Products and services for wind turbines

Electrical drivetrain solutions and

products for turbine subsystems
Profile

A changing wind market Choosing a quality partner

Demand for wind turbines continues to grow, driven by Using ABB products helps manufacturers demonstrate the
commitments to reduce CO2 emissions and to diversify into quality and reliability expected in the turbine design. ABBs
renewable energy sources. During 2009, the market for wind proven products for wind turbines are designed and built to
turbines saw some important changes that place additional operate for long life cycles in the variety of harsh operating
demands on turbine manufacturers: conditions common to turbines. ABB engineers with years
of wind power experience help design the products and
Raw material prices dropped work with turbine manufacturers to integrate these products
Competition increased correctly and efficiently into turbine designs.
Investment capital for large projects became more difficult
to obtain Another factor in demonstrating a quality design is the
availability of service for the products in the turbine. ABBs
This combination of factors requires that turbine global service network supports this factor, offering life
manufacturers more than ever need to ensure that their cycle services for the ABB products installed in a turbine.
products are worth the investment and have the quality, From regional service hubs to onsite support, ABB service
reliability, and long life cycles investors and wind power plant is tailored to turbine manufacturer or wind power plant
operators demand. operators unique needs. For example, implementing
ABB preventive maintenance programs for products like
switchgear, generators, motors and converters is a simple
and manageable way to maximize the turbine operational life
cycle, production, and reduce downtime.

2 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
Manufacturing quality Highlights
ABB designs global products that are manufactured to the ABB is a global company with more than 117,000
same exacting standards, following the same production employees in around 100 countries
processes, and using the same quality materials in its ABB has decades of experience in the wind industry,
production facilities. This enables ABB to conveniently serve starting in the mid 1970s
its customers with the same quality products regardless of ABB produces electrical drivetrain solutions for all of
where they were manufactured. todays turbine concepts
ABB products are used throughout a turbines subsystems
Find out more ABB is globally active in grid code specification working
This brochure provides an overview of ABBs products and groups
services for wind turbines. It provides information that can be Global manufacturing footprint
used when conducting drivetrain studies and proposes ABB Global products
product solutions for todays electrical drivetrain concepts. Global life cycle services
Contact ABB for more information on these products or for
more information on ABBs experience in the wind power
industry.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 3
Turbine systems

Turbines are comprised of many subsystems working Yaw and pitch systems
in unison so that the turbine efficiently and safely The yaw system orients the turbine by rotating the nacelle
produces power. ABB products are used throughout into the desired position. This system uses motors and gears
these subsystems, from the emergency stop button to for the rotation, and braking systems to retain the orientation.
the generator. The function of each subsystem is briefly The pitch system controls the orientation of the turbine blades
described here. in relation to the wind.

Electrical drivetrain Electrical protection and disconnect systems

This system is the main electrical production system of the The protection system ensures that the turbines electrical
turbine and is comprised primarily of the generator and subsystems are protected against unsafe conditions resulting
converter, as well as the stator contactor and breaker. from fault conditions, and isolates those failures from other
electrical systems in the turbine. The electrical disconnect
Grid connection system system exists to ensure that the turbines electrical system
This system is responsible for connecting power produced can be disconnected safely allowing for maintenance and
from an individual turbine to the wind power plants network other in-turbine work.
connection point (connection to the power collection system).
This includes the turbines transformer and switchgear Lightning protection system
components. This system protects the turbines electrical systems from
adverse effects caused by lightning strikes on the turbine.
Turbine control and protection system
This system is responsible for turbine control and operation, Hydraulic and cooling systems
including rotor speed, turbine orientation, startup and These systems are responsible for ensuring the flow of liquids
shutdown. The protection function guards against conditions and air used in the turbine. These may include liquid-cooling
such as over-speed, generator overload, and even excessive systems, heat-exchange systems, or braking systems.
vibrations.
Auxiliary systems
Auxiliary systems are any other system or subsystem within
the turbine that do not fall within one of the mentioned
systems

4 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
Turbine electrical drivetrain concepts

Todays concepts Engineering partner

For todays utility scale wind turbines there are two main Once the electrical drivetrain concept is selected, expert
electrical drivetrain concepts, doubly-fed and full converter. ABB engineers are available to work with the manufacturer
The primary difference in these concepts is the type and size to discuss and integrate ABB products into the turbine
of generator used and the function of the converter. The full engineering drawings, specifications, and plans. Turbine
converter concepts can be further categorized into three manufacturers are able to benefit from ABBs experience,
types, low-speed (also known as direct-drive), medium- resulting in design cost savings and increased efficiencies.
speed, and high-speed. ABB produces products for all of
these concepts. The following section provides a more detailed overview
of each of the electrical drivetrain concepts for use by
Full converter concepts are increasing market share manufacturers during their concept studies.
While the market has largely been dominated by the doubly-
fed concept, the full converter concepts are quickly gaining
market share. There are several factors driving this shift,
including grid code compliance and optimized power
generation at slower wind speeds.

