GEH-6737D

1.5 MW Wind Turbines

20 Nm Non-ESS Pitch Control
System Guide

August 2016

GE Internal
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible
contingency to be met during installation, operation, and maintenance. The information is supplied for informational
purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications,
and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected
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herein.
GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this
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GE Internal – This document is proprietary. It contains information that belongs to the General Electric Company and is
furnished to its customer solely to assist that customer in the installation, testing, operation, and/or maintenance of the
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For further assistance or technical information, contact the nearest GE Sales or Service Office, or an authorized GE Sales
Representative.

Revised: August 2016

Issued: October 2006

© 2006 - 2016 General Electric Company.

___________________________________
* Indicates a trademark of General Electric Company and/or its subsidiaries.
All other trademarks are the property of their respective owners.

We would appreciate your feedback about our documentation.

Please send comments or suggestions to controls.doc@ge.com

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 Document Updates
Revision Update Location Description
D Throughout the Miscellaneous updates to fix format, style, trademarks, spelling and other minor
Aug 2016 document changes

C
Various sections Updated figures for ToolboxST application graphic refresh
Mar 2015

Related Documents
For more information on the Pitch control product, refer to the following documents:

Title Doc #
ToolboxST* User Guide for Mark* Controls Platform GEH-6700
Mark VIe Control Volume III Diagnostics and Troubleshooting Guide GEH-6721_Vol_III

Mark VIe Control Renewable Energy Distributed I/O Modules GEH-6779

GEH-6737D System Guide 3

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 Acronyms and Abbreviations
AEPA Alternative Energy Pitch Axis

AEPC Alternative Energy Pitch Center

BPPx Balance of Plant Processor Board

EGD Ethernet Global Data
E-Stop Emergency stop

FPGA Field Programmable Gate Array

HDC Heavy-duty Connectors

HMI Human-Machine Interface

LED Light Emitting Diode

LOTO Lockout tagout

PCS Pitch Control System

PLC Programmable Logic Controller

PWM Pulse Width Modulator

RTD Resistance Temperature Device

WTG Wind Turbine Generator

4 GEH-6737D 1.5 MW Wind Turbines 20 Nm Non-ESS Pitch Control

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Safety Symbol Legend

Indicates a procedure or condition that, if not strictly observed, could result in

personal injury or death.
Warning

Indicates a procedure or condition that, if not strictly observed, could result in damage
to or destruction of equipment.

Caution

Indicates a procedure or condition that should be strictly followed to improve these

applications.

Attention

GEH-6737D System Guide 5

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Control System Warnings

To prevent personal injury or damage to equipment, follow all equipment safety

procedures, Lockout Tagout (LOTO), and site safety procedures as indicated by
Employee Health and Safety (EHS) guidelines.
Warning

This equipment contains a potential hazard of electric shock, burn, or death. Only
personnel who are adequately trained and thoroughly familiar with the equipment
and the instructions should install, operate, or maintain this equipment.
Warning

Isolation of test equipment from the equipment under test presents potential electrical
hazards. If the test equipment cannot be grounded to the equipment under test, the
test equipment’s case must be shielded to prevent contact by personnel.

To minimize hazard of electrical shock or burn, approved grounding practices and

Warning procedures must be strictly followed.

To prevent personal injury or equipment damage caused by equipment malfunction,

only adequately trained personnel should modify any programmable machine.
Warning

Always ensure that applicable standards and regulations are followed and only
properly certified equipment is used as a critical component of a safety system. Never
assume that the Human-machine Interface (HMI) or the operator will close a safety
critical control loop.
Warning

6 GEH-6737D 1.5 MW Wind Turbines 20 Nm Non-ESS Pitch Control

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 Contents
1 Overview ............................................................................................................................................. 9
2 Non-ESS Pitch Control System .................................................................................................. 11
2.1 Power Flow .......................................................................................................................................... 12
2.2 Network............................................................................................................................................... 13
2.2.1 Hub Layout.................................................................................................................................... 15
2.3 Specifications ....................................................................................................................................... 16
3 Handheld HMI .................................................................................................................................. 17
3.1 Establish Battery Power .......................................................................................................................... 18
3.2 Jog the Pitch Control Using Generator Power.............................................................................................. 19
3.3 Jog the Pitch Control on AC Power .......................................................................................................... 20
3.4 Gear Ratio Parameter and Axis Position Calibration ..................................................................................... 22
3.5 Alternate Energy Pitch Center (AEPC) IP Address Configuration.................................................................... 25
3.6 Powering Off the Handheld HMI .............................................................................................................. 25
4 Center Box (Power Distribution) ................................................................................................ 27
4.1 AEPC Module....................................................................................................................................... 29
4.1.1 Compatibility ................................................................................................................................. 30
4.1.2 AEPC Connectors ........................................................................................................................... 31
4.2 Startup and Heater Control ...................................................................................................................... 32
4.3 Top Box Assembly Inputs ....................................................................................................................... 32
4.3.1 Slip Ring to Hub Point-to-point Terminations ....................................................................................... 35
5 Axis Box............................................................................................................................................ 37
5.1 AEPA Module ...................................................................................................................................... 38
5.1.1 Compatibility ................................................................................................................................. 38
5.2 Pitch Motor Power Converter .................................................................................................................. 38
6 Battery Box ...................................................................................................................................... 41
6.1 Battery Charger ..................................................................................................................................... 42
6.1.1 Battery Charger Automatic Self-Test................................................................................................... 43
6.1.2 Battery Test ................................................................................................................................... 45
7 Pitch Motor ....................................................................................................................................... 47
7.1 Pitch Motor Brake ................................................................................................................................. 48
8 Working with the ToolboxST Application................................................................................. 49
8.1 Display Diagnostic Information ................................................................................................................ 49
8.2 Watch Window...................................................................................................................................... 60
8.3 Signal Trending..................................................................................................................................... 61
8.3.1 Operations Trends ........................................................................................................................... 61
8.4 Parameters ........................................................................................................................................... 63
8.4.1 Gear Ratio Parameter Valid Settings ................................................................................................... 64
8.5 Building and Downloading Configuration .................................................................................................. 66
9 Maintenance..................................................................................................................................... 69
9.1 Recommended Annual Maintenance.......................................................................................................... 69
9.1.1 Fuse Replacement ........................................................................................................................... 70
9.2 DC Motor Brush Replacement ................................................................................................................. 71

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10 Troubleshooting .......................................................................................................................... 77
10.1 Handheld HMI Jogging........................................................................................................................... 77
10.1.1 Jog Operation................................................................................................................................. 80
10.2 Batteries and Charger Alarms................................................................................................................... 81
10.3 Diagnostic Alarms ................................................................................................................................ 82
11 Replacement and Ordering ....................................................................................................... 83
11.1 Handling Precautions.............................................................................................................................. 83
11.2 Replacement Procedures ......................................................................................................................... 83
11.2.1 Replacing an AEPC......................................................................................................................... 85
11.2.2 Replacing an AEPA ......................................................................................................................... 87
11.2.3 Replacing a Battery Charger Module .................................................................................................. 88
11.3 Ordering .............................................................................................................................................. 89

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1 Overview
The 1.5 MW Wind Turbine 20 Nm Pitch Control System (PCS) sets the blade angle
through Pitch Motor Control, responding to pitch angle position commands from the
turbine controller's Bachmann® programmable logic controller (PLC). The PCS returns
the current angular position of the blades back to the turbine controller, allowing it to
regulate rotor speed and torque. For the turbine to be operational, all three blades must be
actively controlled.
The PCS also provides emergency feathering from a grid or battery supply. A hard-wired
control signal over the slip rings from the turbine controller activates the emergency
feather system. If at least two of the three blades feather to the 90° position, the turbine
slows to a safe speed. Although the 1.5 MW wind turbine has a brake on the rotor, it is
only capable of holding a stopped rotor. The brake does not protect the turbine during
high winds, therefore the emergency feathering system must be extremely reliable under
all conditions.
The PCS features high-speed networked I/O boards, Ethernet communications for the I/O
boards, controllers, and an interface to maintenance stations for supervisory activities or
third-party systems. Diagnostic alarm messages and predetermined feedback signals are
available to the communications networks for control, trending, and diagnostics.
The ToolboxST* application is used for programming the controller, configuring I/O
boards, trending, and analyzing diagnostics. It provides a single source of quality,
time-coherent data at the controller and plant level for effectively managing equipment
assets.

