Operating and maintenance manualCustomer:MingyangWindpower Technology Co.Ltd.Daling Precinct Zhongshan TorcPRC GuangdongManufacturer:SSB-Antriebstechnik GmbH&Co.KGNeuenkirchener Str.13D-48499SalzbergenGermanyOrder No.:2061401620614151Machine:Pitch-System for1.5MW wind energyturbineYear of manufacture:2007Index Index (2)1Safety-General information (4)1.1Terminology Definition (5)1.1.1Qualified personnel (5)1.2Transport and storage (7)1.2.1Transport regulations (7)1.2.2Storage of SSB Pitch Systems (8)2Pitch system layout (9)2.1Main pitch ctrl.cabinet (10)2.2Axis cabinets (11)2.3Battery cabinets (11)2.4Electric pitch motors (12)2.5Pre-installed cables (12)3Mechanical dimension drawings (13)3.1Main pitch control cabinet (13)3.2Axis cabinet (14)3.3Battery cabinet (15)3.4Pinion encoder blade bearing (16)4Commissioning (17)4.1Installation of the components (17)4.2Mounting the switch cabinets (17)4.3Installation of the pitch motor (18)4.4Connecting the cables (18)5Manual Operation (19)5.1General information motion controller GEL8230Y001 (19)5.2Characteristic motion controller (20)5.2.1The key pad (21)5.2.2The display (22)5.2.3Menu structure (23)5.2.2.1Main window(Axis) (24)5.2.2.2Main window(I/O) (26)5.2.2.3Main menu (27)5.2.2.4Device information (27)5.2.2.5Stored failures (28)5.3Homing routine axis/blade (29)6Maintenance (30)General (30)6.1Regular maintenance (31)6.1.1Switch cabinets general (31)6.2Recommendation for preventive maintenance (31)6.2.1Disassembling of the battery cases (33)6.3Disassembly of defective devices (34)6.3.1Exchange of the DGNR speed controller (34)6.3.2Exchange of L&B motion controller (35)6.3.2.1Read current parameter set of motion controller (35)6.3.2.2Disassembly/assembly motion controller (38)6.3.2.3Write parameter to motion controller (40)6.3.3Exchange of damaged cables (41)6.4Recommended spare parts (42)6.4.1Axis cabinet (42)6.4.2Main pitch control cabinet (44)6.4.3Battery cabinet (46)Symbols usedWarning A warning contains information which is important for the prevention of dangers.Caution A section marked with"Caution“contains information which is important for the prevention of damage to the system or to accessories.Note A note contains information about the correct operation of the product.1Safety -General informationFor electrical equipment for use in electrical power installations.This information sheet,together with the warning notices,are a component part of the product-specific operating instructions and must be strictly observed for reasons ofsafety.DANGERThese electric machines or devices are equipmentfor use in industrial power installations.During operation thisequipment has concealed,dangerous,live bare-metal parts,and possibly also moving or rotating parts.They could therefore,e.g.in case of impermissible removal of the required covers,improper use,incorrect operation or insufficient maintenance,cause extremely serious injuries or damage.The person responsible for system safety must therefore ensure that:•Only qualified persons are entrusted with working on the machines or devices •These persons must,among other things,always have the operating instructions and other documents of the product documentation included with the system at their disposal at all times and must be obligated to consistently observe these documents •Work on the machines or devices,or nearby is prohibited for unqualified persons.Always note the following safety requirements andrecommendations before commissioning1.1Terminology Definition1.1.1Qualified personnelQualified persons are,due to their training,experience and instruction,as well as their knowledge of the pertinent standards,regulations,accident prevention regulations and operating conditions,have been authorized by the person responsible for system safety to carry out the respectively required activities,and can recognize and avoid possible dangers in the process(for definitions for specially-trained personnel,also see DIN VDE0105or IEC 364).In addition,knowledge of first-aid measures and the local rescue equipment is also required. For work on power installations,the prohibition of the use of unqualified persons is governed, for example,in DIN VDE0105or IEC364.WarningIt is assumed that the basic planning work for the system and all transport,assembly, installation,commissioning,maintenance and repair work will be carried out by qualified personnel and/or checked by responsible specially trained personnel.In the process,particular attention must be paid to the following:•The technical data and information on the permissible use(installation,connection, environmental