Evaluating concepts
Each of the electrical drivetrain concepts results in different
turbine weights, sizes and maintenance needs. The selection
of the electrical drivetrain concept needs to be done carefully,
weighing all of the requirements of the turbine with the
needed certifications and grid code specifications that are
applicable once the turbine is installed.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 5
Electrical drivetrain concepts
Doubly-fed

Doubly-fed concept Advantages compared to constant speed turbines:

This concept uses a wound rotor, asynchronous generator Enables variable speed operation for increased kilowatt-
where the rotor windings are connected to a small converter hour production
using slip-rings and brushes. The generator feeds two-thirds Uses a small converter, one-third of the nominal power
of the nominal power from the directly connected stator Supplies reactive power for grid support
and the one-third from the rotor. The converter is used to High total system efficiency
control the generators speed and power factor, allowing a Is a technical and economical solution for grid code
wider speed range for power production as well as the ability compliance
to feed reactive power to support the grid. A small, partial
converter dimensioned to one-third of the nominal power can
be used because it enables a speed range of approximately
+/-30% of the nominal speed, which is sufficient for the wind
turbine application.

Power cabinet
Stator Stator circuit
contactor breaker

Gearbox

Brake Slip ring

Wind turbine converter
generator
(up to 2000 rpm) Grid
Generator- transformer
Grid-side
side Medium voltage
Pitch switchgear
Rotor bearing drive
Converter control Converter
contactor

Wind turbine
control

6 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
Electrical drivetrain concepts
Full converter

Full converter concept Advantages compared to the doubly-fed concept:

In the full converter concept, the converter decouples the Decouples the generator from the grid
generator and the mechanical drivetrain from the grid. All Reduces mechanical shocks on the turbine during grid
of the generated power flows through the converter to the faults
grid. Synchronous (permanent magnet) and asynchronous Increased grid code compliance
generators are typically used. The converter provides the Enables full speed range
generators torque and speed control. Increased annual power yield
Full reactive power production
There are three main full converter concepts: high-speed, Full control of the power
medium-speed, and low-speed which use different gearbox
and generator solutions.

Wind turbine converter

DC

Generator-
Grid-side
side

Grid
transformer
Integrated Medium voltage
gear or modular Converter control switchgear
system

Brake

PM generator Wind turbine

(up to 500 rpm) control
Rotor
bearing Pitch
drive

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 7
Electrical drivetrain concepts
Full converter

High-speed full converter concept Low-speed full converter concept

The high-speed full converter (HSFC) concept is mechanically The low-speed full converter (LSFC) concept, also known
similar to the doubly-fed type, using a normal three stage as the gearless direct-drive concept, uses a large diameter,
gear box and a small size, high-speed permanent magnet low-speed generator (up to 30 rpm). Permanent magnet or
generator (up to 2000 rpm). Asynchronous generators are separately excited synchronous generators are typically used.
also used.
Advantages:
Advantages: No gearbox
Lowest generator weight and smallest size
Can be used to upgrade existing doubly-fed designs

Gearbox

Brake SCIM or PM generator

(up to 2000 rpm)

Rotor bearing Brake

PM generator
(up to 30 rpm)
Medium-speed full converter concept
With the medium-speed full converter (MSFC) concept,
either a single or two stage gear box is used with a compact,
medium-speed permanent magnet generator (up to 500 rpm).

Advantages:
Lower speeds reduce mechanical stress
Low weight and size

Brake

PM generator
(up to 500 rpm)
Rotor
bearing

8 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
ABB products and services for wind turbines| Electrical drivetrain and turbine systems 9
ABB electrical drivetrain package
For doubly-fed concepts

ABBs offering for the doubly-fed concept includes High voltage insulation technology, small size, and a flexible
slip-ring generators and converters, for both onshore modular construction for easy integration in different turbine
and offshore wind turbines. The main circuit breaker designs is standard with ABB doubly-fed generators.
and contactors complete the ABB drivetrain offering.
This package provides a proven solution for turbine Up to 5 MW
manufacturers. 690 to 12,000 V
2.5 kV rotor insulation
Doubly-fed generators Power factor 0.9 inductive - 1 - 0.9 capacitive
ABB doubly-fed generators enable continuous production of Operational speed range 700 to 2000 rpm
reactive power and have high efficiency for maximized kilowatt Maximum over speed up to 3000 rpm
hour production, with low life time operational costs. Air or water cooling

