APPLICATION WIND TURBINES
SMART PITCH AND YAW SOLUTIONS
V - 1.0 EN

SOLUTIONS FOR WIND TURBINES
Harvesting is as old as mankind and is the foundation for our survival. Mother earth is so kind donating us the WIND as a powerful energy and she allows
us to use it. In respect for future generations, we are asked to save natural resources, and so it is noble to harvest energy out of this wind. Windmills havebeen used over centuries to mill flour or pump water. Today wind turbines are used to produce electrical energy. As wind is not blowing with a constant
speed and direction, it is important to constantly adapt the angle of the blade and turn the rotor into the wind. This makes a maximum power tracking
possible and produces as much energy as possible.
On the other hand, it is necessary to produce electricity with the lowest losses. Highly eﬃcient solutions are necessary for fast amortization and best
revenue. In addition it is also necessary to consider malfunctions and so to avoid damages or destruction of the turbine.
KEB, with its 30 years of experience in design and production of frequency inverters for most challenging applications, has designed robust drives, motors
and brakes for the diﬀerent movements inside the wind turbine. Proud of its 50,000 inverters installed in turbines around the world, KEB has launched
the COMBIVERT P6, a flexible, reliable and easy to use ‘all in one solution’ for pitch control and the COMBIVERT H6 for yaw control. This solution is fromusers’ perspective freely programmable and finds its application on-, near- and oﬀ-shore. Various bus communication protocols allow the drives to beconnected to most turbine controllers.

OPEN SOLUTIONLOCAL ADDED VALUE

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various fieldbus systems without gateway
various encoder inputs on board
PLC programming according to IEC 61131
standard
for AC induction, synchronous and DC pitch
motor
for retrofit applications, the internal PLC canemulate older drives

core components supplied by KEB
local cabinet manufacturingsimple mechanical integration
cost savings

FREELY PROGRAMMABLE
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own pitch algorithms with own know-how
maximization of energy yield
reduction of fatigue loads
increase of availability of the turbine byimplementing suitable reactions for each condition
basic condition monitoring of relevant pitchsystem components
for well-fitting service support
diﬀerentiation from competitors
know-how copy protection available

ALL IN ONE

FUNCTIONAL SAFETY

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pitch inverter, backup charger,
monitoring and PLC in one unit
yaw inverter based on compact
multi-axes system with integrated
PLC
reduced number of components
compact cabinet
clear cabinet layout, less wiring

pitch drive with PL d according to EN ISO 13849
yaw drive with STO and SBC
certified by TÜV Rheinland
Functional Safety is independent of thecustomer PLC programTÜVRheinland ®
Precisely Right.

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COMBIVERT P6 - PITCH SOFTWARE SOLUTIONSSOFTWARE PACKAGES AS REQUIREDThe P6 internal PLC can be programmed as needed. It comes with a Basic Library for all basic tasks, and the customer can program everything he needson his own.
Or the P6 can be complemented with the Extended Pitch Library, which contains pre-defined function blocks for typical tasks of a pitch system. So thecustomer just needs to program the interface specific to the turbine.
Or the KEB experts can write a Customer-Specific Program for the pitch drive according to the customer’s specification.

INVERTER +BASIC LIBRARY
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EXTENDED PITCH LIBRARYCUSTOMER-SPECIFIC PROGRAM

Speed control / Position control
Homing of motor encoder and blade
encoder
Charging circuit control (setpoint value
and actual value)
Temperature measurements
Communication check
Mains failure detection and phase loss
detection•••

Smooth filtering of setpoints
Plausibility check of encoders
Monitoring of motor status and motor
cable

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Customized pitch algorithm to-- improve performance and maximize
energy yield-- reduce fatigue loads on mechanicalcomponents•

Monitoring of ultracapacitors and leadbatteries
Controlled discharge of ultracapacitors(for service)•

Pitch state machine-- Selection of Manual/Automatic operation-- Selection of speed/positioning control

Sample program
Visualization samples
Fan test program

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Processing of digital inputs / outputs
Response to limit switches
Plausibility check of limit switches
Processing of field bus data•

Specific reactions on warnings and errors toincrease the availability of the turbine
Additional conditions that trigger a safety run

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Secondary LVRT response
Automatic adjustment of fieldbus and
IP address
Function test program(brake, inverter, motor)
Data logger, event-triggered

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Additional visualizations for service personnel
Basic condition monitoring of relevant pitchsystem components
Control of auxiliaries (grease pump, cabinet
heater and fan)No matter who does the programming: The know-how of the customer program can be protected against third-party access by using password­protection, compiled libraries and encryption.