and operating conditions),which are included in the catalog,the order documents,•The operating instructions,the rating plate information and the other product documentation•The general installation and safety regulations•The local,system-specific regulations and requirements•The appropriate use of tools,lifting and transport equipment•The use of personal safety equipment•Assembly conditions for devices which are delivered in accordance with IPOO (without covers)if necessary:During operation the required touch guards must beinstalled or a dangerous approach must be prevented.For clarity reasons,the operating instructions cannot contain all detailed information on possible design variants,and in particular cannot take every imaginable installation, operation or maintenance case into account.In accordance with this,the operating instructions mainly contain only those references which are required for qualified personnel (see above)in the case of appropriate use of the machines or devices in industrial application areas.If in special cases the requirements are more demanding when the machines or devices are intended for use in non-industrial areas(e.g.touch guards against children's fingers etc.),these conditions must be ensured during installation with additional protective measures on the system.In case of uncertainty here,in particular in the case of a lack of product-specific detailed information,the required clarifications must be obtained via the responsible SSB agency. Please always specify the machine or device model and serial number for this purpose.It is recommended that,for planning,assembly,commissioning and service tasks,the support and services of the responsible SSB agency be called upon.NoteTo prevent malfunctions,it is necessary to have the specified maintenance,inspection and revision measures carried out regularly by qualified personnel(see above).Changes compared to normal operation(increased power consumption,temperatures or vibrations,unusual noises or odors,actuation of the monitoring equipment etc.)indicate that operation is impaired.To prevent malfunctions which could cause direct or indirect serious injuries or damage,the responsible maintenance personnel must be informed immediately.IN CASE OF DOUBT,SWITCH OFF THE RELEVANT EQUIPMENT IMMEDIATELY!NoteIt is pointed out here that the content of the operating instructions and product documentation is not part of a previous or existing agreement,commitment or legal relationship,nor is it intended to change these in any way.All obligations for SSB result from the respective purchase contract,which also contains the complete and solely valid warranty conditions. These contractual warranty provisions shall be neither expanded nor restricted by the remarks of these instructions and documentation.NoteThe illustrations and pictures used in these instructions are for demonstration purposes and make no claim for reality.If the reader notices differences between the illustration or the picture and the version supplied(in relation to the individual components),an SSB agency should immediately be informed of this,in order to obtain clarification.If operating instructions for individual components are enclosed,they are always to be included as a supplement to the operating instructions at issue.The contents of the operating instructions for the relevant components are neither expanded nor replaced by the“Operating instructions for SSB Pitch Systems”.1.2Transport and storageCautionLifting tools has to be designed for the weight of the machine!In possible assembling or dismantling be careful of rope guide!A switch cabinet,which is not directly put into operation, has to be stored in a dry and vibration-free room.CautionAt housings of electrical devices temperatures up to100°C can occur depending upon load. Contact can cause burns and must be prevented.Also no temperature-sensitive components,e.g.normal cable or electronically parts,should lie close or has to be fastened at the housings.1.2.1Transport regulationsGeneralThis regulation describes the handling for the components manufactured by SSB(switch cabinets and electric motors)for the pitch system:The regulation is to be considered with each unloading and transportation procedure.The carrier is responsible to adhere the requirements of SSB and has to fulfill the legal regulation concerning the transportation lock and the transport insurance.Attention should be paid to:•Using a fork-lift truck the load has to be secured against overbalancing and slipping down from the pallet!