TD-esc-02-De-En-11-003 Rev002 Guideline For Optimising ENERCON Blade Heating Configuration

Technical Notice
Guideline for optimising ENERCON blade heating configuration
Area of application
This document applies to: International
Mechanical Induction Installation Update Precast concrete tower – Installation
Electrical Rotor blade Grid connection Concrete repair Precast concrete tower – Prestressing
CS12 CS20 CS32 CS44b CS58b CS70b CS112a

CS16 CS30 CS40 CS48a CS66 CS82a CS126a
CS17 CS31a CS44a CS58a CS70a CS101a
Document details
Document ID TD-esc-02-de-en-11-003 Rev002 Guideline for optimising ENERCON blade heating
configuration
Confidentiality INTERNAL
Date Language DCC Plant/department

2015-03-17 en DD Service Deutschland GmbH/Electrical Engineering
© Copyright ENERCON GmbH. All rights reserved.
TD-esc-02-de-en-11-003 Rev002 Guideline for optimising ENERCON blade heating configuration i of iii
Technical Notice
Revision table
Revision Date Section Change
000 2011-02-14 - Document created
3.1.4 Section added
3.1.5 Section added
3.2 Added/modified information
001 2015-01-07 3.8 Section added
5 Added/modified information

002 2015-03-17 4.2 Added information
TD-esc-02-de-en-11-003 Rev002 Guideline for optimising ENERCON blade heating configuration ii of iii
Technical Notice
Table of contents
1 General information ...............................................................................................................1
2 Safety instructions .................................................................................................................2
3 Basic principle of the blade heating system ........................................................................3
3.1 Hardware ..........................................................................................................................3
3.1.1 E-44, E-48 and E-53 blade types ...............................................................................3
3.1.2 E-58 to E-70 blade types ............................................................................................3
3.1.3 E-70 and E-82 blade types .........................................................................................3
3.1.4 E-92 blade types ........................................................................................................3
3.1.5 E-101 and E-115 blade types .....................................................................................3
3.2 Operating principle ............................................................................................................4
3.3 Control system ..................................................................................................................4
3.4 Blade heating system: Automatic P1314 ...........................................................................4
3.5 Permit blade heating during operation P1315 ....................................................................4
3.6 Maximum power consumption of blade heating P1316 ......................................................4
3.7 Minimum heating time of blade heating system P1317 ......................................................5
3.8 Blade heating nominal power P1321 .................................................................................5

3.9 Additional Information........................................................................................................6
4 Blade heating control for control system types CS48, CS82 und CS101 ...........................7
4.1 Basic settings ....................................................................................................................7
4.2 Related documents for the operator/owner ........................................................................7
4.3 Software details.................................................................................................................8
4.4 Sites ..................................................................................................................................8
4.4.1 Sites with increased risk .............................................................................................9
4.4.2 Sites with reduced risk .............................................................................................10
4.4.3 Sites with low risk .....................................................................................................11
4.5 Note on the Labko ice detection system ..........................................................................13
5 Power adjustment of blade heating element ......................................................................13
TD-esc-02-de-en-11-003 Rev002 Guideline for optimising ENERCON blade heating configuration iii of iii
Technical Notice
1 General information
This document replaces Technical Information documents TD-esc-02-ger-xxx-10-016 and
s-e-02-ger-xxx-08-011. Its contents have been updated to reflect the most recent knowledge.
The photos/figures in this document serve as illustrations and may differ from the actual compo-
nents.
This document applies to WECs with the indicated control system types that are equipped with a
blade heating system. Control system types CS58, CS66 and CS70 are not covered in detail; only
the basic principle is explained.
This document is for internal use only; the settings contained herein are recommendations only.
The WECs are equipped with blade heating systems using recirculating air.
Written confirmation from the customer or another authorised person is required prior to activating
and configuring the blade heating system. The final approval for operating and configuring the
blade heating system is given by Technical Service Dispatch or Customer Relations.
The operator/owner is responsible for assessing the hazards at the site. Based on his
assessment, the corresponding settings are made.