HIGHLIGHTS
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specific software libraries available
programming support
flexible solution for customer add-ons

TECHNICAL DATAVARIOUS SIZESThe P6 hardware is available in two electrical sizes for AC and for DC motors, suitable for pitch systems of 1 … 8 MW wind turbines.

INVERTER SIZE

18

Rated input voltage

19

19 DC

3 AC 400 V

Output rated power

[kW]

18

Output rated current AC[A AC]

45

52-

Maximum current AC at ≥ 6 Hz for 3 s[A AC]

90

120-

Output rated current DC[A DC]--

52

Maximum current DC for 12 s

[A DC]--

120

Rated current for shunt winding[A DC]--

5

Rated switching frequency

[kHz]

4

2

2

Max. switching frequency

[kHz]

4

4 (at I < 45 A)

4 (at I < 45 A)

Ultracaps charging current[A]

5

Dimensions[mm]

240 x 400 x 310

Weight[kg]

16

Mains input

External braking resistor

Heater input

I/0’s
16 digital inputs
incl. safety run inputLED‘sAddress selector switch
Diagnostic interface COMBIVIS

I/0’s
9 digital outputs
1 relay output
2 analog inputs
4 Pt100 inputs
24 V DC supply
Fieldbus
CANopenPROFIBUS
EtherCATPROFINET
2 Encoder inputs

24 V brake
Motor temperature sensor
150…300 V brake (option)
Ultracaps / batteries terminals

Shield connection rail
(option)Motor output

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COMBIVERT P6 SYSTEM INTEGRATIONEASY INTEGRATION OF P6 INTO THE SYSTEM
Typically, KEB supplies the core components of the pitch system, as marked in red.
The customer makes the cabinet construction and manufactures the cabinet locally; this increases the value added locally. Thus, the mechanicalintegration of the pitch cabinet into the nacelle is achieved easily, while the electrical integration into the system is simple due to using the P6.
communication
CANopen / PROFIBUS / EtherCAT / PROFINET
safety chain
limit switches,
temperatures,
analog values

PLC
moduleI/O‘s

3AC 400 V±20 %P6charging /monitoring
moduleblade
encoder

encoderinterfaceMbrake supply+ control
moduleenergy storage
ultracaps / batteries
Pitch cabinet

By using the highly integrated KEB P6, just very few components are needed externally in the cabinet.

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gearboxmotor
encoderblade

CONTROLLED YAW SOLUTIONSNON-REDUNDANT SYSTEMSFor the yaw drive of wind turbines, KEB can provides diﬀerent yaw solutions.
They all contain• smooth movement of the nacelle• torque sharing• reduction of mechanical load
• reduction of wear of the material.
Depending on the system configuration, the pitch drive controllers can also
• tense up the drives against each other• use the electrical motor brakes instead of a hydraulic brake• add STO for the safety of service personnel during service operations.

REDUNDANT SYSTEMS
Used with a multiple inverter solution, the KEB Yaw Library PLC software
ensures• improved torque sharing• monitoring and protection of motors, cables and gearboxes• redundant operation, even if one drive is not operational• increased availability, especially for oﬀshore turbines.
This can be implemented by adding turbine-specific enhancements tothe pre-programmed IEC 61131 function blocks.

HIGHLIGHTS•••

smooth movement of the nacelle
reduction of wear
increased availability

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CONTROLLED YAW SOLUTIONS - HARDWARESINGLE INVERTERDOUBLE INVERTER

3~ 400 V AC
24 V DC3~ 400 V AC
24 V DC

Input AC 3PH 50/60 Hz
400V XXXXXX
Output: AC3PH 0…U XXXXXXX
XXXkVA / XXXX
Mat.No. 0000000-0000
Cust.No.

Input AC 3PH 50/60 Hz
400V XXXXXX
Output: AC3PH 0…U XXXXXXX
XXXkVA / XXXX
Mat.No. 0000000-0000
Cust.No.

CAUTION
Risk of Electrical ShockCAUTION
Risk of Electrical Shock

F1

F2

F3

F1

F4

F2

ENTER

Motor
monitoringMotormonitoringMotormonitoringMotormonitoringMotormonitoring

Fieldbus toturbine controller

DISCRETE MULTIPLE INVERTERCOMPACT MULTIPLE INVERTER

3~ 400 V AC
24 V DCBus

3~ 400 V AC

Input AC 3PH 50/60 Hz
400V XXXXXX
Output: AC3PH 0…U XXXXXXX
XXXkVA / XXXX
Mat.No. 0000000-0000
Cust.No.

