Installation and Operating Instructions for Trained Personnel, Certified by Woodward

Installation and operating instructions for trained personnel, certified by Woodward

(Exemplary illustration)

- MP1  Frequency converter system

Document no.: 9943-1707 Revision: B EN GB

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

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

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Table of contents

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

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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

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1 Safety

1.1 Classification of the warning notices with relation to actions

DANGER

Imminent danger to life or danger of severe injuries

WARNING

Danger of minor injuries

CAUTION

Danger of material or environmental damage

NOTICE

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.

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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.

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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.

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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

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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.

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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.

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2 Information about the documentation

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.

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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

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3 Product and functional description

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

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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 10 dv/dt choke and DC-link limiter 5 Machine side converter 11 Overvoltage protector 6 Decentralised control unit

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3 Product and functional description

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

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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

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3 Product and functional description

3.1.6 Filter cabinet (optional)

Fig. 3-6 Front view - filter cabinet

1 Heat exchanger 2 4 filter slots with protection

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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.

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3 Product and functional description

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.

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3 Product and functional description

3.3 Operating modes

3.3.1 Start sequence

Fig. 3-8 Start sequence of the wind turbine

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3 Product and functional description

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.

DANGER

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).

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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”

NOTICE

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.

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3 Product and functional description

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.

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3.4 Operating ranges

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

Synchronous rotation speed: = · 60 𝑓𝑓 𝑠𝑠 𝑠𝑠 f𝑛𝑛 = Frequency𝑝𝑝 of𝑚𝑚𝑚𝑚𝑚𝑚 the stator voltage p = Pole pairs of the generator

Slip: = 𝑛𝑛𝑠𝑠− 𝑛𝑛𝑚𝑚𝑚𝑚𝑚𝑚ℎ 𝑠𝑠 𝑛𝑛𝑠𝑠 • 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

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3 Product and functional description

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

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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

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3 Product and functional description

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.

NOTICE

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)

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• 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”.

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3 Product and functional description

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.

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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

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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

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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.

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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 Do not use from heat hand hooks

Centre of gravity Sling here Do not use Clamp as Maximum hand trucks indicated stacking load

Do not cut Admissible No forklifts packaging temperature range

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

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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.

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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

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4.1.3 Safety instructions for storage

7. Observe the environmental conditions defined in the appendix (→ Chap. 14.1.1). 8. Observe the technical data of the product, especially the weight (→ Chap. 14.4). 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

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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). 2. Observe the environmental conditions defined in the appendix (→ Chap. 14.1.3). 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. 5. Observe the technical data of the product, especially the weight (→ Chap. 14.4).

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)

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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

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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!).

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5 Electrical installation

5.2 Connect stator cable

Fig. 5-2 Stator connection

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

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5 Electrical installation

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!).

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6 Hydraulic installation

Fig. 6-1 Coolant connections

► Connect the coolant lines with: • Coolant supply (1) • Coolant return (2)

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7 Commissioning

DANGER

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.

CAUTION

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.

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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

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8 Operation

DANGER

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.

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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).

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10 Inspection, maintenance and repair

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

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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.

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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.

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13 Customer service

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

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14 Appendix

14.1 Environmental conditions

CAUTION

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 — No (rain, snow, hail, etc.)

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

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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)

Environmental parameters Unit Value

Climatic environmental conditions (according to class 2K2)

Low air temperature °C -20 *

High air temperature in unventilated containers °C +60 in ventilated containers or outdoors °C +40

Temperature change Air/air °C -25/+25 Air/water — No

Relative air humidity not combined with quick temperature change % / °C 75 / +30 combined with quick temperature change: — / — No / No Air/air at high relative air humidity

Absolute air humidity — No combined with quick temperature change: Air/air at high water content

Precipitation, rain — No

Sunlight W/m2 700

Water (excluding rain) — No

Wetness — No

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Environmental parameters Unit Value

Biological environmental conditions (according to class 2B1)

Chemically active substances (according to class 2C1)

Sea salt — No

Mechanically active substances (according to class 2S1)

