Processor

Date: 2. Dec 1997 Class: 2 Item no.: 941877.R4 Page: 1 of 13

Processor
Contents............................................................................................................................................. Page

1. Modules in the Top- and Ground processor .............................................................................. 2

2. Top-processor................................................................................................................................ 4

3. Ground processor.......................................................................................................................... 5

4. Grid processor............................................................................................................................... 5

5. Flow from control-output to feedback-input.............................................................................. 5

6. Description of CT-modules .......................................................................................................... 6

7. Watch-dog.................................................................................................................................... 10

8. Upload of VMP-release............................................................................................................... 11

9. Initializing processors................................................................................................................. 12

10. Sending/update of parameters ................................................................................................... 12

11. Use of button 1 and 2. ................................................................................................................. 13

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1. Modules in the Top- and Ground processor

The turbine-controller as a whole includes three processors in this type of turbine. They are
communicating via the so called ArcNet.

The processors are named as Top, Ground and Grid and are placed as shown in figure 1. The Grid-
processor is physically placed in the Ground-processor.

The communication between Top and Ground goes through an optical fiber up through the tower.

The Ground processor is connected to the operator terminal as permanent installation.

A transportable service terminal, CT248 or a PC can be connected via an optical serial adapter (CT236)
to the ArcNet module CT3514 in Top.

Top-processor. Service term.

CT3514 (CT248)
or PC.

CT236

RS232

RS422 To RCC/VRCC (only for 600/660 kW)

ArcNet
Optic fiber

Top
Ground

Ground-processor. Grid-processor (CT3251)

CT3514 AA PC
ArcNet

CT236 RS232

RS422 CT218
Operator terminal
(Permanent)

Figure 1 Communication between Top-, Ground- and Grid-processor.

The Top- and Ground-processors are equipped as illustrated in figures 2 and 3.

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The position number of each in/output is defined by the module in which the signal is read/written and
the vertical position (LED no.) of the signal.
The input modules are called X and the output modules are called Y (eg. the signal from anemometer
(B301) position X3.5).
Z is used for modules which communicate with other modules.

X1 X2 X3 Y1 X4 Y2 X5
CT3357 CT3514 CT3503 CT3220- CT3181 CT3133 CT3218 CT3153 CT3220 CT3181 CT3232 CT3133 CT3364
5VDC ArcNet Proc. FFFF Empty DC in Count DC out E/G Empty An. out DC in 24VDC
An. in An. in

R206 S100 B401 K100 A800 Y800 S208

⊗ 1 R300 S101 B400 K101 A203 S307

1 ⊗ 2 R402 S102 S200 ------- F308

2 R503 S103 ------ K414 S313

3 R504 S104 B301 Y210 F314

4 R406 S105 B302 K315 S412
R310 F106 B303 Y211 ------
R306 F107 S304 K501 S501
S204 K204 S209

1 S201 K506 S804

2 S202 K307 S931

3 S207 K313 ------

4 F205 U405 ------


5 S403 K502 S502

6 S405 K801 ------

Error

7 S902 K900 ------
Error

5VDC
24DC

8

RS422 to RCC/VRCC (only for 600/660 kW)

Optic fiber to Ground Processor (ArcNet).

Figure 2 Topprocessor.

• CT 3357 Internal Power Supply, 5VDC

• CT 3514 ArcNet/RS422, communication and watch.
• CT 3503 Processor module.
• CT 3220,FFFF X1.x Analog input , Temperatures
• CT 3133 X2.x Digital input , PNP 24V DC
• CT 3218 X3.x Digital input , counter, PNP 24V DC
• CT 3153 Y1.x Digital output, PNP 24V DC
• CT 3220,E/G1 X4.x Analog input, Pitch and hydr. pressure.
• CT 3232 Y2.x Analog output, controlvoltage.
• CT 3133 X5.x Digital input , PNP 24V DC
• CT 3364 External Power Supply, 24VDC.
• CT 3409 The rack unit.