Overview GEH-6737D System Guide 9

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Notes

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2 Non-ESS Pitch Control System
The Pitch Control System (PCS) changes the blade angle, which either increases or
decreases the force of the wind on the blade. The force on the blade creates torque at the
hub center, causing the hub to rotate. The total power generated by the turbine is
proportional to the rotor speed multiplied by torque.
The PCS includes a Center box, three Axis/Battery boxes, and three pitch motors each
with an integral brake and incremental encoder. The Center box contains power, control
interlocks, and Ethernet distribution to each Axis box. Each Axis box contains the motor
control and protection, including individual position and speed regulators per Axis. Each
Battery box supplies power to the motor for emergency feathering, regardless of power
grid conditions.
During normal operation, the PCS operates from ac power in auto mode. In auto mode,
pitch start/stop commands, pitch motor brake control, and angular position set points are
given by the turbine controller. Under ac power, the PCS can also be operated in manual
mode.
In manual mode, the handheld Human-machine Interface (HMI) plugs into the Center box
to gain an Ethernet connection to the controller. The turbine controller sends the pitch jog
forward, jog reverse, and calibrate commands to the pitch system.
The PCS can also operate in a maintenance mode. This mode is used for blade installation
on the ground. Power to the PCS is supplied entirely by batteries.
When the PCS is in operational mode, activating the emergency stop (E-Stop) causes the
blade to pitch to the 90° limit switch using battery power, bringing the turbine to a safe
speed. However, if the PCS is in maintenance mode, activating the E-Stop causes blade
motion to stop.

Blade Positions

Non-ESS Pitch Control System GEH-6737D System Guide 11

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2.1 Power Flow
The Center box distributes power and control to the three Axis boxes. In each Axis box,
the main 400 V ac is stepped down to 63 V ac and rectified to dc voltage. Control power is
24 V dc. Battery-charging voltage is supplied by 230 V ac single-phase. Lighting is 110 V
ac single-phase. The Top box provides all of the power inside the hub through the slip
rings.

Power Flow Diagram

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2.2 Network
For more information, refer to
the section, AEPC Module.
Non-ESS Pitch Control System
GE Internal
Control signals from the turbine controller flow through an RS-422 connection to the
Alternative Energy Pitch Center (AEPC) module. These signals are then sent to each
pitch axis controller (AEPA) over Ethernet. Status and feedback are gathered by the
AEPC using the same Ethernet link, and passed back to the turbine controller through the
RS-422 connection.
For diagnostics and trending, a computer with the ToolboxST application is connected
through the Ethernet downtower with a CAT5 cable to the Ethernet switch inside the
turbine controller. The link to the PCS is through a fiber-optic cable spanning the turbine
tower height to another Ethernet switch in the Top box inside the Nacelle. All control
signals to the hub are also wired from the Top box through the generator slip rings. The
following figure displays Ethernet and serial communications.
GEH-6737D System Guide 13
 Network Diagram

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The torque that is used by the
generator to make power is
negative, and wants to slow
down the hub.
Non-ESS Pitch Control System
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2.2.1 Hub Layout
Each Axis has an Axis box and a corresponding Battery box. The Axis box is mounted on
the inside access of the hub, and the Battery box is mounted behind the blade access
portal. Each Axis box contains the motor control and protection per blade, the individual
pitch position, and speed regulators.
Changing the blade pitch increases/decreases the force of the wind on the blades. The
blade force makes torque at hub center, causing rotation. Power generated is proportional
to speed times torque.
The Battery box supplies power for the control to perform an emergency pitch regardless
of the condition of the power grid. The batteries also provide power for rotation during
site assembly and blade mounting.
PCS Layout Inside Hub
GEH-6737D System Guide 15
2.3 Specifications
Item PCS Specification
Main input power 400 V ac ±10% 50/60 Hz
Input control power 24 V dc ±10% from UPS, 8 A maximum
Accessory power input 120/230 V ac nominal, ±10% 1500 W maximum (receptacles and
lights are 60 Hz-capable only)
Rated operating temperature ambient (inside hub) -30 to 50°C (-22 to 122 °F)
Survival temperature -40 to 60°C (-40 to 140 °F)
Agency approvals CSA NRTL/C UL508C CSA C22.2#14
Pitch motor output voltage 80 V dc maximum
Pitch-rated torque output per axis 20 Nm, continuous
Pitch overload output per axis 300% for one minute following full-load operation

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3 Handheld HMI
For troubleshooting handheld
HMI and jogging issues, refer
to the section, Troubleshooting.
The Exor/UniOP® ePALM10 is a handheld HMI with a graphic display and a keypad. It
plugs into the Center box for manual control of each pitch axis controller. Manual control
can be used while on ac or dc power.
When switching power sources, or at startup, the handheld HMI does not activate until
startup has completed. Refer to the following table for part numbers when ordering
handheld HMI parts.

Part Number Cable Model Reference Drawing Numbers

Type/Length
104W3803P001 Ethernet/5m ePALM10-DA071 104W2594 and 105W1922
151X1225HS01PC01

Note When cycling pitch system power, unplug the handheld HMI. When the PCS has
been restarted and is operational, plug in the handheld HMI.

The handheld HMI powers on faster than the Pitch controller. If it is plugged in on
startup, the handheld HMI tries to communicate with the pitch control. If the pitch control
has not finished powering on, the handheld HMI displays a misleading error message that
the pitch URL does not work. Follow the instructions on the ePalm screen to restore
communications to the Pitch system.

In battery power mode, the batteries are powering

all control and movements. Leave the battery
disconnect switches on only as long as absolutely
necessary to rotate the blades/bearing. Long term
Caution discharge will damage the batteries.

This section provides the following procedures:

• Establish Battery Power

• Jog the Pitch Control Using Generator Power
• Jog the Pitch Control on Ac Power
• Gear Ratio Parameter and Axis Position Calibration
• Alternative Energy Pitch Center (AEPC) IP Address Configuration
• Powering Off the Handheld HMI

Handheld HMI GEH-6737D System Guide 17

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3.1 Establish Battery Power
➢ To establish battery power
1. Verify that all three Battery box disconnect switches are in the OFF position.
2. Plug the conduit from the Battery box into the maintenance connector of the Axis
box.
3. Set the Auto/Manual switch to Manual.
4. Set all three Battery box disconnect switches to the ON position.
5. Allow the processors to power on and the dc link to charge (approximately one
minute).

Note In this mode, the batteries are providing all power. Leave the Battery box
disconnect switches on only as long as absolutely necessary to rotate the blades/bearing.

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3.2 Jog the Pitch Control Using Generator Power

➢ To perform jogging
For troubleshooting 1. Plug the Exor EPalm10 handheld HMI into the Center box plug. If the .htm file
assistance, refer to the section, cannot be found, unplug the device, wait a minute, and then plug it back in. The
Handheld HMI Jogging. screen displays the following:

• F1 IP Address View
• F2 Jog View
• F3 Cal View
2. Press F2 to navigate to the Jog View. The screen displays the following:

• Jog View
• F8 Home
• F7 Cal View
• F1 Axis 1 Jog View
• F2 Axis 2 Jog View
• F3 Axis 3 Jog View
3. Press F1, F2, or F3 to navigate to the view where the blade may be jogged. The
screen displays the following:

• Axis1 Jog
• F8 Home
• F7 Cal View
• F1 Fwd F2
• Rev F3 Stop
• F4 FFwd
• F5 FRev

Handheld HMI GEH-6737D System Guide 19

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 4. Verify that the E-Stop push-buttons on the handheld HMI and the Center box are
released.
5. Press the deadman switch so that it clicks once, and is not positioned all the way in or
out.
6. Press F1 to go toward the 90° limit switch or press F2 to go toward the 0° limit
switch. To move faster, press F4 to go toward the 89° limit switch, or press F5 to go
toward the 0° limit switch. Press F3 to stop, or release the deadman switch.