Sand in air — No

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

Sinusoidal vibrations (frequency range) Hz 2-9 / 9–200 / 200-500 Amplitude of the deflection mm 3.5 Amplitude of the acceleration m/s2 10 / 15

Noise vibrations (frequency range) Hz 10–200 / 200-2000 Acceleration Spectral Density m2/s3 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 ° ±35 ** Period s 8 **

* Deviating from the standard ** Class 2M2

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

Environmental parameters Unit Value

Climatic environmental conditions (according to class 3K3)

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

Biological environmental conditions (according to class 3B1)

Chemically active substances (according to class 3C1)

Sea salt — No *

Mechanically active substances (according to class 3S1)

Sand in air — No

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Environmental parameters Unit Value

Mechanical environmental conditions (according to class 3M2)

Sinusoidal vibrations, stationary (frequency range) Hz 2-9 / 9-200 Amplitude of the deflection mm 1.5 Amplitude of the acceleration m/s2 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) Peak acceleration â — No

Shocks, non-stationary (Total shock response spectrum: type II) Peak acceleration â — No

* Deviating from the standard ** applicable for cold climate version *** applicable for hot climate variant

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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 FPGA reported watchdog trip. ► Check hardware. * protection F2: IGBT over- Report of an electric line from the IGBT ► Check if the error persists. load LSC power stack of the line side converter. ► 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 DC-link voltage exceeded critical value. ► Check if the error persists. volt. too high Message via DCU. ► Check hardware control. ► Check electric connection for short- circuits. ► Check IGBT. F4: Booting of system with default ► Load valid set of parameters. * Default- parameters. parameter active F5: Commissioning of system not completed ► If rotary stator field is incorrect, Commissioning or commissioning counter reset. connect correctly. missing ► If rotary field rotor is incorrect, connect correctly. ► If generator current transformer is incorrectly connected, connect correctly. ► Fully complete commissioning. F6: Emergency Message via digital input that safety chain ► Close safety chain. stop is interrupted. Emergency stop activated.

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Error text Meaning Correction

F7: CB Gen. I> Message via digital input that overcurrent ► In case of overload, check power | I>> tripping of the circuit breaker activated. 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 Voltage for checking of the rotating field ► Check encoder. * sequence check not reached. F9: Synchronization failed. ► Check stator capacitors, symmetry Synchronizing Angular difference or amplitude difference and load. Fault too big. ► Check IGBT current wave form and hardware of the driver. ► Check IGBT. ► Generator pointer angle and parameter for vector check. * F10: C.B. Gen. The set feedback time of the circuit ► Check wiring and driver. Fault breaker on the stator/grid is exceeded or ► Record switching cycles. feedback although no command has been given. F11: CB LSC The set feedback time of the contactor on ► Check wiring and driver. fault the line side converter is exceeded or ► Record switching cycles. there is feedback although no command has been given. F12: C.B. Fault The set feedback time of the contactor on ► Check wiring and driver. (contactor) the stator/grid (parallel to circuit breaker) ► Record switching cycles. is exceeded or there is feedback although no command has been given. F13: DC link Set precharge voltage of the DC-link is ► Check fuse in the precharging circuit. precharge not reached in the time frame. ► Measure charging voltage. F14: DC link B6 Set B6 charging voltage of the DC-link is ► Check fuse in the precharging circuit. charge not reached in the time frame. ► Measure charging voltage. F15: Gen. Tripping on DSP. ► Check hardware and parameter. * voltage low Minimum stator voltage undercut. F16: Gen. Tripping on DSP. ► Check hardware and parameter. * voltage high Minimum stator voltage exceeded. F17: Gen. Tripping on DSP. ► Check hardware and parameter. * current fault Maximum stator current exceeded. F18: Mains Tripping on DSP. ► In case of overload, check power current fault Maximum mains current exceeded. curve of the WPP. F19: WTC Message via digital input that feedback of ► Check WTC output of the WPP. release missing the superordinate wind turbine control is ► Check wiring up to CSC. missing. ► Check CSC-input.