1
Turbines retrofitted to higher hydraulic oil pressure the E-piggyback has been changed to a G-type.

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X1 Y1 Z2
CT3357 CT3514 CT3503 CT3181 CT3133 CT3153 CT3251 CT3182 CT3182 CT3364
5VDC ArcNet Processor Empty DC in DC out Power Contr. Empty Empty 24VDC

⊗ 1 S309 ------
⊗ 2 S311 ------
1

1 S603 K603
2

2 S604 K604
3

3 S601 K601

4 S602 K602
S920 K922

1 S921 K923

2 S700 K700

3 S702 -------

4 S305 -------

5 S9 K312

6 ------- -------


7 S8 Q8

8 S906 K906

Error
S903 K901
Error

5VDC
24VDC

RS 422 Operator terminal CT227 Meas Trafo Box

Optic fiber to Top Processor (ArcNet). CT228 Thyristor Driver

Figure 3 Groundprocessor.

• CT 3357 Internal Power Supply, 5VDC

• CT 3514 ArcNet/RS422, communication and watch
• CT 3503 Processor module.
• CT 3133 X1.x Digital input , PNP 24V DC
• CT 3153 Y1.x Digital output, PNP 24V DC
• CT 3251 Z2.x Grid input and thyristor trigging (Grid processor module).
• CT 3364 External Power Supply, 24VDC.
• CT 3409 The rack unit.

2. Top-processor
Function of the Top-processor:
• Registration/calculation of temperatures, windspeed and -direction, generator-, rotor speed
and pitch position.
• Registration of digital signals for cable twisting, hydraulic pressure, vibration etc.
• Calculation and control of pitch angle on basis of generator RPM and production.
• Controlling and communicating with the RCC/VRCC (only for 600/660 kW) in the
generator.
• Controlling the hydraulic system (pump and valves).
• Controlling the yawing system.
• Controlling the gear oil coolingsystem.
• Security systems: Emergency stop and overspeed guard (VOG).

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3. Ground processor
Function of the Ground-processor:
• Connecting and disconnecting generators and power factor correction, partly on basis of data
received from the Top-processor.
• Monitoring for faults in the turbine, partly on basis of data received from the Top-processor
and the grid-processor.
• Communication with operator terminal and remote control system.
• Security systems: Emergency stop and Watch-dog.

4. Grid processor
Function of the Grid-processor:
• Registration/calculation of current, voltage, power and frequency. Sampled 32 times pr. grid
period and synchronized by a zero-cross detection.
• Firing thyristors when connecting and disconnecting.
• Communication with Ground-processor.

5. Flow from control-output to feedback-input

To illustrate the signal flow from any output from controller to relay and contactor to feedbacks from
these following figures shows the principles with the hydraulic motor as example:
CT3153 CT3133
DC Output DC Input

*9 Y1.9 K204 *9 X2.9 S204

* 13 X2.13 F205
230VAC
24VDC
D204
Relay
690VAC
L1 L2 L3

K204
Contactor
S204

N
F205
Thermorelay

Hydr. motor M240 24V 24V

Figure 4 Flow from output to input.

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The processor turns the outputsignal Y1.9 “Hydr. Motor” on and off via the digital output module
CT3153. The LED follows the output. The helping relay D204 is connected to the output and closes
the power to the contactor K204.

The contactor connects the three phases to the motor. The contactor closes another contact which is
used as feedback to the input module CT3133. (Input X2.9 S204). The contactor is equipped with a
thermorelay that is normally closed. Signal from this is connected to the input module too. (Input
X2.13 F205).

The respective LED´s on the front of the inputmodule follow the inputs.

6. Description of CT-modules
CT3514 ArcNet/Optical incl. RS422.
The CT3514 is a multi interface module used in Ground- and Top-rack.
External connection to ArcNet is established by an optic link, which accepts glass fiber.
The ArcNet is furthermore interfaced to the backplane so connection to I/O modules is available.
On board there is an RS422 serial channel. Connection takes place via a 9-pole female D-sub
connector on the bottom of the module. This channel is powered from a galvanically separated supply.
In the Top-processor of this turbine the RS422-port is reserved for RCC/VRCC (600/660 kW only).
In the Ground-processor the port is used for the Operator Terminal.
Furthermore the module is equipped with an Optical Serial Port on the module front. In conjunction
with a CT236 Serial Adapter, this port acts as an ordinary RS232 serial port to a PC with a maximum
data rate of 38400 baud. Otherwise it is possible to connect a service terminal as often used in the top
of the turbine.
Inside the module a number of dipswitches is set for selecting the position in the ArcNet, a so called
node-number (Ground, Top). How to set the switches is shown on a label at the module cover.