3.3 Jog the Pitch Control on AC Power

➢ To establish ac power
1. Verify that the Center box ac disconnect switch is in the OFF position.
2. Plug the conduit from the Battery box into the operation plug of the Axis box.
3. Switch the Center box ac disconnect to the ON position.
4. Allow the dc link to charge.

➢ To perform jogging
1. Plug the Exor EPalm10 handheld device into the Center box plug.
2. If the .htm file cannot be found, unplug the handheld HMI. Wait a minute and then
repeat step one.
3. Verify that the handheld E-Stop bypass button is out.
4. Set the Auto/Manual switch to Manual.

Note If the handheld device is removed with the switch in Manual, the turbine safety
chain opens.

The handheld HMI displays the following overview:

• F1 IP Address View
• F2 Jog View
• F3 Cal View
5. Navigate to the Jog View by pressing F2. The screen displays the following:

• Jog View
• F8 Home
• F7 Cal View
• F1 Axis 1 Jog View
• F2 Axis 2 Jog View
• F3 Axis 3 Jog View

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 6. Navigate to the view for the blade to be jogged by pressing F1, F2, or F3. The screen
displays the following:

• Axis 1 Jog
• F8 Home
• F7 Cal View
• F1 Fwd
• F2 Rev
• F3 Stop
• F4 FFwd
• F5 FRev
7. Verify that the E-Stop push-buttons on the handheld HMI and the Center box are
released, and that the jumpers have been removed from the Center box.
8. Press the deadman switch so that it clicks once, and is not positioned all the way in or
out.
9. Press F1 to go toward the 90° limit switch or F2 to go toward the 0° limit switch. To
move faster, press F4 to go toward the 90° limit switch, or F5 to go toward the 0°
limit switch.

Handheld HMI GEH-6737D System Guide 21

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3.4 Gear Ratio Parameter and Axis Position Calibration
Entering a gear ratio from the handheld HMI is only required if a gearbox is exchanged
with another gearbox that has a different gear ratio.

Pitch Gearbox Vendor Gearbox Ratio Pitch Parameter (Gear

Ratio) Value
SMEI® 106.56 987.456
Liebherr® 105.45 977.170
ZOLLERN™ 108.30 1003.580
Nanjing (NGC)® 110.00 1019.333

Bosch Rexroth® 105.60 978.560

SMEI 133.47 1236.822
Liebherr 133.20 1234.320
ZOLLERN 130.00 1204.667
Nanjing (NGC) 131.63 1219.771

Bosch Rexroth 133.94 1241.177

SMEI 187.30 1735.647
SMEI 174.00 1612.400

➢ To enter a gear ratio from the handheld HMI

1. Add a gear ratio entry screen to display prior to the calibrate screen (V01.01.15C and
above). The handheld HMI screen displays the current gear ratio and allows you to
skip the entry.

• Axis1 Gear Ratio

• F8 Home F7 Jog View
• Current: 981.09
• New: [999.9]
• F3 Save
• F4 Skip
2. Enter a value and press F3. The screen display the following confirmation:

• Saving Gear Ratio:

• Axis 1 Value: 999.9
• F2 Confirm
• F3 Cancel

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 3. To confirm, press F2. This sets a bit on the IONet EGD and the GearRatioNew
output going to the AEPA. This bit saves the gear ratio value to the calsave.dat file.
The original calibrate screen displays.

Note If Skip or Cancel is pressed, the original calibrate screen displays without saving
the new gear ratio.

• Axis 1 Calibrate
• F8 Home F7 Jog View
• F1 Calibrate
• F2 Calibrate Abort
4. To calibrate, press F1. The screen displays the following:

• Axis 1 Calibrating
• F8 Home F7 Jog View
• F1 Calibrate
• F2 Calibrate Abort
• F3 Check OK when Done
5. When calibration is complete, press F3. If the 90° limit switch drop out is between
87° and 95°, Calibrate OK displays. If this does not occur, a Calibration setting 120.1
not between 87 and 95°, please recalibrate diagnostic occurs and the Calibrate OK
run permissive goes False. This permissive has been added as a new auto run
permissive that only resets when a successful calibration has occurred.

• Axis 1 Calibrate
• F8 Home F7 Jog View
• Calibrate OK: 1
• 1=OK, 0=Needs redone

Handheld HMI GEH-6737D System Guide 23

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 ➢ To calibrate the Axis position
1. Plug the Exor handheld HMI into the Center box plug.
2. Verify that the E-Stop bypass button is out.
3. Switch the Auto/Manual switch to Manual.

Note If the handheld device is removed with the switch in Manual, the turbine safety
chain will open.

4. Navigate to the Jog View for the blade to be calibrated.

5. Jog the blade to the 0° position using the handheld HMI. Refer to the procedure, To
perform jogging.
6. Enable the absolute encoder calibrate button by unscrewing the cover and pressing
the Encoder Calibrate to zero the absolute encoder.
7. Navigate to the Calibrate View page. The screen displays the following:

• F8 Home
• F7 Jog View
• F1 Axis 1 Cal View
• F2 Axis 2 Cal View
• F3 Axis 3 Cal View
8. Navigate to the Cal View for the blade to be calibrated by pressing F1, F2 or F3.
The follow page displays:

• F8 Home
• F7 Jog View
• F1 Calibrate
• F2 Calibrate Abort
9. Press the deadman switch of the handheld HMI and hold it during calibration.
10. Press F1 to initiate calibration. The blade is moved by the calibration logic until it
reaches the 90° limit switch. It then changes directions, and moves until the limit
switch drops out. When the limit drops out, the calibration logic records the precise
angle at which it drops out, and saves it to flash memory.

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3.5 Alternate Energy Pitch Center (AEPC) IP Address
Configuration
The Alternative Energy Pitch Center (AEPC) IP address must be properly set to allow for
connection to the farm and tower network, and connection to diagnostic tools.

➢ To set the AEPC IP address

1. Plug the Exor handheld HMI device into the Center box plug.

Select F1.

Enter the IP address in the

brackets, next to EN0.

If this mini-op screen

displays, do not enter the
IP address in this screen.

2. Press F3 to save.

3.6 Powering Off the Handheld HMI

Before leaving the hub, perform the following:

• Unplug the handheld HMI and secure the cover over the plug.
• Switch the Manual/Auto switch to the Auto position.
• Switch off the lights.
• Make sure the power connectors are in operational mode to run from ac power.

Handheld HMI GEH-6737D System Guide 25

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Notes

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4 Center Box (Power Distribution)
The Center box channels power, control, and position references to each Axis box,
including the main ac disconnect, the transformer primary fuses, the auxiliary power
circuit breakers, and the AEPC. Blade position references and position feedbacks are sent
between the BPPx processor board and the turbine controller over an RS-422 serial link.
The received position reference is then sent to each Axis box over Ethernet.
The Center box also contains the E-Stop button, the Auto/Manual selector switch, the hub
master light switch, and the 120 V ac power outlet. The Auto/Man selector switch toggles
between Auto mode and Manual mode. In Auto mode, position commands are sent from
the turbine controller. In Manual mode, position commands are sent from a handheld
HMI.