The optimised configuration and use of the blade heating system depends on the WEC site. The
settings must be adjusted to match conditions on-site. If the operation of the blade heating system
could result in injury or property damage due to ice shedding, the blade heating system may not be
run in automatic mode.
TD-esc-02-de-en-11-003 Rev002 Guideline for optimising ENERCON blade heating configuration 1 of 13

Technical Notice
2 Safety instructions
DANGER!
Improper conduct in or around the WEC
Death or severe injury
Therefore:
 ENERCON health and safety regulations apply.
 Follow all relevant ENERCON instructions for safe use as well as the manufactur-
ers’ operating manuals and instructions.
 Should the safety standards of the respective country be more stringent than those
required by ENERCON, the national regulations apply.
DANGER!
Electric current
Death or severe injury from electric arcs and electric shocks
Therefore:
Follow the 5 safety rules:
 Disconnect

 Secure isolation
 Prove dead
 Earth and short-circuit
 Cover or close off adjacent live parts
DANGER!
Ice shedding or ice throw
Injury and damage to property
Therefore:
The blade heating system may only be activated if the following conditions are met:
 A written confirmation has been provided by the customer.
 Final approval has been given by Technical Service Dispatch or Customer Rela-
tions.
The operation of the blade heating system can cause increased ice throw while the
WEC is running.
 At sites where injury or property damage may be caused by ice throw, the blade
heating system may not be run in automatic mode.
 The vicinity of the WEC must be clear of persons and buildings.
 At sites where personal injury or property damage may be caused by ice shed-
ding, the blade heating system may not be run in automatic mode.
 It must be ensured that no injury or property damage can occur.

Technical Notice
3 Basic principle of the blade heating system
3.1 Hardware
This section lists the blade types and their components.
3.1.1 E-44, E-48 and E-53 blade types

Each E-44, E-48 and E-53 rotor blade equipped with an air circulation system features the follow-
ing components:
 Heating element including safety thermostat (10 kW or 13 kW).
 Radial fan (1.3 kW or 2.2 kW)
 Temperature sensor to regulate the system
3.1.2 E-58 to E-70 blade types

Each blade equipped with an air circulation system (except E-70/4 blades) features the following
components:
 Heating element including safety thermostat (12 kW)
 Radial fan (approx. 0.8 kW )

3.1.3 E-70 and E-82 blade types

Each E-70/4, E-82/1 and E-82/2 rotor blade equipped with an air circulation system features the
following components:
 Heating element including safety thermostat (20 kW or 25 kW)
 Radial fan (approx. 3 kW )
3.1.4 E-92 blade types

Each E-92 rotor blade equipped with an air circulation system features the following components:
 Heating element including safety thermostat (max. 50 kW but limited to 37.5 kW)
 Radial fan (5.5 kW )
3.1.5 E-101 and E-115 blade types

Each E-101 and E-115 rotor blade equipped with an air circulation system features the following
components:
 Heating element including safety thermostat (max. 75 kW but limited to 68.8 kW)
 Radial fan (5.5 kW )

Technical Notice
3.2 Operating principle

Hot air is blown from blade flange to blade tip along the leading edge. The air is then redirected
and returns through the central chamber and trailing edge chamber of the blade. Hence the air
temperature is highest in the front chamber at the leading edge. This ensures that the most affect-
ed areas thaw first.
3.3 Control system

In principle, the air circulation heating system can be operated with control systems CS48, CS58,
CS66, CS70, CS82 and CS101. The basic difference is in the way the heating elements are acti-
vated.
For CS58, CS66 and CS70 control systems, all heating elements are switched off once the maxi-
mum control temperature has been reached inside one blade. Once the air inside this blade has
cooled down and reached the minimum control temperature, all heating elements are switched on
again. The blade with the highest or lowest temperature thus determines heat regulation.
For CS48, CS82 and CS101 control systems, each blade regulates the control temperature inde-
pendently so the optimum temperature is achieved in each of the three blades.
3.4 Blade heating system: Automatic P1314