CT3503 Processor Module.

This is a general purpose microprocessor module and is based on an 80C186-25 (25MHz)
microprocessor. The module is equipped with 256 Kbyte (CT3503.02) or 512 Kbyte (CT3503.01) on
board Flash Program Memory, 256 Kbyte are battery supported SRAM for Data Memory.
The groundprocessor has to be of the type CT3503.01.
Inside the module there are six switches which are program determined. (Only used for IO-tests).
On the frontplate of the module eight LED indicate function of the module.
Above these indicators there are two push-buttons with program determined functions, described in
other parts of this chapter.
The Data Memory in the module is battery supported. The batteries are placed in the battery holder at
the bottom of the module. Only non-rechargeable batteries should be used. Replacement of batteries
can take place with the rack power turned off, due to an internal charge storage, but is not
recommended. If chosen to do so, the operator should observe the rule that power, just prior to battery
replacement, must be turned on for at least one minute. The internal charge storage will maintain the
contents of Data Memory for more than 15 minutes.

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CT3133. DC-input.
The used digital input module in Top- as well as Ground-rack is equipped with 16 digital inputs
dimensioned for 24 VDC signals with PNP logic. All external signals on 24 VDC external side are
galvanically separated from the internal logic by optocouplers. In the same time this is an EMC-barrier.
Each input has a 10 ms symmetric filter for eliminating electrical noise. Active input level is high (i.e.
24VDC).
24VDC is supplied from the power supply in rack, CT3364.
LED´s on the front plate shows the state of the input. Electrically the LED´s are placed at the external
side of the mentioned barrier.
All inputs are connected to the bottom connector.

CT3153. DC-output.
As well in Top as Ground-rack the digital output module CT3153 is used.
It is constructed with 16 digital 24VDC Outputs with PNP transistor logic.
All external signals on the 24 VDC side are galvanicalle separated from the internal PLC-logic by
optocouplers. In the same time this is an EMC-barrier.
Active output level is high (i.e. 24VDC).
The load current is dimensioned for maximum 350 mA and the module can not stand if a high output
signal is short-circuited to ground.
LED´s on the front plate shows the state of the output.
All outputs are connected to the bottom connector.

CT3218. Counter.
CT3218 is a highly flexible microprocessor-based input/output module for local data pre-processing or
control of electronics outside to the rack. The module has a local 80C32 microprocessor on the board
and an internal communication link to the rack processor.
The local 80C32 processor works with its own RAM and EPROM memory independently of the main
processor (32 kbyte each). All inputs and outputs on the board (including the eight LED´s on the front
that shows the state of each port.) are connected to the processor for processing.
CT3218.01 is programmed on factory and can not be changed by the VMP-software or belonging
software-tools. CT3218.02 is flash-programmable in the field.
Eight 24VDC inputs based on PNP-logic are provided to the local processor. These inputs are for high-
speed applications and constructed without hardware filters.
The first input is dedicated to special counting purpose and is directly connected to a 16 bit counter
resident in the microprocessor. In the turbine controller application this input is used for the high speed
tacho frequency.
Output from the modules is not used in the turbine application.
Four DIL-switches are available in the module to set-up of the processor. They are set from factory for
use in the turbine application.
All inputs are connected to the bottom connector.

CT3220 Analogue input.

The CT3220 is an analogue input card with eight multiplexed inputs. The resolution of the A/D-
converter is 10 bits.
The inputs are separated in four piggybacks (small printed circuits placed in DIL-connectors inside the
module) with two analogue input channels on each.
Internal logic is separated from the A/D-converter and analogue amplifiers by optocouplers. In the
same time this is an EMC-barrier.