Center Box Inside Hub

Center Box (Power Distribution) GEH-6737D System Guide 27

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 Typical Center Box Layout

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4.1 AEPC Module
The AEPC module is located in the Center box and provides the following:

• 24 V dc power distribution to the three Axis boxes

• Fan-out and optical isolation of several discrete inputs to the three Axis boxes,
including:
− Signals from the turbine controller across the slip rings
− Auto/Manual selector switch
− Handheld HMI
− Surge protection monitor
• Fan-out of position commands received through RS-422 serial communication from
the turbine controller to the three Axis boxes over Ethernet
• Center box temperature monitoring to the Axis 1 controller through an on-board
thermistor
• 120 V ac power distribution for hub lighting

Center Box (Power Distribution) GEH-6737D System Guide 29

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The IS215AEPC is replaced as
a single module (AEPC and
BPPx processor board). Refer
to the section, Replacing an
AEPC.
30 GEH-6737D
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AEPCH1A/H1D Functional Block Diagram
4.1.1 Compatibility
The AEPC module has two versions and includes a compatible BPPx processor boards, as
listed in the following table.
Version Description
IS215AEPCH1A BPPB processor board
IS215AEPCH1D BPPC† processor board
† Supported with ControlST* software suite V04.06 and higher
1.5 MW Wind Turbines 20 Nm Non-ESS Pitch Control
 4.1.2 AEPC Connectors
24 V dc power input provides 24 V dc for the pitch system control power from the Top
box.

Note The IS215AEPC power is first distributed to the axis boxes. From Axis 1
IS215AEPA, 24 V dc then returns to the IS215AEPC controller. The PCS will not start up
until the control system boxes are at an appropriate temperature.

TB1 Connectors (To and From Slip Rings)

Pin # Description
1 24 V dc power input
2 24 V dc return (grounded at source)
3 Safety loop supply
4 Main contactor ON
5 Break battery run
6 Hub safety loop
7 Bypass limit switch
8 Battery maintenance switch
9 Positive side of Ethernet differential transmit signal
10 Negative side of Ethernet differential transmit signal
11 Positive side of Ethernet differential receive signal
12 Negative side of Ethernet differential receive signal

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4.2 Startup and Heater Control
When the system is in To avoid frost or condensation on the electronics, the system regulates the internal box
maintenance mode, it can be temperatures between 5 to 10°C (41 to 50 °F) during cold weather conditions. When the
operated using the handheld system is started, it operates if the temperatures inside the Center box, the three Axis
HMI, regardless of internal boxes, and the three Battery boxes are above 10°C (50 °F). If the temperature inside the
box temperatures. boxes is below 10°C (50 °F), the heaters in each box switch on and the system becomes
operational when the temperature inside all boxes reaches 10°C (50 °F).

4.3 Top Box Assembly Inputs

Safety loop supply is a hard-wired input from the Top box, which contains E-Stop
push-buttons and safety-related interlocks throughout the tower. Dropping out the safety
loop input causes the blades to emergency pitch to 90º on battery power. These inputs can
be seen in the diagnostic software, labeled as SafetyLoop_A1, SafetyLoop_A2, and
SafetyLoop_A3.
Main contactor on (Mains on) is a contact input from the Top box that closes to pick up
the dc power contactor to the pitch motor controller. It opens to initiate an emergency
pitch, causes the pitch motor converter to disable, and the dc pitch motor to run on battery
power until the blade runs to the 90° limit switch.
Break battery run (battery maintenance switch), causes the pitch operation from the
batteries to disable, if set to True. If the safety loop is open, battery operation continues.
Hub safety loop is an output from the pitch controller of its E-Stop push-buttons to the
Top box safety relay string.
Bypass limit switch causes the limit switch inputs for 0 and 90° to be ignored.
Battery maintenance switch sends a feedback signal from the pitch control to the wind
turbine generator (WTG) control when any of the axis batteries are disconnected.

TB2 Connectors (To and From Slip Rings)

Pin # Description
13 Positive side of RS-422 differential receive signal

14 Negative side of RS-422 differential receive signal

15 Positive side of RS-422 differential transmit signal

16 Negative side of RS-422 differential transmit signal

17 Cable shield
18 Switched P24 V dc (500 mA maximun)

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 J2/3/4 Connectors (To Axis -1/2/3 J1)

Pin # Description
1 Fused 24 V dc supply to AEPA

2 P24 return/GND (signal common)

3 ID Input 0

4 ID Input 1

5 Safety loop supply from SR to battery

6 Mains contactor ON
7 Break battery run

8 Bypass limit switch

9 Surge auxiliary

10 Fused /P24 source for battery main. Switch +

11 Battery main. Switch -

12 Deadman switch +
13 Deadman switch -
14 Auto/Manual switch +
15 Auto/Manual switch -
16 Not used
17 24 V dc switched source (1500 mA maximun)

18 24 V switched GND

J5 Connectors (To Axis-1 J2)

Pin # Description
1 Thermistor +
2 Thermistor -
3 Not used

J9 Connectors (To 110/220 V AC Source)

Pin # Description
1 AC power source for lights

2 No connect, used to space active signals for creep clearance

3 AC power source return for lights

J10/11/12 Connectors (To Axis 1/2/3 Lights)

Pin # Description
1 AC power supply to lights (150 W maximum)

2 No connect – used to space active signals for creep clearance

3 AC power supply return to lights

Center Box (Power Distribution) GEH-6737D System Guide 33

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 J6 Connectors (To E-Stop / Surge Auxiliary / Handheld HMI)

Pin # Description
1 24 V dc source for E-Stop +

2 E-Stop return

3 24 V dc 100 mA supply to E-Stop/surge auxiliary

4 Surge auxiliary

5 Source to E-Stop 1

6 ESTOP 1 return
7 Source to E-Stop 2

8 E-Stop 2 return (return of string to SR)

9 24 V supply to DM right

10 DM right return

11 24 V supply to DM left

12 DM left return
13 Auto/Manual switch +
14 Auto/Manual switch n
15 Not used

J7 Connectors (To Ethernet Switch)

Pin # Description
1 24 V dc, 250 mA switched supply

2 24 V switched return/common

J8 Connectors (To handheld HMI)

Pin # Description
1 24 V dc, 250 mA switched supply

2 24 V switched return/common

J14 Connectors (To Device)

Pin # Description
1 24 V dc, 250 mA supply

2 24 V return/common

J13 RJ-45 Connector (To Ethernet Switch)

Pin # RJ-45 Ethernet Port

1 Positive side of Ethernet differential transmit pair

2 Negative side of Ethernet differential transmit pair

3 Positive side of Ethernet differential receive pair

4, 5, 7, 8 Not used
6 Negative side of Ethernet differential receive pair

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 4.3.1 Slip Ring to Hub Point-to-point Terminations
Terminal Board Wire Code Slip Ring Wire Description
400 Main Supply
Q2-L1 1 L1 400 V ac Phase 1
Q2-L2 3 L2 400 V ac Phase 2
Q2-L3 5 L3 400 V ac Phase 3
X3.CB.1-25 25 N 400 V ac neutral
PE stud STUD PE Protected earth
400 Heater Supply
X3.CB.4-3 1L1 1L1 Heater Phase 1
X3.CB.4-5 1L2 1L2 Heater Phase 2
X3.CB.4-7 1L3 1L3 Heater Phase 3
X3.CB.4-9 1N 1N Heater neutral
X3.CB.4-1 1PE 1PE Protected earth
24 V dc/ 120 V ac Supply and Signals
X3.CB.4-11 1 1 UPS 120 V ac
X3.CB.4.13 2 2 UPS neutral
CB7-1 3 3 120/230 V L1
X6.CB.1-9 4 4 120/230 V N
AEPC TB1-1 5 5 24 V dc
AEPC TB1-3 6 6 Safety chain loop input to hub
AEPC TB1-2 7 7 0 V dc
AEPC TB1-4 8 8 Mains on contactor input
AEPC TB1-5 9 9 Break battery run input
AEPC TB1-6 10 10 Safety chain out
AEPC TB1-7 11 11 Bypass limit switch
AEPC TB1-8 12 12 Battery maintenance switch
X3.CB.4.15 13 13 Spare
Communications