•Transporting several switch cabinets on a pallet these are to be secured against slipping,because otherwise a damage of the housing can occurNoteStrong vibrations and hard impacts are to be avoided during transport as well as when lifting and setting down!1.2.2Storage of SSB Pitch SystemsGeneralThis regulation describes the correct storage of the components for the pitch system, manufactured by SSB:The storage contains:•the keeping of the SSB components up to the intended installation of the products into a wind energy plant•the keeping of the inserted components in a plant component up to the evacuation of the component to the building site.For the handling the transportation regulation is to be considered.The following items have to be considered:•The components that are not fitted must be stored in a closed hall•The hall temperature is to be maintained in the range of0°C to+40°C•During storage the relative humidity should be between0%and55%•In the case of temperatures lower than0°C care must be taken to ensure that the heating systems are in good working order so as to achieve an internal cabinet temperature of>0°C•Built-in battery packs are to be protected against discharging by regular trickle charging•During storage the components are to be protected against high humidity and water condensation inside the housing by suitable drying agents•Battery cabinets and pitch motors are not stackable•A maximum of up to3converter cabinets or3control cabinets can be stacked.When doing so,ensure that the external converter box heat sink is not damaged during storage•For protected transport,housing openings must be closed by plugs or adhesive tape and must also remain closed to prevent the ingress of foreign bodies •All housings must always remain closed during storage•The temporary corrosion protection of the unpainted fixing flange in pitch motors must be renewed at regular intervals.2Pitch system layoutThe pitch-system is placed inside the hub of the wind power plant.The scope of supply includes one main pitch ctrl.cabinet,three axis cabinets,three battery cabinets,three direct current electric motor,the required cable connections and the operating manuals.The pitch control system and speed control work together to maintain the rotor at constant power output.Wind gusts cause the rotor to accelerate,but subsequent adjustment of blade pitch smoothly reduces the speed once again.This leads to a significant reduction of the loads on the turbine while at the same time the power is supplied to the grid with a high level of compatibility.In order to maintain blade pitch in the event of grid loss or failures in the pitch power supply or control units,each rotor blade has its own battery back-up that rotates with the blade.In addition to controlling power output,the pitch mechanism serves as the primary safety/ brake system.Each blades pitch mechanism operates independently of the others.Thus in the event of a storm each blade can be moved to a safe position(feather position)to restore the rotor from abnormal situations to safe rotational speeds.Fig.2.1:plot of the pitch system layout2.1Main pitch ctrl.cabinetThe main pitch ctrl.cabinet is the interface between the axis cabinets in the hub and the top box,located in the machine house.The connection between the main pitch ctrl.cabinet and the top box is realized by slip ring. Via this slip ring the main pitch ctrl.cabinet is supplied with power and control signals from the top box.Additionally a Profibus-DP connection for the data exchange between the system management computer and the pitch controller is performed via slip ring.The positioning controller is mounted in the main pitch ctrl.cabinet and controls the positioning of the blades.In addition,the charging process of the back-up system(batteries) in the three battery cabinets is controlled by a central charging unit fitted in the main pitch ctrl.cabinet.Fig.2.2:Main pitch ctrl.cabinet2.2Axis cabinetsThere are three axis cabinets in the pitch system.One axis cabinet is allocated to each blade.The converter operates in4-quadrant mode to control the speed of the corresponding pitch motor.Fig.2.3:Axis cabinet2.3Battery cabinetsLike the axis cabinet,one battery cabinet is allocated to each axis.For the case of a power failure or a reset of the EFC-signal(Emergency Feather Control-signal)each blade will be separately moved to the feather position(limit switch).Fig.2.4:Battery cabinet2.4Electric pitch motorsThe electric pitch motors are direct current machines.Fig.2.5:Electric pitch motorDetailed information concerning the motor(technical data,maintenance etc.)is contained in the appropriate document“Operating