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External circuit can be supplied from the external 24VDC rack supply (CT3364).
The module is available with up to four piggybacks, which is constructed in different versions for
various applications (voltage-input, current-input, PT100-interface etc.).
The piggybacks are mounted, tested and calibrated from factory, but can be changed in the field.
The calibration of the inputs will then be less fine. Be sure to place them in the same position.
Piggybacks is designated with letters A to G, which is written on a label at the module box. Though
configuration of the module is dedicated.
Pay attention to this when modules are changed in the field.
In the VMP-systems following types of piggybacks are used:
B: Channel 1: 0-10 VDC, Channel 2: 0-10 VDC
E: Channel 1: 0-10 VDC, Channel 2: 4-20 mA
F: Channel 1: PT100, Channel 2: PT100
G: Channel 1: 0-10 VDC, Channel 2: 4-24 mA
All inputs are connected to the bottom connector.
The external power-supply 24VDC is put to the connector for external use.
The reference (0 V) for the analogue inputs internal in the module is separated from this supply but is
external wired together in the turbine-application for security reasons.

CT3232. Analogue output.

CT3232 is a Digital to Analogue converter module with one outputport.
The resolution is eight bits but the softwarecontrol of the module makes it working as ten bits. The
nonlinearity is specified to 0.24% of full scale.
The possible output voltage is ±15 VDC with a load of min. 10 kΩ.
The D/A converter is powered from the 24VDC external power supply (CT3364) in the rack, and
electrically separated from the internal processor logic by optocouplers. In the same time this is an
EMC-barrier.
All ouputterminals are connected to the bottom connector.
The reference (0 V) for the analogue outputs internal in the module is separated from the supply
reference but is wired together in the turbine-application for security reasons.

CT3251. Power Control.

The CT3251 is a power line control module, which has a separate microprocessor with ArcNet
interface, an analogue input part and a digital output part used for control of power lines (tyristors).
In the turbine configuration it is placed in the Ground-rack.
The module is supplied by 5VDC separate from the internal supply given from the CT3357 module,
and is equipped with a regulated ± 7VDC supply for the analogue circuit.
The functions of the module is controlled by an Intel 80C188XL-16 (16 MHz) microprocessor
supported by 128 Kbyte RAM and 128 Kbyte FLASH memory. The microprocessor is interfaced to the
rack and processor module via ArcNet.
The analogue part is interfacing A/D converted AC signals to the other processors. The module offers
six inputs to be sampled and converted at the same time, beside having an analogue interface to
measure power line frequency and zero cross detector circuit.
This is for interfacing the Measure Transformer Box (CT206/CT277), used for measuring on the
electrical grid.
The Zero cross detector signal is passed to the processor via optocouplers and interrupts logic.
Furthermore the signal is passed to a 16-bit counter to measure the power line frequency.
The digital output part has seven differential drivers for interfacing the CT175/CT228 thyristor driver
module and an auxiliary output to be configured as differential output or 24 V PNP output.

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Signal to and from thyristor and gridmeasuring modules are connected to the module in two different
connectors in the bottom of the module.

CT3357. Internal Power Supply.

CT3357 is a power supply for the CT3400 rack system. Placed leftmost.
It is supplied from 230 VAC and provides a 5VDC supply for the internal logic in the rack modules, a
20 VDC internal supply and a separate 5VDC supply for external low noise applications (CT3514).
The power outputs are galvanically separated from power input by a transformer.
The module has three support circuits which generates system control signals. All three signals have
signal reference to internal 0VDC.
A reset-circuit generates a hardware reset to the system. The reset is generated as soon as the internal
5VDC drops below 4.50 VDC.
An early warning circuit generates an interrupt to the microprocessor in case of a voltage drops in the
main supply.
A zero-cross detector generates an interrupt to the microprocessor each time the main supply crosses
the zero volt level.
On the front plate is placed a tongue-switch for switching on and off the power supply, which is
indicated on the lowest LED.
Use of the LED called “error” is not implemented.
The power supply is constructed with so called “Fold-back” that means if the output voltage is short-
circuited to ground the supply current will be approx. 3 A. When the short-circuit is removed again the
voltage automatically returns to normal conditions.