AEPC TB1-11 14 WHT-1 14 Ethernet TX + (Top box)

AEPC TB1-12 15 BLK-1 15 Ethernet TX - (Top box)
N.C. 16 SHD-1 16 TX Shield, No connect
AEPC TB1-9 17 WHT-2 17 Ethernet RX + (Top box)
AEPC TB1-10 18 BLK-2 18 Ethernet RX - (Top box)
N.C. 19 SHD-2 19 RX Shield, No connect
AEPC TB2-13 20 WHT-3 20 RS-422 RX+ (Bachmann)
AEPC TB2-14 21 BLB-3 21 RS-422 RX- (Bachmann)
AEPC TB2-17 22 SHD-3 22 Shield (Umbrella)
AEPC TB2-15 23 WHT-4 23 RS-422 TX+ (Bachmann)
AEPC TB2-16 24 BLK-4 24 RS-422 TX- (Bachmann)
AEPC TB2-17 25 SHD-4 25 Shield (Umbrella)

Center Box (Power Distribution) GEH-6737D System Guide 35

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Notes

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5 Axis Box
The Axis box contains an application board (AEPA), a 3-phase transformer (three
single-phase toroidal transformers), a 3-phase rectifier, power converter, and dc
contactors. The AEPA accepts position references received by the AEPC from the turbine
controller, and converts the position reference to a torque reference that is sent to the
power converter. The main 400 V ac power is converted to approximately 63 V ac, and
then rectified to supply the Pitch power converter with 80 V dc. The Pitch power
converter controls the dc motor.

Typical Axis and Battery Boxes Layout

Axis Box GEH-6737D System Guide 37

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5.1 AEPA Module
Refer to Mark VIe Control
Renewable Energy Distributed
I/O Modules (GEH-6779).
Refer to the section, Replacing
an AEPA.
5.2 Pitch Motor Power Converter
38 GEH-6737D
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The AEPA is a special-purpose I/O module that controls the pitch of a wind turbine blade
through a series-wound dc motor. The IS215AEPA is replaced as a single module (AEPA
module and BPPx processor board). The ToolboxST application includes an AEPA
HTML help file.
5.1.1 Compatibility
The AEPA module has two versions and includes a compatible BPPx processor boards, as
listed in the following table.
Version Description
AEPAH1A BPPB processor board
AEPAH1C BPPC† processor board
† Supported with ControlST* software suite V04.06 and later
The Pitch Motor Power Converter supplies the power to the pitch motor by pulse-width
modulating (PWM) the dc voltage to regulate dc motor current. The AEPA supplies a
hard-wired output Enable signal and a 4-20 mA current reference to the motor controller.
The RS-485 link sends converter feedbacks and diagnostics from the converter to the
AEPA. The Pitch Motor Power Converter provides the AEPA with a hard-wired Enable
Acknowledge signal.
Do not service the Pitch Motor Power Converter. If
a problem occurs, replace the entire component.
Attention
1.5 MW Wind Turbines 20 Nm Non-ESS Pitch Control
 Pitch Motor Power Converter

Axis Box GEH-6737D System Guide 39

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Notes

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6 Battery Box
Refer to the section, Handheld
HMI.
The Battery box, which supplies 48 V dc power during emergency and manual blade
pitching, is paired with an Axis box. It contains four 12 V dc lead-acid, dry-type batteries.
A handheld HMI plugged into the Center box port allows manual pitching during hub and
blade installation
The 48 V dc battery power is used to pitch the blade under emergency feathering
conditions. Hardware logic on the AEPA is used to switch motor control from the power
converter to the batteries during emergency feathering, giving the system the ability to
pitch the blades to a safe position regardless of grid condition.
The Axis and Battery boxes are referenced by their orientation to the Center box cabling.
The Center box contains harness wires to each Axis box. There is also I/O wiring to DI0
and DI1, which identifies the #1 (AEPA-21), #2 (AEPA-22), and #3 (AEPA-23) Axis
boxes to both the software and network.

Battery Box GEH-6737D System Guide 41

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6.1 Battery Charger
The ToolboxST Watch Window
feature can be used to view
diagnostics on the battery
charger. Refer to the section,
Watch Window.
42 GEH-6737D
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The current and voltage for each 12 V battery is monitored by its dedicated charger
module, 151X1225EK01PC03. Each charger module charges at approximately 12.5-15 V
dc during normal operation, but with current limited to 2 A dc. When in a current limited
charging mode, the charger output voltage is automatically reduced. Each battery charger
communicates diagnostics through an RS-485 serial network to the AEPA module.
Connector PL2 has hard-wired jumpers that define each charger’s unique drop (node)
number.
Battery Charger Module LEDs
Color Indicates
Green Power on
Yellow Battery is charged above 80% capacity
Red Fault
Not lit No power to charger, or a broken module
The battery charger will not charge if the battery voltage is less than 8.5 V dc or greater
than 15.5 V dc. The charger is designed to recharge the batteries in one hour after three
battery-powered emergency pitches occur in a 30 to 40-minute window.
1.5 MW Wind Turbines 20 Nm Non-ESS Pitch Control
 6.1.1 Battery Charger Automatic Self-Test
The AEPA battery conducts a self-test every 30 minutes. This test connects a load resistor
(mounted on the charger module) briefly across the battery and measures the battery
discharge response. The typical cycle time for this test is 35 to 40 seconds. The following
figure displays an example of this operation (Variable Pitch01mode_A1 =).

Battery Charger Automatic Test Trend Chart

Battery Box GEH-6737D System Guide 43

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 Pitch01C1mode_A1

Code Description
1 Battery charger regulating charging current

2 Battery charger regulating charging voltage

3 Float mode, trickle charges battery

4 Charger is running load test

5 Faulted, refer to the status code, ChargeStatsCx, by selecting the

Diagnostic tab in the ToolboxST application

Pitch01C1mode_A1

Code Description
Pitch01 Pitch control in tower 01
C1 Charger #1

Mode Signal name

_A1 Pitch Axis #1

Pitch01C1LoadTest_A1

Code Description
1 Executing load test

2 Normal operation

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 6.1.2 Battery Test
The PLC runs a battery test every 400 hours. This test adjusts the pitch of all three Axis to
85º and then to 90º. Individually, each blade position is set at 0°. This is the only time that
the blades operate asymmetrically. The Mains on input is dropped out and the Axis
emergency pitches on battery power to the 90º limit switch. The PLC measures the
position angle change against the time. This procedure is repeated independently, once for
each Axis. The following figure displays the behavior of this normal operation.

Battery Test Trend Chart

Battery Box GEH-6737D System Guide 45

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Notes

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7 Pitch Motor
The hub contains three series-wound dc pitch motors, one for each blade. A pinion gear is
mounted to the output end of the drive gear. The pinion gear meshes with the
blade-bearing slew gear. Proper programming of the gear ratio used with the pitch
controller is critical.
The motors are driven by the pitch power converters located in the Axis boxes. An
incremental encoder mounted inside the pitch motor is wired to the AEPA to determine
motor speed and blade position.
The motor leads are labeled A1 and A2 for the armature circuit. Series field leads are
labeled S1 and S2. The incremental encoder has its own connector, with leads wired per
the encoder instruction sheet.

Motor Accessory Connector Pinout

Pitch Motor GEH-6737D System Guide 47

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7.1 Pitch Motor Brake
Each pitch motor is equipped with an electric dc solenoid brake, which is released when
voltage is applied. During normal operation, the brake release command is sent by the
turbine controller. The brake voltage is driven by the AEPA, which applies 60 V dc for
150 ms to quickly force magnetization of the coil. It regulates to 40 V dc for 5 seconds to
ensure pickup before reducing to a holding voltage of 20 V dc. When the motor operates
under battery power during emergency feathering, the brake is picked up directly off the
batteries and released when the 90° limit switch is reached.