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Error text Meaning Correction

F20: Heat-sink Message via digital input that ► Check cooling system. overtemp. overtemperature of external device was ► Check environmental conditions. detected. ► In case of overload, check power curve of the WPP. F21: DC link Rated voltage of the DC-link not reached. ► Check hardware and parameter. * rated voltage F22: Stator Rated voltage of the stator not reached. ► Check hardware and parameter. * rated voltage F23: Stator Rated frequency of the stator not reached. ► Check hardware and parameter. * rated frequency F24: Ringline Message via digital input that ringline 1 is ► Check fuses and circuit breaker shut down 1 interrupted. according to circuit diagram. ► Check CSC-input. ► Measure voltage. ► Check settings. F25: Ringline Message via digital input that ringline 2 is ► Check fuses and circuit breaker shut down 2 interrupted. according to circuit diagram. ► Check CSC-input. ► Measure voltage. ► Check settings. F27: Rotary field The rotary field rotor is incorrect. ► Check connection of the rotor cables. rotor F28: Shaft Position encoder reports failure of bars. ► Check true running (→ Technical encoder Safe operation not guaranteed. 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 ► Check for mains fault. input. ► Check parameter of the grid Detailed information: protection relay. see event recorder. ► Check CSC-input. F30: Can-bus- CAN bus connection faulty. ► Check CAN bus connection error CSC → CSK. (internal/external). Connection to display not monitored. F31: Cooling- Message via digital input that pressure ► Check CSC-input. system error switch has reported fault and fan has ► Check cooling system. switched off. F32: Rotary field The rotary stator field is incorrect. ► Check connection of the stator cables. stator F33: Encoder adjustment has not been carried ► Check alignment of encoder. Shaft encoder out correctly. ► Check fixing of encoder. (90° Error) Deviation = 90°. F34: I stator Stator current transformer connected ► Check installation direction. current incorrectly. ► Check connections. transformer ► Check connection between the cabinets.

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Error text Meaning Correction

F35: I grid Current transformer connected incorrectly. ► Check installation direction. current ► Check connections. transformer ► Check connection between the cabinets. F37: HW & SW Hardware and software not compatible. ► Install correct Hardware. * incompatible F38: LSC AC Tripping on DSP. ► Check hardware and parameter. * Voltage Admissible LSC voltage exceeded or undercut. F39: DC link Tripping on DSP. ► Check hardware and parameter. * over voltage Maximum DC-link voltage exceeded. F40: DC link Tripping on DSP. ► Check hardware and parameter. * under voltage Minimum DC-link voltage undercut. F41: duzk/dt Increase or decrease of the DC-link ► Check hardware and parameter. * voltage too high. F42: LSC Tripping on DSP. ► Check hardware and parameter. * current Maximum LSC current exceeded (I2t protection). F43: Rotor earth Current sum supervision of the rotor ► Measure insulation at rotor. fault currents detected sum not equal to zero. F44: LSC line to Current sum supervision of the line side ► Measure insulation at the choke. earth converter currents detected sum not equal to zero. F45: LSC DC Offset in the measuring chain (to be ► Check LSC current measurement in current Offset aligned at system start) exceeded Data visualizer. admissible value. ► Check offset of the measuring section. F46: MSC DC Offset in the measuring chain (to be ► Check MSC current measurement in current Offset aligned at system start) exceeded Data visualizer. admissible value. ► Check offset of the measuring section. F47: IGBT over- Report via fibre optics of the IGBT power ► Check if the error persists. load MSC stack of the MSC. ► 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 Circuit breaker (upstream of the stator ► Check stator contactor for burnt-in CB tripped contactor) is open. contacts. F49: INI file Faulty INI file input. ► Input correct INI file and boot. * System has booted with backup file.