CT3364. External Power Supply.

The CT 3364 is a power supply for the CT3400 rack system.
The module is supplied from 230 VAC and provides 24VDC for the external logic in the rack modules.
There is galvanic separation between power input and power output.
Possible load is 1.5 A.
On the front plate a LED indicates if the supply is switched on.
Use of the LED called “error” is not implemented.
The power supply is constructed with so called “Fold-back” that means if the output voltage is short-
circuited to ground the supply current will be approx. 1.5 A. When the short-circuit is removed again
the voltage automatically returns to normal conditions.

CT3409. Rack Unit.

All I/O modules can be placed in any positions, while placement of the processor and the belonging
interface module is fixed to the leftmost position in the rack.
Communication between the processor module and the belonging interface is based on a 16-bit wide
databus, while communication with all other rack positions is established by the TMS-CRU bus and
ArcNet backplane mode.
Depending on the power supplies, the rack units basically distribute 5VDC internal from the leftmost
supply and 24 VDC external from the rightmost.
There are jumpers for configuring interrupt lines and enabling 5VDC separate as well as enabling of
the leftmost power supply controlled fold down of 24VDC external. Jumpers are set from factory.

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9. Initializing processors.
Initializing of Top- and Ground processor will reset all data in Top and Ground-processor.
Disconnect power to the processor by opening F32.
After at least five seconds the power is connected again and at the same time button 1 and 2 on the
CT3503-module are pressed until LED no. 2 is turned on permanently.
Meanwhile the LED´s 1 to 5 will do a selftest and then all LED´s are “running”.
The service panel displays some selecting pictures where mode and type of turbine is selected.
When the selection is completed following picture is shown:

Press any key to accept or ESC to regret

Vnn - nnn kW - nnnVnnHz

If something is incorrect press <ESC> and the selecting pictures will be shown again else press any
key.
Now the processor will be reset and boot. (Send stored parameters to respective units.)
When completed, picture number 1 “Overview” will be shown with information about status,
production, rotation, windspeed and pitchangel.
The turbine will be in “EMERGENCY”.
This completes upload and initialization of the controllers.
If this stage is not reached then look for troubleshooting in the electrical manual.
To put in stored counters etc. run the PC-program “Re-establish”.
If the turbine is used together with a Remote Control system then set-up the RCS.
If ramdump is not available voltage, calibration values, reset-time, turbine no. has to be set.
Eventually changed parameters for this specific turbine have to be checked and eventually re-entered.

Important: Use of reset function (button 1 and 2) involves reset of all production and hour counters,
all logs and system numbers and parameters.
The reset function (button 1 and 2) should only be used as a last try, button 2 should be used before reset
function.
In case of processor replacement or software upgrading, reset function should always be used.

10. Sending/update of parameters

Whole the set-up of the turbine is contained in the parameter set.
Default values is placed in a part of the up-loaded program called InitVal (Initializing Values) and is
initially placed in the respective RAM.
It is the parameters in the RAM which determine the function of the turbine.
It is possible to change parameters stored in RAM in picture 24.
Overview of changed parameters can be read by pressing <#> in picture 24.

If default parameters is to be replaced in RAM, do as follows.

Disconnect power to the processor by opening F32.
Reconnect when button 2 is pressed.
Select type of turbine, then parameters are sent.

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11. Use of button 1 and 2.

To give an overview of the use of button 1 and 2 on the processor module following flowchart is
present. Primary steps during a power-up and handling of errors is shown too:

Power-up

Program
up-loaded.
Checksums OK
No
Yes
Button 1
Button 1+2 Button 2

Reset counters
and logs.

Set time

Select InitVal
Place in RAM

Test of Error
parameter set.

Send parameters Error

to Topproc.

Send parameters Error

to Gridproc.

Boot-mode Turbine program System error.

running. Stop trig of WD.
Up-load by PC via CT236 or ArcNet.
System error
Figure 7 Processor start-up. Boxes with shadow illustrate possible states of the processors.

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