In the Basic settings menu, menu item Blade heating: automatic can be used to speci-
fy whether the blade heating system should be activated automatically once icing has been detect-
ed.
3.5 Permit blade heating during operation P1315
DANGER!
Ice throw
Injury and/or damage to property
Therefore:
 This feature may only be activated in areas where personal injury and property
damage can be ruled out.
In the Basic settings menu, menu item Permit blade heating during operation can
be used to specify whether the blade heating system should be operated while the WEC is run-
ning.
3.6 Maximum power consumption of blade heating P1316
The description below applies to all specified control system types except CS58, CS66
and CS70.
The blade heating system draws power from the power grid. In the Basic settings menu,
menu item Max. power consump. of blade heat.: can be used to configure the maximum
power consumption up to the configured value of P1321. The blade heating system does not con-
sume more than the specified power consumption value; this takes the current WEC power output
over a 2-minute average into account. If, for instance, P1316 is set to 30k W, the blade heating
system consumes a maximum of 30 kW if the WEC is at a standstill or outputting 0 kW. An
E-82 E-2 with 85 kW of installed blade heating power, with a WEC power output of 55 kW over a
2-minute average and 30 kW of maximum power consumption, would then run the blade heating at
full power because a total of 85 kW would be available.

Technical Notice
3.7 Minimum heating time of blade heating system P1317

In the Basic settings menu, menu item Min. heating duration of blade heating
can be used to configure the operating time of the blade heating system (between 1 h and 10 h).
This setting applies if the blade heating system is on (manual or automatic operation) while the
WEC is standing still and if with setting Permit blade heating during operation status
14:xx still occurs.
3.8 Blade heating nominal power P1321
The setting for P1321 is project-specific; if in doubt, a clarification on-site is necessary.
Depending on the WEC type, this parameter requires different settings. Table 1 indicates the typi-
cal settings for parameter P1321 for the various control system and WEC type:
Control sys- WEC type P1321 setting
tem type
E-44, E-48, E-53 (10 kW heating element per blade) 34 kW
CS48
E-44, E-48, E-53 (13 kW heating element per blade) 46 kW

E-70 and E-82 blade types with 20 kW heating element per blade 70 kW
CS82 E-70 and E-82 blade types with 25 kW heating element per blade 85 kW
E-92 blade types with 37.5 kW heating element per blade 129 kW
CS101 E-101 and E-115 blade types with 68.8 kW heating element per 225 kW
blade
Table 1: Settings
The control system uses parameter P1321 as basis for calculating the activation time of the blade
heating system. Example: If an E-70 WEC has an installed nominal blade heating power of 70 kW
and parameter P1316 is set to 30 kW, this results in a clockable power of 60 kW because the pow-
er of the blade heating fans is subtracted. With a maximum power consumption of for example
30 kW, the blade heating system is switched on 50 % of the time over a 2-minute average.

Technical Notice
3.9 Additional Information

The operator/owner should be aware that the max. power consumption of the blade heating sys-
tem (with recirculating air) can be configured to a value up to the installed nominal blade heating
power. In addition, he should know that it is technically possible to operate the heating system
while the WEC is running.
This function has been programmed to avoid excessive power consumption in large wind farms, for
instance, and to avoid excessive costs. Since all WECs in a wind farm normally ice up at the same
time, their heating systems would also all start up at almost the same time if this is how they are
configured. In this case power consumption increases and, unless it is registered with the utility,
the owner/operator incurs high costs. Power Consumption Management can also be used to avoid
excessive costs.
Because of very minimal thawing, it is not effective to set blade heating at WEC standstill to less
than 50% of available heating power. In such cases, it is recommended to stagger de-icing; this
can only be done if more than one WEC is connected to the utility's measuring point.
For best de-icing results, the blade heating system should operate at maximum power.

