming used in functional operation and control of the trainer. The PLC and master interface are shown here.

The Distributed I/O System is system is a collection of input/output modules, each with its own specifi c func-tion, that carries out integrated data acquisition and control applications via a controller and a remote com-munication bus.

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Model 46124 – Hydraulic Pitch Hub Training System 120 V 60Hz 230 V 50 HzPower Requirements Current 12 A 6 A

Physical Characteristics W x H x D 41 x 58 x 64 in (104.1 x 147.3 x 162.6 cm)

Shipping Weight (Crated) 725 lb (328.85 kg)

Hydraulic Pitch Mechanism

Slewing Bearing TypeBlade mechanism

GreaserSafety

52 cm (20.5 in) steelRepresentation. 0-90° markings for movement repre-sentationAutomatic. Configured through dip switches.Protective transparent plastic surrounds entire mechanism to prevent contact during operation.

Hydraulic Cylinder TypeSlewing Ring Driver

Parker 10” strokeIntermediate fixed trunnion; linear displacement transducer (4-20 mA) feedback

Hydraulic Power Unit

Motor TypePhase

DutyNominal PowerNominal Speed

Nominal FrequencyNominal Voltage

Frame Size

AC MotorThreeInverter½ HP3450 rpm60 Hz230 VNEMA 56C

Fluid Reservoir Capacity 3.8 L (1.0 gallon)

Accumulator TypeCapacity

45 cubic in.2600 psi

Other Components Ten (10) µm filterFour (4) solenoid valves actuated through 24 V DC coils; can also be actuated manuallyTwo (2) check valvesThree (3) logic valvesOne (1) adjustable relief valveOne (1) adjustable shuttle valveOne (1) 0-3000 PSI pressure transmitter with 4-20 mA feedbackTwo (2) pressure gauges which can be connected at several points in the system for visual monitoring of the pressureOne (1) hand pump¼” diameter hoses

Hydraulic Fluid Type ISO32 or AW32

SPECIFICATIONS

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HYDRAULIC PITCH HUB TRAINING SYSTEMMODEL 46124

Other Components AUTOMATIC and MANUAL modesReal-time reading of the system’s I/Os Emulation of the behavior of a real wind turbineService window to troubleshoot all the mechanisms and electronics in the systemAlarm monitoringFault insertion (with delay if needed) is done through the HMI with Instructor password protection

Electrical Panel Dimensions (W x H x D) 24 x 30 x 12 in (61 x 76.2 x 30.4 cm)

PLC Siemens Simatic ET200SIM151-8 PN/DP CPUDigital 24 V DC input Analog Voltage 0-10 V inputAnalog Current 4-20 mA inputRelay outputEthernet (PROFINET) communication portPROFIBUS communication port

Converter Siemens Simatic Net ScalanceEthernet-to-Fiber Optic Converter

Power Supplies 24 Vdc – 120 W; fuse-protected

Current Requirement 3.2 A 120 V 60 Hz

Other Components Parker analog controller for the hydraulic cylinder of which the type is the amplifi er type for proportional directional control valvesSiemens Micromaster 420 variable frequencies drive to control the hydraulic unit motor using PROFIBUS communicationOne (1) Siemens Sirius contactorOne (1) Siemens Sirius motor protective breaker with auxiliary contact for feedbackOne (1) red disconnect switch to power up/down the systemOne (1) green illuminated push-button to start the systemOne (1) emergency mushroom button (twist to un-lock)Main breaker for the complete systemWiring ducts and wiring terminals for proper wiringTransparent, key-lockable door5 meter fi ber-optic cable to connect the hub trainer to the nacelle trainer

Control System

HMI Siemens Simatic TP 177B Touch-Screen; includes PROFINET/PROFIBUS communication ports.

Other Components Automatic and Manual modesReal-time reading of system I/OsEmulation of real wind turbine behaviorsService window to troubleshoot system mechanisms and electronicsAlarm monitoringFault insertion (with delay, if needed)

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ORDERING NUMBERS

120 V/230 V – 60Hz/50 Hz 220 V– 50 Hz 240 V– 50 HzENGLISH FRENCH SPANISH ENGLISH FRENCH SPANISH ENGLISH46124-00 N/A N/A 46124-05 N/A N/A N/A88390-20 N/A N/A 88390-20 N/A N/A N/A88390-30 N/A N/A 88390-30 N/A N/A N/A88391-20 N/A N/A 88391-20 N/A N/A N/A88391-30 N/A N/A 88391-30 N/A N/A N/A88392-20 N/A N/A 88392-20 N/A N/A N/A88392-30 N/A N/A 88392-30 N/A N/A N/A88393-20 N/A N/A 88393-20 N/A N/A N/A88393-30 N/A N/A 88393-30 N/A N/A N/A88394-20 N/A N/A 88394-20 N/A N/A N/A88394-30 N/A N/A 88394-30 N/A N/A N/A88395-20 N/A N/A 88395-20 N/A N/A N/A88395-30 N/A N/A 88395-30 N/A N/A N/A88396-20 N/A N/A 88396-20 N/A N/A N/A88396-30 N/A N/A 88396-30 N/A N/A N/A88397-20 N/A N/A 88397-20 N/A N/A N/A88397-30 N/A N/A 88397-30 N/A N/A N/A

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HYDRAULIC PITCH HUB TRAINING SYSTEMMODEL 46124

88464-00

Refl ecting Lab-Volt’s commitment to high quality standards in product, design, development, production, installation, and service, our manufac-turing and distribution facility has received the ISO 9001 certifi cation.

Lab-Volt reserves the right to make product improvements at any time and without notice and is not responsible for typographical errors. Lab-Volt recognizes all product names used herein as trademarks or registered trademarks of their respective holders. © Lab-Volt 2012. All rights reserved.