Pitch Motor Brake Voltage Regulator

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8 Working with the ToolboxST
Application
The ToolboxST application
provides a single source of
quality, time-coherent data at
the controller and plant level
for effectively managing
equipment assets.
The ToolboxST* application is used to configure the Wind Pitch control system and
provides diagnostic tools. No license key is required to install this product, but, to run the
ToolboxST application after installation, a valid hardware key plugged into any Universal
Serial Bus (USB) port is required. Refer to the ToolboxST User Guide for Mark Controls
Platform (GEH-6700) the section, Licensing.

8.1 Display Diagnostic Information

➢ To display diagnostic information
1. From the System Editor File menu, select Open System. The Open dialog box
displays.
2. Select the system .tcw file and click Open. The system displays in the System
Editor.

Working with the ToolboxST Application GEH-6737D System Guide 49

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 From the Summary View,
double-click the component.

Note For Pitch control, the redundancy is simplex, and the frame rate is 20 ms.

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The AEPC is the master
controller. Network Adapter 0
refers to the AEPC network
settings. Network Adapters 1, 2,
and 3 refer to the AEPA network
settings that are automatically
set based on the AEPC setting .

Network settings for remote workstations, laptops and Recorder computers should be set
for an IP address corresponding to the control network, such as 192.168.4.xxx. The IP
address must be different from all other network devices.
For local tower connections, the Ethernet connection should be made at the Ethernet
switch in the Top box. Connection can be made inside the hub by removing the Center
box cover and connecting to the Ethernet switch.

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The Hardware tab
displays each axis
controller as an
I/O block.

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 The Summary View displays a graphical overview
for organizing the details of each axis controller
.

From the Tree

View, select an
AEPA module
to edit the
configuration.

Working with the ToolboxST Application GEH-6737D System Guide 53

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 The Software tab displays specific AEPC variable scaling
and conditioning for signals passed to the turbine controller
.
These settings cannot be modified.

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 From the Component Editor , select the Dynamic Data Recorderstab.

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 The EGD tab displays definitions of all EGD signals passed from
each AEPA to Ethernet . These definitions cannot be modified .

Click Go Online /Offline to go online with the Pitch controller.

From the
Hardware tab
Tree View, select
an AEPA module
to display the
Summary values.

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 The Variables tab displays analog values(green) for the selected module.

The Analog/Digital Inputs tabs display live I/O values (green) for the selected module.

Working with the ToolboxST Application GEH-6737D System Guide 57

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 The Diagrams tab displays signal flow for the selected module.

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 The Diagnostics tab displays sequence status, faults, and alarms for the selected module.

Working with the ToolboxST Application GEH-6737D System Guide 59

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8.2 Watch Window
Refer to the ToolboxST User
Guide for Mark VIe Controls
Platform (GEH-6700), Chapter
6, the section, Watch Window.
60 GEH-6737D
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A Watch Window displays a collection of variables, their attributes, and live values, in a
stand-alone window. The Watch Windows feature can also be accessed from the
ToolboxST System Editor, as well as from the individual Component Editors. Once a
Watch Window is created, it can be exported to .xml and .csv files.
➢ To add a Watch Window
1. From the View Menu, select Watch Windows.
2. From the Watch Windows dialog box, click Add.
3. The Add Watch Window dialog box opens. Enter a name and click OK.
4. When the new Watch Window opens, place the cursor in the blank area and
right-click to select variables.
5. Select all variables (for example, Bat, Battery, or Charger) in the description, then
click OK.
1.5 MW Wind Turbines 20 Nm Non-ESS Pitch Control
8.3 Signal Trending
The Trender contains
diagnostic features. Refer to
the Trender for the ToolboxST
Application Instruction Guide
(GEI-100795), the section,
Data Resources.
Working with the ToolboxST Application
GE Internal
When an event is intermittent, or requires specific environmental conditions to reproduce
the event, a live trend can capture data to help understand the event better.
8.3.1 Operations Trends
The Trender window displays normal operation of the control. The Graph View displays
traces for the selected values. The Auxiliary View displays Variable information. The
Pitch angle reference is received from the PLC, with the feedback following the
reference. The torque reference is generated with the AEPA speed regulator, and this
value's analog outputs to the pitch motor controller. The trend displays that the converter
dc contactor is closed while the battery dc contactor is open, as the Pitch motor converter
is controlling the pitch motor. As long as the mains on input and safety loop input remain
closed, operation continues this way. If either of these inputs open, the axis pitches on
battery power. The pitch motor brake is directed to pick up and drop out by the PLC. The
AEPA controls the actual brake voltage. The brake is forced on to provide for a faster
pickup time, then reduces to approximately 20 V dc for steady state operation.
Normal Operation of Pitch Control Trend
GEH-6737D System Guide 61
 From the View menu,
select Trenders to add
a new trend and upload
the Capture Buffer.

Stacked Trend Example

If a PCS trips, begin troubleshooting by trending the Axis angle feedbacks, Axis torques,
and the signals. Refer to Mark VIe Control Mark VIe Control Renewable Energy
Distributed I/O Modules (GEH-6779), the section, Diagnostic Alarms for specific trip
alarm descriptions and solutions.

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8.4 Parameters
Each AEPA has individual parameters. During assembly and commissioning, these
parameters are tested and preset for normal operation.

Note You must build and download the controller configuration to modify parameters.
Refer to the section, Building and Downloading Configuration.

➢ To modify parameters

From the Hardware tab Tree View, select an AEPA module, then select the
Parameters tab to display the parameters for the selected module.

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 8.4.1 Gear Ratio Parameter Valid Settings
Blade type and size, bearing torque, and other manufacturing considerations vary
according to gearbox types and sizes. When a motor gearbox is replaced, the gear ratio
may need to be modified.

Gear Ratio
Gearbox Vendor Gearbox Nameplate Parameter Value
SMEI 106.56 987.456
SMEI 133.47 1236.822
Bosch Rexroth™ 105.6 978.56
Nanjing 110.001 1019.3426
Zollern™ 108.3 1003.58
Liebherr™ 105.45 977.17

Changing the gear ratio parameter automatically calculates the scaling of blade rpm and
position, pitch speed regulator gains, reflected inertia, and delivered pitch torque. The
blade rpm equates to the pitch motor rpm by the gear ratio:
Blade rpm = pitch motor rpm/gear ratio
Gear ratio = motor gearbox ratio

Note Blade bearing slew gear teeth = 139, pinion gear teeth = 15

➢ To view gear ratio parameters

From the Device menu ,

select Upload to verify the
current versions of the
parameters .

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Working with the ToolboxST Application GEH-6737D System Guide 65
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8.5 Building and Downloading Configuration
The Build command performs error checking, and calculates internal limits based on
higher level parameters. The Download command allows you to load parameters, as well
as upgrade AEPA and AEPC firmware revisions, setup, and data recorders

Note All errors must be resolved before performing a download command.

➢ To perform a build and download

From the Component Editor

toolbar, click Build.

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 From the toolbar, click Build.

Working with the ToolboxST Application GEH-6737D System Guide 67

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Notes

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9 Maintenance
9.1 Recommended Annual Maintenance
Replacement fuses are listed in
the table, Fuse Replacement.
Maintenance
GE Internal
This section provides the following maintenance procedures:
• Recommended Annual Maintenance
• Dc Motor Brush Replacement
Perform the following recommended maintenance annually:
• Conduct a visual inspection of general condition. Check carbon brushes for wear, and
clean or replace if the brush spring is below the specified minimum distance. The
actual dimension must be recorded in the Maintenance and Inspection Proof.
• Conduct a function test of the auxiliary fans.
• Conduct a visual inspection of the Axis cabinets, their attachments, fuses, and their
bolted connections. Re-tighten bolted connections with specified tightening torque.
• Conduct a visual inspection of tightness, attachment of all components, terminal
grease, bolts of the battery contacts, and cable clamping. Check terminals for secure
attachment and for spark marks.
GEH-6737D System Guide 69
 9.1.1 Fuse Replacement
The following table lists replacement fuses for the PCS.