Input AC 3PH 50/60 Hz
400V XXXXXX
Output: AC3PH 0…U XXXXXXX
XXXkVA / XXXX
Mat.No. 0000000-0000
Cust.No.

Input AC 3PH 50/60 Hz
400V XXXXXX
Output: AC3PH 0…U XXXXXXX
XXXkVA / XXXX
Mat.No. 0000000-0000
Cust.No.

500 V DC bus
24 V DC bus
EtherCAT

Input AC 3PH 50/60 Hz
400V XXXXXX
Output: AC3PH 0…U XXXXXXX
XXXkVA / XXXX
Mat.No. 0000000-0000
Cust.No.

S1
CAUTION
Risk of Electrical Shock

Capacitors discharge time is 5 minutes.
A fault protective switch is not permissible
as the only protective measure!

CAUTION
Risk of Electrical Shock

Capacitors discharge time is 5 minutes.
A fault protective switch is not permissible
as the only protective measure!

CAUTION
Risk of Electrical Shock

Capacitors discharge time is 5 minutes.
A fault protective switch is not permissible
as the only protective measure!

CAUTION
Risk of Electrical Shock

Capacitors discharge time is 5 minutes.
A fault protective switch is not permissible
as the only protective measure!

Error Run

X6B
OL VCCF1

X2

Fieldbus
to turbine
controller

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ENTER

F2

F3

F3

Capacitors discharge time is 5 minutes.
A fault protective switch is not permissible
as the only protective measure!

F4

F1

ESC

ENTER

F2

F3

F4

ESC

ESC

Fieldbus toturbine controller

Run
Stop
Clear

CAUTION
Risk of Electrical Shock

Capacitors discharge time is 5 minutes.
A fault protective switch is not permissible
as the only protective measure!

Capacitors discharge time is 5 minutes.
A fault protective switch is not permissible
as the only protective measure!

ENTER

Input AC 3PH 50/60 Hz
400V XXXXXX
Output: AC3PH 0…U XXXXXXX
XXXkVA / XXXX
Mat.No. 0000000-0000
Cust.No.

F4

F1

ESC

ENTER

F2

F3

F4

F1

ESC

ENTER

F2

F3

F4

F1

ESC

ENTER

F2

F3

F4

ESC

Fieldbus
to turbine
controllerMotormonitoringMotormonitoringMotormonitoring

COMPARISON OF HARDWARE SOLUTIONSFEATURESSINGLE
INVERTERDOUBLE
INVERTERDISCRETE
MULTI INVERTERCOMPACT
MULTI INVERTER

adapted industrial design
simple and user-friendly handling

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Feedback control
Open loop operation
closed loop operation
Multiple encoder interface

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Common DC bus

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O

X
X
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DC Fuses incl. monitoring function

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24VDC 2A Brake supply

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X

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Integrated 24V/25A supply

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Integrated safety module STO and SBC1)

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X

X

IEC 61131 Programmable Control unit——

External

Yaw Library——

Webserver functionality

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X
O

X
X
X
X
X
X
X
X
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X
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Diagnostic and monitoring via PC software

O
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O
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O
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O
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Motor control
Induction
SMPM
IPM

X
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X
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I²•t motor protection

External

External

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X
X
X

X
X
X
X

—
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X
—

X
X

X
X

X
O
O

X
O
O

X
O
O

O
X
O

O
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O
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O
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O
O

Size of drive components

Small

MediumLarge

MediumWiring complexity

MediumMediumExtensive

SimpleBus Communication to turbine controller
CAN, EtherCAT, PROFIBUS, PROFINET

Redundancy
SingleMultiple
Heatsink design
Forced ventilated
Flat rear
Push throughSupply with AFE for regulated DC Voltage
External
Internal

X Integrated
O Option1)
depending on inverter type9

DIAGNOSTIC TOOLS & PROGRAMS - PITCH AND YAWKEB PITCH AND YAW - DIAGNOSITIC TOOLS & PROGRAMSProgramming and diagnostic tools optimized for this application reduce engineering eﬀorts.
COMBIVIS 6

PROGRAMMING WITH COMBIVIS studio 6

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Diagnostic tool for the pitch inverter P6 and for yaw drives
Display of operating conditions
Oscilloscope function
Download of customized adjustments
Analysis of communication between drive and control

CoDeSys based on IEC 61131-3
Programming language: ST, IL, SFC, LD and FBD/CFC
Integrated visualisation
Simulation
Debugging and file-management