instructions for SSB DC Motors Model:GHTIF-07200403.81”2.5Pre-installed cablesThe connection between the main pitch ctrl.cabinet and the top box is realized by slip ring. Via this slip ring the main pitch ctrl.cabinet is supplied with power and control signals from the top box.Additionally a Profibus-DP connection for the data exchange between the system management computer and the pitch controller is performed via slip ring.The connection between the main pitch ctrl.cabinet,the axis cabinet,the battery cabinets and the electric pitch motors is made by pre-installed cables.The delivered cables are coded to prevent an interchange between cables and cabinets.3Mechanical dimension drawings3.1Main pitch control cabinetFig.3.1:Dimension drawing main ctrl.cabinet3.2Axis cabinetFig.3.2:Dimension drawing axis cabinet3.3Battery cabinetFig.3.3:Dimension drawing battery cabinet3.4Pinion encoder blade bearingFig.3.4:Dimension drawing pinion encoder blade bearing4Commissioning4.1Installation of the componentsNoteThe installation of the components and the connecting cables should only be carried out by qualified personnel.WarningThe installation and the cable connection are only to be carried out if all power supplies are disconnected or switched off.The pitch system is to be disconnected from power supply until all components are correctly installed and connected to each other.The batteries for the emergency power supply are already installed.For this reason,the battery maintenance switch must be switched to“off”and only switched to“on”after all connections are made. Caution is needed if the battery cabinet is open and the batteries are interconnected,since there is a voltage of216VDC between positive and negative terminals.WarningThe installation of the pitch system must be carried out with great care.There is a risk of injury or death related to the great dead weight of the components as well as from pointed and sharp edges.Lifting and transporting must be carried out with suitable lifting and transporting equipment(see also Chapter1.2).4.2Mounting the switch cabinetsFig.4.1:Holding rail for the cabinetsFor installing the cabinets inside the hub,the switch cabinets have retaining brackets to which they can be attached with screws or bolts in frames designed for the purpose.When doing so,a firm fit must be ensured.The fastenings can become loose through vibrations in the hub during operation of the wind energy plant,so the screws or bolts must be secured against becoming loose independently.A dynamic suspension is recommended,to protect the cabinets against damage caused by the vibrations.4.3Installation of the pitch motorFig.4.2:Pitch motor4.4Connecting the cablesCautionDo not remove the coding of the plug pare the coding of the plugs with the coding on the cabinets.The inscriptions have to correspond.If the coding at the plug and cabinet is equal,but the inscriptions are different,please contact SSB.Mixing up connections can cause malfunctions in the pitch system and a damage of the plant.Fig.4.3:Connectors at the axis cabinet and the battery cabinetIf all components (cabinets and motors)are installed in the hub,the pre-wired cables can be connected.The plug system is marked and secured by coding pins.5Manual OperationWarningManually movement of the blades can present a risk for personnel and the wind energy plant if not carried out correctly.All essential safety precautions must be taken before a manual operation of the pitch system is undertaken.For this purpose,the appropriate operating instructions are to be consulted and the plant manufacturer’s safety measures are to be noted.WarningOnly one blade should be moved out of the parking position.Consequently,before moving a second blade,it must be ensured that the first blade is in parking position again.5.1General information motion controller GEL8230Y001The Motion Controller is intended exclusively for the control of rotor blade drives in a wind power plant.The three axes are equipped with a redundant encoder system.Encoder A:located at the motor shaftEncoder B:located at the blade bearingIn case of an invalid encoder signal it is possible to select the second encoder set.Control and nominal value preset are carried out by means of an attached field bus module (PROFIBUS-DP)using the specific communication protocol"LB2".The controller measures the motor currents of the three axes via current transducer connected to analog current inputs and three temperatures via analog PT100inputs,and provides averaged values.The values can be accessed via the LB2protocol(8bits)or converted and displayed