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Error text Meaning Correction

F50: Coolant Cooling liquid temperature exceeded ► Check cooling liquid pump. temperature maximum admissible value. ► 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 Overflow at calculation of the DSP ► Adhere to value range during value overflow parameters. parameter setting. * ► Set to default parameter. F55: External No communication via Anybus module. ► Check communication connection Comm. between CSC and bus master. * supervision ► 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 Failure protection of the circuit breaker ► Check stator contactor for welded protec. Step 1 has tripped on the 1st level. contacts. Current is flowing although stator switch should be open. F57: CB failure Failure protection of the circuit breaker ► Check circuit breaker and contactor in protec. Step 2 has tripped on the 2nd level. the stator section for welded contacts. Signal should act on the medium voltage breaker. F58: Chopper DC-link limiter is about to shut-off. ► Check hardware control. Counter Converter is separated from the grid. ► Check electric connection for short- shutdown circuits. ► Check IGBT. F59: IGBT driver Power supply of the IGBT driver stage is ► Check power supply at the driver voltage supply not in the specified range. stages. * F60: Wrong Product detected during start-up that the ► Input software again with Device FPGA version currently active FPGA design cannot be Installer. used with active firmware version. F67: LSC IGBT Error from IGBT (no overcurrent). ► Check cooling system. L1 ► Check IGBT. F68: LSC IGBT Error from IGBT (no overcurrent). ► Check cooling system. L2 ► Check IGBT. F69: LSC IGBT Error from IGBT (no overcurrent). ► Check cooling system. L3 ► Check IGBT. F70: MSC IGBT Error from IGBT (no overcurrent). ► Check cooling system. K ► Check IGBT. F71: MSC IGBT Error from IGBT (no overcurrent). ► Check cooling system. L ► Check IGBT.

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Error text Meaning Correction

F72: MSC IGBT Error from IGBT (no overcurrent). ► Check cooling system. M ► Check IGBT. F73: Chopper If DCU is connected: ► Check IGBT. IGBT IGBT error at the DC-link limiter. F74: Power Power supply of the PPA boards faulty. Supply IGBT Driver F75: Power Power supply of the DCU adapter board ► Check power supply at the DCU Supply IGBT faulty. adapter board. Adapter F76: Cabinet- Cabinet inside temperature too high. Temperature F77: Battery Battery voltage drops too much. ► Replace battery. * failure F78: UPS Uninterrupted power supply is missing. ► Measure UPS voltage. missing (24V) F79: LSC Over Voltage at the line side converter Voltage exceeded critical value. F80: App0 DCU contains incorrect revision of the ► Update bootloader. * VHDL/FW in FPGA configuration of the DCU DCU (bootloader). F81: App1 Device Installer contains incorrect revision ► Update Device Installer. * VHDL/FW in of the FPGA configuration of the DCU DCU (application). F82: Adapt. Device Installer contains incorrect revision ► Update Device Installer. * VHDL/FW in of the FPGA configuration of the DCU DCU adapter board (application). F83: Main CB Automatic restart, insertion of switch closing failed failed. F84: Insertion of short circuit contactor for Stator short positioning mode failed. circuit contactor failed F85: Mains Surge arrestors at grid connection have surge arrestor tripped. F86: Stator Surge arrestors at stator connection have surge arrestor tripped. F87: Rotor Surge arrestors at rotor connection have surge arrestor tripped. F88: Aux. Surge Surge arrestors have tripped. arrestor F89: Over- Overfrequency detected. Frequency Parametrised limits have been left.

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Error text Meaning Correction

F90: Under- Underfrequency detected. Frequency Parametrised limits have been left. F91: df/dt Error Frequency change too big. F92: Chopper DC-link limiter discharged DC-link in non- path failure 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 ► Check stator voltage measurement. voltage control). ► 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

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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 or warning message. Not possible. warning W1: Ringline Notice of a warning via digital input ► Check fuses and circuit breaker alarm warnings. according to circuit diagram. ► Check CSC-input. ► Measure voltage. ► Check settings. W2: Line Line break in channel 0 of the mA-inputs. ► Check mA-output of the WPP. interruption ► Check wiring up to CSC. 20mA ► Check CSC-input. Channel 0 W3: Position Position encoder reports failure of bars. ► Check true running (→ Technical encoder warning Safe operation guaranteed. data). W5: Coolant Cooling liquid temperature (measured via ► Check cooling liquid pump. temperature 4-20-mA-channel) exceeded limit for ► Check coolant level. warning. ► Check temperature detection. W6: Line Line break in channel 1 of the mA-inputs. ► Check mA-output of the WPP. interruption ► Check wiring up to CSC. 20mA ► Check CSC-input. Channel 1 W7: Line Line break in channel 2 of the mA-inputs. ► Check mA-output of the WPP. interruption ► Check wiring up to CSC. 20mA ► Check CSC-input. Channel 2 W8: Line Line break in channel 3 of the mA-inputs. ► Check mA-output of the WPP. interruption ► Check wiring up to CSC. 20mA ► Check CSC-input. Channel 3 W9: Encoder Automatic encoder adjustment reports ► Check if encoder has been changed Offset-Warning high deviation of the offset compared to (warning will not occur at next start). the last start. ► Check if encoder has turned on the shaft. W10: Climate No temperature increase despite active ► Check cooling liquid pump. Control heating. (Power cabinet and/or cooling ► Check coolant level. liquid). ► Check temperature detection. ► Check fan heater.