Technical Notice
4 Blade heating control for control system types CS48, CS82 und CS101
4.1 Basic settings

Prior to putting the blade heating system into service, the following settings must be agreed with
the operator/owner; the agreement must be documented. These settings are required for the basic
configuration.
 P1314 Automatic blade de-icing - ON/OFF
 P1315 Permit blade de-icing during operation - YES/NO
 P1316 Max. power consumption of blade heating
 P1317 Min. heating duration of blade heating – 1 h-10 h
4.2 Related documents for the operator/owner

Because the operator/owner is responsible for choosing the settings of parameters 1314 to 1317,
the operator/owner must be provided with the following document which is stored in the ISI data-
base (05 - Technik – Außen- und Innendienst  Formulare und Vorlagen):
 D0167474-4_ger_Parameter_Blattheizung
or
 D0169938-4_eng_Parameters_Blade_heating

Technical Service Dispatch must be in possession of this document in order to be allowed to make
the corresponding settings for parameters 1314 to 1317.
The procedure instructions for WEC parameter modification (Service) describe where to store the
documents in the SAP system.

Technical Notice
4.3 Software details

Starting with software version "Display V1.54", the following settings can be viewed on the control
cabinet display; however, they can no longer be modified except for switching the blade heating
system on/off.
On the Control cabinet I/O-Board, modifications can still be made but only by using a Ser-
vice code:
 P1314 Automatic blade de-icing - ON/OFF
Control system WEC type Typical power consumption
E-44 0 kW to 34 kW
CS48a E-48 or
E-53 0 kW to 46 kW
E-70/4 0 kW to 70 kW
or
CS82a E-82 E1 to E5
0 kW to 85 kW

E-92 0 kW to 129 kW
CS101a E-101 and E-115 0 kW to 225 kW
Table 2: Power consumption by WEC type
 P1315 Permit blade de-icing during operation - YES/NO

 P1317 Min. heating duration of blade heating – 1 h-10 h
Starting with software version "Display V1.54", it is no longer possible to manually con-
trol the blade heating system from the control cabinet display.
It is still possible to start/stop the blade heating without using a Service code.
4.4 Sites
The site where the WEC is located determines whether de-icing may be done manually or auto-
matically.
If the WEC is located at a site with increased risk, de-icing must be carried out manually. At sites
with reduced or low risk, de-icing may be carried out automatically. There are two different settings
for automatic mode. The first option is to stop the WEC first and then start the heating system. The
second option is to activate the blade heating system while the WEC is running.

Technical Notice
4.4.1 Sites with increased risk
DANGER!
Ice shedding
Injury or damage to property
Therefore:
 Operate the blade heating system manually.
 After operating the heating system and before restarting the WEC, check the blades
for any remaining ice.
 Personal injury and property damage must be ruled out.
At sites where injury or property damage must be expected, the blade heating system must be
operated manually. Such sites include:
 Sites near roads
 Sites in immediate proximity of residential areas
 etc.
For the manual operation of the blade heating system, the following settings must be made on the
control cabinet I/O Board in the Basic settings menu:
 P1314 Automatic blade de-icing - OFF

 P1315 Permit blade de-icing during operation - NO
Control system WEC type Max. power consumption
E-44
CS48a E-48 34 kW or 46 kW
E-53
E-70/4 70 kW
or
CS82a E-82 E1 – E5
85 kW
E-92 129 kW
CS101a E-101 and E-115 225 kW
 P1317 Min. heating duration of blade heating - 4h

The following settings must be made on Nacelle I/O Board 2 in the Icing parameter
menu:
 P4107 Automatic restart after icing – Off
 P4100 Wind tolerance for power curve – 0.8 to 1.2
Once all settings have been made and the WEC has stopped with status 14.xx, activate the blade
heating system manually. To ensure maximum safety, after operating the heating system and be-
fore restarting the WEC check the blades for any remaining ice.