WIND SOLUTION SERVICE TOOLSWEBSERVER
a functionality can be integrated in the pitch drive as well as in the control unit
for the yaw control
ADVANTAGES:• No specific software is requiered• A simple browser installed on a device can connect to the KEB products• Password levels provides access to diﬀerent information•

With KEB FTP tool, project documentations can be stored inside thememory and uploaded on site

COMBIVIS connect
COMBIVIS studio 6
COMBIVIS studio HMICOMBIVIS connect
RuntimeInternet

CONNECT ROUTER
RESET

LAN

WAN

POWER

RUN /
STOP

REMOTECONNECTCOM RxCOM Tx

LAN
ETH 1

COM

WAN
ETH 2

F1

ENTER

F2

F3

F4

ESC

COM

LAN
EtherCAT
EtherCAT

S1
Run
Stop
Clear
Error Run

X6B
OL VCCX2

COMBIVIS connect
Server infrastructure

HIGHLIGHTS
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Remote monitoring using Ethernet-based router
Worldwide support from several server locations
Also available as router with integrated 2G/3G/3G+ modem
Access to remote devices via Ethernet or serial interface
Proven COMBIVIS connect software connects the plant to be monitored to your workplace via VPN
Additional HMI functionality for datalogging, long-term machine diagnostics and notification by e-mail and SMS

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PITCH MOTOR
POWERFUL, EFFICIENT AND EXCESSIVELY RELIABLE
The KEB Pitch Motors are available for various wind turbines in the power range up to 10 MW.
The high dynamic, vibration resistant servo motors are equipped with a robust encoder system and with the KEB fail-safe brake.
The high protection degree IP65 as well as the special corrosion painting allow using the KEB Pitch Motors in various climate conditions. If it is oﬀshore
or CCV / HCV – the KEB Pitch Motors guarantees safe and reliable operation. The dedicated housing design allows operation without additional forced
ventilation.

PLUG AND DRIVE
KEB oﬀers pre-assembled motor and feedback cables with very robust and easy-to-handle connector systems.

6 MW Pitch Motor

All-in-one motor cable

HIGHLIGHTS
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Vibration resistant
HCV / CCV resistantOﬀshore operation, IP65
Corrosion protection category C4M according to DIN EN ISO 12944-5
Integrated holding brake, 24 V DC or 150 - 300 V DC with energy saving function
Unique connector design with integrated power, encoder, brake and temperature sensor connectors

COMBISTOP PITCH AND YAW BRAKESTWO BRAKE DESIGNS, OPTIMIZED FOR APPLICATIONS WITH HIGH DEMANDS ON THE PROTECTION DEGREE

2 MW Spring applied pitch brake
IP 65 Type 28 mounted between gearbox and motor

COMBISTOP 28

IP65

Size

M2N1)
[Nm]

P20
[W]

øA

05

50

48

06

90

07

6 MW Spring applied pitch brake
IP 00 type 38 mounted inside the motor

L

COMBISTOP 38

WITH SPECIAL SEALING

Size

M2N1)

P20

[Nm]

[W]

165

30

58.2

05

36

48

147

30

57.7

75

180

30

68.8

06

70

62

164

35

68.8

150

90

210

45

74.2

07

100

65

190

45

75.5

08

225

90

240

60

88

08

150

75

218

60

87.4

09

375

115

276

60

102

09

250

80

253

60

101.7

10

500

130

307

75

110.8

øD

L

øA

øDH7
max.

øA

øD

L

max.

1) rated torque after running-in

HIGHLIGHTS
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More than 300,000 pitch and yaw brakes successful in operation
HCV / CCV version available
Rated voltage up to 300 VDCHigh vibration resistance (safety and lifetime)
Coated and redundant springs with long lifetime for safe power-oﬀ stopSpecial friction lining for high emergency stop energy≥ 200 Nm special anti-condensation and anti-icing design
Low energy and low coil temperature rise system

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OTHER DRIVES FOR WIND TURBINESINVERTER FOR SERVO PUMP OF
HYDRAULIC PITCH SYSTEMAUXILIARY DRIVES FOR PUMPS,
FANS AND AIR CONDITIONING

LIFT AND HOISTDRIVES AND BRAKESC6 ROUTER FOR REMOTE MONITORING
C6 HMI14KEB PARTNER

KEB WORLDWIDE
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E-Mail: info@keb.at Internet: www.keb.at

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201611 Shanghai P. R. China
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E-Mail: info@keb.cn Internet: www.keb.cn

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15

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32683 Barntrup

Germany

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Tel. +49 5263 401-0 E-Mail: info@keb.de© KEB 0000000-51P6 07.2018 Subject to technical alterations!

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