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Error text Meaning Reaction W11: CB On systems without LSC contactor, the ► Close cabinet doors. Release mains side circuit breaker opens at open cabinet door. W12: Heating System is in operating status “preheating” ► Wait until temperature has been operation active or “subsequent heating”. reached. W13: Converter- Time delayed shut-off of the CSC at faulty Off timer runs 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 Outside temperature (measurement ► Wait until outside temperature drops temperature value 4642) exceeds the value set in below the value set in parameter 5136. parameter 5136. W15: Cabinet Cabinet temperature (measurement ► Wait until the cabinet temperature temperature value 4641) exceeds the value set in drops below the value set in parameter 5137. 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. W16: Coolant Coolant pressure (measurement ► Wait until coolant pressure has system pressure value 4658) is below the value set in increased again: parameter 4623. p > parameter 4623+parameter 4624. W17: Mains Surge arrestors at grid connection have surge arrestor tripped. W18: Stator Surge arrestors at stator connection have surge arrestor tripped. W19: Rotor Surge arrestors at rotor connection have surge arrestor tripped. W20: Aux. Surge arrestors have tripped. Surge arrestor W21: Over- Overfrequency detected. Frequency Parametrised limits left. W22: Under- Underfrequency detected. Frequency Parametrised limits left.

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Error text Meaning Reaction W23: df/dt Excessive positive frequency deviation (positive) within a certain period of time. The system shuts down with error message F29. W24: df/dt Excessive negative frequency deviation (negative) within a certain period of time. The system shuts down with error message F29. W25: UPS Subordinate wind turbine control reports failure outage of the USV (display in System Tool only). W26: Filter Filter test skipped, if: supervision skip • 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

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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.

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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

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15 List of terminology and abbreviations

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

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16 Index

A N Antifreeze additive ...... 44 Name plate ...... 33 C O CE marking ...... 33 Obligations of the operator ...... 9 Central control unit ...... 20 Operating modes ...... 21 Commissioning...... 44 Operating ranges ...... 25 Commissioning protocol ...... 44 Operation ...... 46 Coolant ...... 44 Option reactive power supply ...... 23 Customer service ...... 51 Q D Qualification of personnel ...... 10 DC-link ...... 20 Decentralised control unit ...... 20 R Decommissioning ...... 49 Recooling system ...... 45 Dimensions ...... 67 Recycling ...... 49 Disposal ...... 49 Repair ...... 48 E Revisions ...... 2 Electrical installation ...... 40 S Environmental conditions ...... 52 Safety instructions ...... 7 Error messages ...... 57 Scope of delivery ...... 37 F Set-up ...... 13 Storage ...... 34 Functional principle ...... 19 T G Target groups ...... 12 General safety instructions ...... 7 Technical data ...... 67 H Tightening torques ...... 39 Transport...... 34 Hydraulic installation ...... 43 Troubleshooting ...... 47 I W Inspection ...... 48 Warning messages ...... 64 Installation location ...... 38 Warning notices ...... 6 Intended use ...... 6 Warranty ...... 50 M Maintenance ...... 48

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Woodward reserves the right to modify and update any part of this publication at any time. All information provided by Woodward has been checked for correctness to the best of our knowledge. However, Woodward is not liable for the contents if Woodward does not give an explicit warranty. © Woodward. All rights reserved at Woodward. October 2015