Part Number Quantity Description 3

Center Box (151X1225HA01SA01Rxx xx=revision #)

151X1225DG01PC02
323A2396P59
1.5 MW Pitch Axis-Battery Assembly (151X1225CA01SA01Rxx xx=revision #)
Axis Box
151X1225HG02PC02
151X1225DG05PC02
Battery Box
151X1225HG04PC02
151X1225DG05PC02
342A4908ABP22
9 20 A, 600 V ac, Class J time-delay
fuse
3 4 A, 250 V ac time-delay fuse
3 60 A, 600 V ac, Class J fast-acting
fuse
2 5 A, 600 V ac fast-acting fuse
1 80 A, 125 V dc forklift truck fuse
1 5 A, 600 V ac fast-acting fuse
1 .315A A, 250 V dc fuse Littelfuse
FA1, FA2, FA3 Mersen™ AJT20
AEPC-FU1, AEPC-FU2, AEPC-FU3
F1A, F1B, F1C Mersen A4J60
F2, F3 Mersen ATM5
F1 Mersen ACK80
F2 Mersen ATM5
Battery charger FU3 Wickmann™ 0315
195; Schurter™ 34.3112; Littelfuse™
2183.15

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9.2 DC Motor Brush Replacement

To prevent personal injury or damage to equipment,

follow all GE safety procedures, LOTO, and site
safety procedures as indicated by EHS.
Warning

➢ To replace the brushes on a pitch motor

1. Verify that the power to the motor is turned off and disconnected, and the motor is
cool to the touch.
2. Remove the bolt holding the cover band, and fully remove the cover band.

3. Loosen the bolt that fastens the brush lead to the brush mechanism.

Do not fully remove this bolt; just loosen it enough

to slide the brush lead from under the screw.

Caution

Note Repeat steps 3 through 6 for all brushes.

4. Using a pair of needle-nose pliers, pull the brush spring back. Pull the brush straight
out by gently pulling on the brush lead. Gently let the spring move back to its
position.

Maintenance GEH-6737D System Guide 71

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 To prevent damage to the spring, do not allow the
brush spring to snap back into place.

Caution

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 5. Using a pair of needle-nose pliers, pull the brush spring back and put the new brush
in with the lead facing the rear of the motor. Push on it by hand to verify that it is
fully seated on the commutator. Gently let the spring rest on the back of the brush.

6. Place the brush lead back under the bolt. While holding it in place, tighten the bolt to
the specified torque. Verify that the brush lead is in the correct position (refer to the
following figure).

It is very important that the brush lead not be

kinked, and is completely out of reach of the brush
spring.
Attention

Maintenance GEH-6737D System Guide 73

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 7. Replace the cover band by lining up the cutouts with the terminals. Verify that it is
seated firmly against the end-shield.

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 8. While holding the cover band in place, replace the bolt and tighten it to the specified
torque.

Maintenance GEH-6737D System Guide 75

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Notes

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10 Troubleshooting
10.1 Handheld HMI Jogging
Potential jogging problems to troubleshoot while the hub is on the ground or mounted to
the turbine, include the following:

• Deadman switch
• Safety loop
• Mains-on
• Auto/Manual switch not in Manual position
• Brake loss
• Tachometer loss

➢ To troubleshoot if jogging does not work: from the Component Editor

screen, select the Hardware tab.

Select the Diagrams tab.

From the Tree View,
View AutoRunMode if operating in automatic mode.
select an Axis box.
View ManualRunMode if performing a jog.

Note When cycling system power, unplug the handheld HMI. When the system has been
repowered and is operational, plug the handheld HMI back in.

Troubleshooting GEH-6737D System Guide 77

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 ➢ To troubleshoot the handheld HMI when plugged into the Axis box 1
1. Unplug the handheld HMI and plug it back in.

Note The handheld HMI power-on cycle is faster than the controller. If it is plugged in
when power is turned on, the handheld HMI tries to communicate with the control
immediately. If the control has not finished starting up, the handheld HMI displays a
misleading error message that the URL does not work.

2. Ensure that the turbine generator network and components are completely wired and
powered on.
3. Check the handheld HMI on a different system, or a different handheld HMI on the
same system, to determine if the system or the handheld HMI is the problem.
4. Verify power to the system from the Top box, or the proper setting of the
maintenance position plug and disconnect switches on the Battery boxes.

➢ To troubleshoot the handheld HMI if it displays the message Cannot link

to the file /start.htm

• Determine if the hub Down Tower handheld HMI is not configured.

• Check for Axis box 1 N-TRON® problems, loose Ethernet connections, or an AEPC
problem.
• Verify that the Axis box 1 in powered on.
• Ensure that the new handheld HMI is configured properly.

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 ➢ To configure the handheld HMI
1. Enter the configuration mode on the handheld HMI and press and hold the return key
for 2 to 3 seconds until the following screen displays:

• PGS ALM EVT PSW CFG

• TIM ACC SYS EXT
2. Using the left cursor key, navigate to PGS ALM EVT PSW CFG, and select Enter.
The following screen displays

• UniOP 5.20P
• CONFIGURATION MODE
• IP: 192.168.1.100
• ETH: 0030D80108CF
• SN: 255.255.255.0
• GW: 192.168.1.8

Note If the screen does not display the above text, change the IP, SN, and GW to match
the above.

➢ To change the IP, SN, and GW: press the up and down cursor arrows
simultaneously to update the IP, SN, and GW addresses to match the settings. Refer
to the procedure, To configure the handheld HMI.

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 10.1.1 Jog Operation
Potential jogging problems to troubleshoot while the hub is on the ground, or mounted on
the turbine, include the following:

• Deadman switch
• Safety loop
• Auto/Manual switch not in Manual position
• Brake loss
• Tachometer loss
• Axis select switch
• Rotor assembly mode

➢ To troubleshoot if jogging does not work

1. From the Hardware tab, click the Diagrams tab.
2. To operate in automatic mode, view in AutoRunMode. To perform a jog, view in
ManualRunMode.
3. Select the Diagnostics tab to display faults. Red-flagged faults indicate an issue
that should be corrected.
4. Resolve any faults and perform jogging.

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10.2 Batteries and Charger Alarms
For information on changing
the battery charger module,
refer to the section, Replacing
a Battery Charger Module.
Troubleshooting
GE Internal
If the battery charger’s red LED is lit, it has a latched alarm. To reset and clear the battery
charger alarm, the 230 V power input needs cycled. To cycle the pitch heater and battery
charger power cycle (Top box, Q19A, Q19B, Q19C or DTA PDC auxiliary panel, Q13),
the charger connector P1 needs disconnected or the battery charger’s circuit board fuse
cover needs opened momentarily.
During first commissioning, a battery charger will fault due to a badly discharged battery.
A battery charger will not recharge a battery if its cutoff voltage is less than 8.5 V.
Therefore, remove and place the battery on a separate external charger.
A badly discharged battery will cause the charger to fault. While in the latched fault
condition on a severely depleted battery, the feedbacks can display zero battery volts and
current. Therefore, before replacing the charger, ensure that the battery voltage is present
and cycle the battery charger power.
If a charger is non-operational, check for 230 V ac power to PL3, and the condition of
fuse FU1 on the 151X1225EK01PC03R1. Inspect the battery surrounding area for loose
hardware and signs of arcing to case ground.
GEH-6737D System Guide 81
10.3 Diagnostic Alarms
AEPA Specific Alarms Refer to Mark VIe Control Renewable Energy Distributed
I/O Modules (GEH-6779), the section, AEPA Specific Alarms.

Common Module Alarms Refer to Mark VIe Control Renewable Energy Distributed
I/O Modules (GEH-6779), the section, Common Module Alarms.