as motor current in Ampere or as temperature in degrees Celsius respectively.A brief overview of the method of functioning and the operation of the controller is given here. The operator interface and the menu guidance are only for display and do not equate strictly to the supplied version in terms of the controller layout and software.NoteFor general information,safety instructions etc.or a detailed description of the controller, consult the supplied manual.5.2Characteristic motion controllerThe following sketch shows the principle of functioning of the control:Fig.5.1:Operating principle of the controllerFig.5.2:Principle axis controlGeneral information:Information in square brackets refers to the main system parameters for the corresponding blocksFor the actual value inputs/axes/nominal value outputs nos.2…6the same contents apply in principle as for no.1;differences occur with several factory settings and adjustable characteristicsFunction elements with grey background are,by default(from the factory),de-activated.5.2.1The key padFig.5.3:Keyboard1.Function keys(assignment dependent on the current window)2.Numerical keys(value input)3.Menu keys(assignment dependent on the current window,line orientated)4.Delete value input5.Cancel input/function;return to next higher menu level6.Confirm input,select/call marked entry(doubly available)7.Select keys(select characteristic of a system parameter)8.Scroll keys(move window within the displayable list by one line upwards/downwards)5.2.2The displayFig.5.4:Main window1.Number of the currently shown window with total number of windows(e.g.01/03means the first of three possible display2.Designation of the menu or function window3.Function of the menu key‘M1’;with the other menu keys the list entries shown on theleft can be activated in some windows(‘M2’→1st list entry etc.)4.Each list entry is assigned a definite number;when entering a number a searchfunction will be started,which let you go directly to an entry which is currently not visible,or the entry will be activated if it is already shown in the window5.Function of the keys‘F1 (5)(here I/0→‘F1’:display of the input/output states;'UP'→’F4’:scroll1window upwards;'DOWN'→‘F5’:scroll1window downwards)6.List entries The blinking cursor marks the entry which will be selected i.e.activatedwith the confirmation(Enter)keys(see previous section,item6);this is also possible by means of the menu keys M2..M4.7."Scroll bar":Information(qualitative)about the position of the current window(*)within the displayable list(|)Further explanations about the various windows you will found in the following descriptions of the menus.5.2.3Menu structureFor operating and observing of the motion controller various hierarchically classified display windows and configuration menus are available.The following diagram gives an overview of the menu structure.Detailed information for each window/screen is given in the corresponding reference manual of the motion controller.Fig.5.1:Menu structureAfter the device is switched on,the start screen(main window axis)with the angle positions of the axis(blades)will be displayed.The second main window contents an overview according to the status of the analog and digital inputs and the digital outputs of the motion controller(main window I/O)5.2.2.1Main window(Axis)Fig.5.6:Main window with examplePossibilities:1.Browse with and2.Display operating data for marked axis with Enter or e.g.M3(in the window asdisplayed above)for blade2(axis2/4).Fig.5.7:Operating data(Blade2)Explanations of the display:•Velocity(a/n)=actual and nominal speed•DeltaS=control deviation=difference between the calculated nominal value from the feedback control and the actual value•Voltage=control voltage on the analog output(here for Blade2at terminal block A2)•The drive can be operated manually(jog)or calibrated by means of certain function keys if the corresponding blade parameters have been correctlyconfigured(see Reference Manual of motion controller)F1:Fast jog in backward directionF2:Slow jog in backward directionF3:Calibration(see below)F4:Fast jog in forward directionF5:Slow jog in forward directionM1:Return to the MAIN WINDOW(AXES)3.Call information about the inputs and outputs of the Motion Controller:Change to theWINDOW(I/O)by means of F1;see next section4.Call device information or configure system parameters:Change to the MAIN MENUby means of M1Calibration(see also chapter5.3Homing routine axis/blade)Fig.5.8:Calibration(blade2)With the key F3an actual value correction can be activated for a specific blade(encoder group A and B).The value is