Technical Notice
4.4.2 Sites with reduced risk

At sites where there is a reduced risk of injury or property damage, the blade heating system may
be operated automatically. Such sites include:
 Sites without any persons in the immediate vicinity of the WEC.
 Sites without any buildings in the immediate vicinity of the WEC.
 Restricted areas
 etc.
For these sites, option Permit blade heating during operation:P1315 option must be
deactivated (Off). This setting means that the WEC must first come to a standstill before the heat-
ing system starts up.
For the automatic operation of the blade heating system, the following settings should be made on
the Control cabinet I/O Board in the Basic settings menu:
 P1314 Automatic blade de-icing - ON
 P1315 Permit blade de-icing during operation - NO
E-44

E-53
E-70/4 70 kW
or
CS82a E-82 E1 – E5
85 kW
E-92 129 kW
CS101a E-101 and E-115 225 kW
 P1317 Min. heating duration of blade heating - 4 h

The following settings must be made on the nacelle I/O Board 2 in the Icing parameter menu:
 P4107 Automatic restart after icing – On
 P4100 Wind tolerance for power curve – 1.2
Once all settings have been made and the WEC has stopped with status 14.xx, the blade heating
system is activated automatically. After a heating time of 4 hours, the heating system is turned off.
After the heating cycle has completed, the counter for status 14:xx is reset by a specific value and
the WEC attempts to start up. If after a specified time period, the WEC power output or the blade
angle are outside the tolerance range, the blade heating system is re-activated.

Technical Notice
4.4.3 Sites with low risk

At sites where there is no risk of injury or property damage, settings can be made for yield-
optimised WEC operation. Yield-optimised WEC operation means that the maximum yield (for the
site) is achieved. Such sites include:
 Sites without any persons in the immediate vicinity or wider surroundings of the WEC.
 Sites without any buildings in the immediate vicinity or wider surroundings of the WEC.
 Restricted areas
 etc.
For these sites, option Permit blade heating during operation:P1315 option can be
activated (On). As a result of this setting,
 additional menu items in the control system become available, see Table 5.
 the blade heating system is activated while the WEC is running
If option Permit blade heating during operation:P1315 has been activated, the blade
heating system starts up while the WEC is running. The WEC continues to run for as long as the
climatic conditions allow and the ice detection system (optional) does not respond. The blade heat-
ing control system has been redesigned to allow its optimum utilisation during operation. The menu
items listed in Table 5 have been added to the control system:

Pa-
I/O Typical
Menu rame- Menu item Note
board value
ter ID
Wind tolerance
of power curve If the actual value exceeds this tolerance
4101 0.6 m/s
for blade heat- value, the blade heating system starts up.
ing V(∆P)
If the actual value exceeds this tolerance
Wind tolerance
value, the WEC stops due to icing. The blade
4100 for power 1.8 m/s
heating system continues to run for a speci-
curve V(∆P)
fied time period.
Power toler-
I/O Board 2 Nacelle
ance at more
Icing parameter
If the actual value drops below this tolerance

4103 than 10.5m/s 90 %
value, the blade heating system starts up.
for blade heat-
ing P(Tol)
Power toler- If the actual value drops below this tolerance
ance at more value, the WEC stops due to icing. The blade
4102 75 %
than 10.5m/s heating system continues to run for a speci-
P(Tol) fied time period.
Wind tolerance
of blade angle If the actual value exceeds this tolerance
4105 2.0 m/s
curve for blade value, the blade heating system starts up.
heating V(∆P)
If the actual value exceeds this tolerance
Wind tolerance
value, the WEC stops due to icing. The blade
4104 of blade angle 3.0 m/s
heating system continues to run for a speci-
curve V(∆P)
fied time period.
Table 5: New menu items in WEC control system

Technical Notice
For the yield-optimised WEC operation, the following settings should be made on the Control
cabinet I/O Board in the Basic settings menu:
 P1314 Automatic blade de-icing - ON
 P1315 Permit blade de-icing during operation – YES
E-44
E-53
E-70/4 70 kW
or
CS82a E-82 E1 – E5
85 kW
E-92 129 kW
CS101a E-101 and E-115 225 kW