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11 Replacement and Ordering
11.1 Handling Precautions
Replacement parts may contain static-sensitive components. Therefore, GE ships
replacement parts in anti-static bags. When handling electronics, make sure to store them
in anti-static bags or boxes and use a grounding strap (per the following Caution criteria).

To prevent component damage caused by static

electricity, treat all boards with static-sensitive
handling techniques. Wear a wrist grounding strap
when handling boards or components, but only after
boards or components have been removed from
Caution potentially energized equipment and are at a
normally grounded workstation.

To prevent personal injury or damage to equipment,

follow all GE safety procedures, Lockout Tagout
(LOTO), and site safety procedures as indicated by
Employee Health and Safety (EHS) guidelines.
Warning

This equipment contains a potential hazard of

electric shock, burn, or death. Only personnel who
are adequately trained and thoroughly familiar with
the equipment and the instructions should install,
Warning operate, or maintain this equipment.

11.2 Replacement Procedures

Troubleshooting should be done at the system component level. The failed system
component (least replaceable part) should be removed, returned to GE, and replaced with
a known good spare. Do not attempt to repair system components.

To prevent electric shock, turn off power to the

equipment, then test to verify that no power exists in
the board before touching it or any connected
circuits.
Warning

To prevent equipment damage, do not remove,

insert, or adjust board connections while power is
applied to the equipment.
Caution

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 Replacement of the terminal board requires full
reconfiguration of the changed component using the
ToolboxST application. For this reason, it is
generally preferable to replace only the I/O pack
unless the terminal board is known to be the point of
Attention failure.

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 11.2.1 Replacing an AEPC

Note Replacement of an IS215AEPCH1A with an IS215AEPCH1D may require an

upgrade to ControlST software suite V04.06 or higher. Refer to the section, Compatibility.

➢ To replace the AEPC

Do not upload the AEPC configuration to the

ToolboxST .tcw file. Always use the default settings
found in the system file to download.
Attention

Note The AEPC is replaced as a single module (AEPC and BPPx processor board).

1. Verify that the replacement AEPC module is compatible with the one being replaced
by comparing the model numbers on the module labels.
2. If replacing an IS215AEPCH1A with an IS215AEPCH1D, the ControlST software
suite must be version 4.06 or later. Verify the version and upgrade if needed. Refer to
the ControlST Upgrade Instruction Guide (GEI-100694).
3. If replacing an IS215AEPCH1A with an IS215AEPCH1D, upgrade the firmware
before physically replacing the hardware. Refer to the BPPC I/O Upgrade V05.01.05
Instruction Guide (GEI-100847).
4. Perform the lockout tagout (LOTO) procedure for all power sources, including 400 V
ac input, 24 V dc UPS power, and accessory power.
5. Unplug all connectors.
6. Remove the four AEPC mounting screws.
7. Remove the AEPC and install the new module.
8. Re-install all connectors and verify that all connector and cable terminations are
plugged back into the same location.
9. Reapply power to the 24 V dc control power.
10. From the handheld HMI, set the correct IP address. Refer to the procedure, To set the
AEPC IP address.
11. Turn off the 24 V dc control power and turn power back on to reset the AEPC.
12. If replacing an IS215AEPCH1A with an IS215AEPCH1D, change the hardware form
and download the application code.
13. From the ToolboxST application, download the configuration files into the AEPC.
a. From the System Editor, create a new or open an existing system file.

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 Specify a subnet mask of
255.255.252.0 for the
UDH network.

b. From the Tree View, insert a Mark VIe Controller.

Select the platform type of the

AEPC controller.
If the platform type is unknown,
enter the IP address of the
controller in the available field
and click Detect. The
ToolboxST application
communicates with the AEPC
controller to determine the
platform type.

c. From the Application drop-down menu, select the appropriate Pitch System
Application and Version. Click Next, then click Finish.
d. From the Summary View, double-click the component to open the device.
e. Perform a Build and Download the configuration to the device.
14. Turn off the 24 V dc power, then restart the system.

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Refer to the ControlST
Upgrade Instruction Guide
(GEI-100694).
If configuration problems
persist with a BPPC-based I/O
pack, refer to the BPPC I/O
Upgrade V05.01.05 Instruction
Guide (GEI-100847).
Replacement and Ordering
GE Internal
11.2.2 Replacing an AEPA
➢ To replace the AEPA
1. Verify that the replacement AEPA module is compatible with the one being replaced
by comparing the model numbers on the faceplates.
2. If replacing an AEPAH1A with a functionally compatible AEPAH1C, the ControlST
software suite must be of a version compatible with the new I/O module. Verify the
version and upgrade if needed. Refer to the BPPC I/O Upgrade V05.01.05
Instruction Guide (GEI-100847).
3. If replacing a AEPAH1A with a AEPAH1C, upgrade the firmware before physically
replacing the hardware. Refer to the BPPC I/O Upgrade V05.01.05 Instruction Guide
(GEI-100847).
4. Perform LOTO procedures for the field equipment and isolate the power source.
5. Turn off the power to the UPS that supplies 24 V to the PCS across the slip ring.
6. Remove the two screws in the middle of the board, keeping track of the screws.
7. Unplug the Ethernet cables and mark the positions of the cables to remove.
8. Unplug the various Mate-N-Lock® connections around the perimeter of the board.
9. Remove two of the mounting bolts and loosen two of the mounting nuts that hold the
plastic board carrier in place to slide the holder apart.
10. Loosen ground standoff and remove spade terminal.
11. Carefully remove the AEPA from the holder and install the new AEPA.
12. From the ToolboxST application, open the Pitch system (.tcw) file.
13. If replacing an AEPAH1A with a functionally compatible AEPAH1C, refer to the
BPPC I/O Upgrade V05.01.05 Instruction Guide (GEI-100847). for the steps to
change the hardware form and download the application code.
14. Click Download to open the Download Wizard and download the parameters for
the replacement AEPA. Refer to the section, Building and Downloading
Configuration.
15. If the new Pitch system configuration cannot be accessed, perform a Compare
Parameters on an existing AEPA to obtain the gear ratio parameter and apply it to the
replacement AEPA.
16. From the handheld HMI, verify the gear ratio entry and recalibrate the axis position.
Refer to the section, Gear Ratio Parameter and Axis Position Calibration.
GEH-6737D System Guide 87
 11.2.3 Replacing a Battery Charger Module
➢ To replace a battery charger module
1. Turn off all power sources (400 V ac, 230 V ac, and 24 V dc).
2. Verify that the Battery box disconnect switch is in the OFF position.

Even with all power disconnects open and external

voltage sources removed, the batteries may be fully
charged, each with a potential of 12 V dc. Ensure
that nothing comes in contact with the battery
terminals or shorts the battery terminals to ground
or the metal case. Place an insulating dielectric
Warning cover/blanket across the battery terminals, and
follow all rules for personal protection equipment
(PPE).

3. Remove connectors PL1, PL2, and PL3 to the battery charger.

Note Replace the battery charger board and battery holder as a single unit.

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11.3 Ordering
First 12 characters
of the part number
On the replacement part , the revision letter
will be the same or a higher letter.
The ML number is provided on
the data nameplate.
Replacement and Ordering
GE Internal
Prior to ordering a replacement part for a GE product, the following items should be
understood:
• How to accurately identify the part
• If the part is under warranty
• How to place the order
Note Renewals and spares (or those not under warranty) should be ordered by contacting
the nearest GE Sales or Service Office, or an authorized GE Sales Representative.
Control system electronics are identified by a 12-character alphanumeric part number and
a single revision letter.
Serial number
Example
When ordering, be sure to include the following items:
• Complete part number and description
• Serial number
• Material List (ML) number
When ordering, be sure to include the complete part number and revision letter. All digits
are important when ordering or replacing any device. The factory may substitute newer
versions based on availability and design enhancements, however, GE ensures backward
compatibility of replacements.
GEH-6737D System Guide 89
Notes

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GE Internal