to be defined at the blade parameters for the concerning axis (see Reference Manual motion controller).Condition:high level at terminal E1.2("/Stop")).5.2.2.2Main window(I/O)Fig.5.9:Main window(I/O)1.Digital inputs0…7on terminal block I22.Logic states of the8inputs in bit form,LSB(right)state of I2.0;1=High approx.24V3.Logic states in hexadecimal formatPossibilities:1.Browse with and2.Display actual values of axes:Change to MAIN WINDOW(AXES)with F1;3.Call device information or configure system parameters:Change to MAIN MENU withM1;see following section5.2.2.3Main menuMenu key M1activation in one of the two main windows:Fig.5.10:Main menuPossibilities:1.Browse with and2.Activate marked menu point with“Enter”and process the next sub-point(seefollowing sections);one of the menu keys M2...M4can also be used for activating3.Change to the MAIN WINDOW(AXES)or MAIN WINDOW(I/O)with F1,M1or ESC;5.2.2.4Device informationThis window informs about the hardware and software versions of the MotionControllers and about the cumulated runtime of the device as shown as an example:Fig.5.10:Device information5.2.2.5Stored failuresThis window displays a list with up to20failures occurred(most recent on top).Principle of memory management is a ring buffer.Fig.5.11:Fault memory("1.05"->axle1,fault code5)The following failures will be recognized:•DeltaS>DeltaS max. Drag error exceeds its maximum value when moving in forward direction(see blade parameters in the reference manual motioncontroller)•DeltaS<DeltaS min. Drag error exceeds its maximum value when moving in the reverse direction•General data transmission failure(stop bit,parity,overwriting or checksum error) and Error in the LB2protocol(see reference manual motion controller)Fig.5.13:Blade-specific window(in this case blade2)By selecting M1you return again to the main menu.(See also Chapter4.1.4)5.3Homing routine axis /bladeWarningOnly one blade should be moved out of the parking position.Consequently,before moving a second blade,it must be ensured that the first blade is in parking position again.The axis to be referenced must first be directly selected in the main window by use of the keys M2-axis1,M3-axis2and M4-axis3.When an axle is selected the following windowopens:Fig.5.14:Blade 2operating dataThe blade to be referenced must now be moved manually to the mechanical zero point of the blade.When this is done,in order to exclude a counting range overflow,the sensor must be set to the counting range mean value by operating the yellow pushbutton.The button is located at the rear of the sensor under a screw cap.Fig.5.15: Sensor pushbuttonThe referencing of the blade can now be started with the F3key.After “Carrying out the calibration”has been confirmed with F1,the current angle value is automatically accepted as the zero point and stored in axis parameter 53.The displayed actual angle value must now be 0°.The referencing is now completed.Return to the main window using M1.6MaintenanceGeneralBecause of the varied operating conditions in which the plant operates(depending on the climatic environment and the load of the wind energy plant),only general recommendations concerning the required maintenance intervals can be given.Regular and careful inspection is required as well as maintenance in order to prevent malfunctions and to detect and remedy faults as they occur,before serious damage happens.In these operating instructions,as regards the maintenance interval,there is only a recommendation which has no effect on contractually specified agreements(especially in relation to the warranty).Before starting any work on the pitch system,especially before opening the covers of live parts,you must ensure that the components and the plant are disconnected in accordance with regulations.In addition to the main circuits also look out for possible boosting or auxiliary circuits,especially standstill heating systems!Here the"5Safety Rules"are(e.g.as per DIN VDE0105):•isolate•secure against restarting•establish isolation from supply•grounding and short-circuiting(for voltages above1000V)•safeguard or cover adjacent live parts.NoteThe supplied operating instructions for the components in question are always applicable for the maintenance intervals and the replacement of components.Always quote the plant number when returning faulty components to SSB.Warning/CautionBecause of the heavy dead weight of a cover or components(such as battery container, pitch motor,transformer,etc.)they must always be removed with great caution,so that they are not damaged during removal,do not damage other components or cause injuries.。