 P1317 Min. heating duration of blade heating – 1h
The following settings must be made on Nacelle I/O Board 2 in the Icing parameter
menu:
 P4107 Automatic restart after icing – On
 P4108 Automatic restart during icing– On or Off
The option Automatic restart after icing (On) P4107 means that the WEC
is permitted to restart automatically if outside temperatures are high enough or if the
minimum heating duration of blade heating P1317 has been reached.
Based on the described settings, option P4108 Automatic restart during ic-
ing is disabled. It is therefore irrelevant whether the option is set to On or Off.
 P4100 Wind tolerance power curve – 1.8 m/s
 P4101 Wind tolerance power curve for blade heating– 0.6 m/s
 P4102 Power tolerance at more than 10.5 m/s – 75 %
 P4103 Power tolerance at more than 10.5 m/s for blade heating – 90 %
 P4104 Wind tolerance of blade angle curve– 3.0 m/s
 P4105 Wind tolerance of blade angle curve for blade heating– 2.0 m/s
If option Permit blade heating during operation:P1315 has been activated, a second
counter is used for the blade heating system (in addition to the regular counter of the ice detection
system). The first counter for the ice detection system counts up from 0 to 30 and affects statuses:
 14:11
 14:12
 14:13
 14:14

Technical Notice
The second counter turns the blade heating system on or off and has a value range of 0 to 60.
If option Permit blade heating during operation:P1315 has been activated, the maxi-
mum power consumption can be reduced as far as 0 kW. In this case, the system only consumes
the power that is generated by the WEC. As a result, substantial icing can form on the blades at
low wind speeds and the WEC may stop with status 14:xx even though the blade heating system is
running. In this case, it is not possible to de-ice the WEC while it is at a standstill.
4.5 Note on the Labko ice detection system

The blade heating system can currently not be controlled by the Labko ice detection system. The
ice detection system must be considered a preventive tool. The system stops the WEC if prevailing
weather conditions may cause icing of the rotor blades. The goal is to prevent substantial ice build-
up on the leading edges of the blades. The purpose of the system is to protect people; it does not
indicate actual icing of the rotor blades. If a WEC is equipped with a blade heating system and an
ice detection system, the blade heating system must always be operated in manual mode.
5 Power adjustment of blade heating element

For the blades of WEC types E-70 E4 and E-82 on E-82 E2, the power of the blade heating ele-
ments has been adjusted from 20 kW to 25 kW each.

Because of the power adjustment of the heating elements for E-82 E2, the heating elements of
WEC types E-70 E4 and E-82 have been blocked in SAP. The 20 kW (SAP 86248) and 25 kW
(SAP 94866) heating elements have been replaced with a new 25 kW heating element made by
Türk und Hillinger (SAP 514985).
The design of the new 25 kW heating elements is almost identical to the old 25 kW heating ele-
ments made by Egger. This heating element will be installed in all new WECs.
When replacing a defective 20 kW or an old 25 kW heating element with a new 25 kW heating el-
ement in E-70 E4 or E-82 blades, make sure to remove the three marked brass bridges in the ter-
minal box of the 25 kW heating element before installation. Observe Technical Instructions
TD-esc-07-ger-ger-14-015.
Since -J02 has moved, the "adapter cable for the 20 kW heating element" (SAP 91847) is needed
in existing WECs.
When retrofitting or upgrading E-70 E4 or E-82 E1 WECs, follow the same procedure
as for replacing defective heating elements.

TD-esc-02-De-En-11-003 Rev002 Guideline For Optimising ENERCON Blade Heating Configuration

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Technical Notice

Guideline for optimising ENERCON blade heating configuration

CS12 CS20 CS32 CS44b CS58b CS70b CS112a

Date Language DCC Plant/department

© Copyright ENERCON GmbH. All rights reserved.

© Copyright ENERCON GmbH. All rights reserved.

© Copyright ENERCON GmbH. All rights reserved.

© Copyright ENERCON GmbH. All rights reserved.