The robust rotor design uses a special carbon fiber winding- Doubly-fed wind turbine converters
end support ring that can withstand sudden, uncontrolled ABBs doubly-fed converters synchronize the generator to
over speeds. The increased rotor insulation allows a wide the grid. They provide dynamic active and reactive power,
range of converters to be used. Minimized low total harmonic fault ride-through, and low voltage ride-through. Direct
distortion (THD) specifically on the 5th and 7th order, offers high torque control provides the speed and torque reference to
power quality. ABB has over 50 years of design experience in the generator, and monitors generator torque 40,000 times
making reliable slip-ring units. This experience is used for the a second. Liquid-cooled models offer completely enclosed
demanding wind power application. The optimized cooling cabinets for increased protection from harsh ambient
air flow and use of the correct brush materials, as well as conditions such as dust, salt, sand, and high humidity.
the expertise of the leading slip-ring manufactures results in
reliable operation. ABBs proven bearing-end shield insulation 0.85 to 3.8 MW
construction protects against harmful bearing currents. Direct torque control (DTC) for generator control
Active and reactive power control
Grid code support
IGBT power modules with integrated DC capacitors and
control electronics
Very low total harmonic distortion (THD)
Air or liquid-cooling
Liquid-cooled models have completely enclosed cabinets

10 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
 Power cabinet
Stator Stator circuit
contactor breaker

Gearbox

Brake Slip ring

Wind turbine converter
generator
(up to 2000 rpm) Grid
Generator- transformer
Grid-side
side Medium voltage
Pitch switchgear
Rotor bearing drive
Converter control Converter
contactor

Wind turbine
control

Coordinated breaker and contactor solutions ABB services

Both grid disturbances and normal turbine operation result in Implementing ABB services for generators and converters,
frequent connection and disconnection of the turbines power such as preventive maintenance, extends the life time of the
circuit. This repeated switching can cause transient over- product and helps ensure continuous, optimized kilowatt-
voltages and tripping which reduces kilowatt-hour production. hour production and reduces turbine downtime. These
The ABB solution is to use a coordinated breaker and services, which include spare part management, onsite
contactor solution with ABB breakers for protection and ABB service, refurbishment, and training, are available globally
contactors for switching. and support turbine manufacturers during turbine planning
and construction, as well as the wind power plant owner
Specific surge protective devices (SPD) or operator throughout the turbines life cycle. ABB service
Wind turbines are at a high risk for lightning strikes. Installing contracts are customizable, tailored to meet the needs of
surge protective devices in the electrical drivetrain increases manufacturers and operators.
the reliability of the turbine. ABB developed specific surge
protection solutions to protect all the equipment within Global products
the electrical drivetrain, including the generator, converter, ABB products, including the generators and converters, are
contactor and breaker. global products which are manufactured locally to the same
quality standards. This ensures that the high-volume, high-
quality products are available to meet customer expectations
and needs.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 11
ABB electrical drivetrain package
For high-speed full converter concepts

ABBs offering for high-speed full converter concepts 1 to 6 MW

includes permanent magnet and asynchronous generators 690 to 3300 V
and full power converters. The generators and converters Typical rated speed 1000 to 2000 rpm
are suitable for onshore or offshore turbines. Generator Proven fatigue-resistant magnet fastening
stator contactors and main circuit breakers complete the
ABB drivetrain offering. Wind turbine converters
Full power converters isolate the generator from the grid and
ABB permanent magnet generators provide the fault ride-through, low voltage ride-through, and
ABBs proven high voltage insulation technology and vacuum dynamic and flexible grid code support including active and
pressure impregnation system maximize the operational life reactive power control. ABB offers a selection of both low
time and enable a high momentary overload capacity. All of voltage and medium voltage wind turbine converters. The
the ABB generators offer maximum efficiency at all speeds, converters set and monitor the generators torque and speed
especially at low wind speeds with a robust design and low reference, and guard against sudden jolts caused by grid
maintenance. disturbances that would otherwise add mechanical stress on
the drivetrain. ABB full power converters are suitable for both
The extensive ABB permanent magnet generator design onshore and offshore turbines.
expertise and experience ensures:
Low voltage full power converters
The specific magnetic circuit design necessary for each of ABBs direct torque control (DTC) monitors the generators
the low, medium or high-speed concepts torque 40,000 times per second, enabling the most efficient
The selection of the right neodymium magnet properties generator control, providing the foundation for grid code and
available on the market for each individual case fault ride-through compliance. Liquid-cooling transfers the
Correct dimensioning and low operating temperature heat from the converter to outside the turbine and enables
prevents demagnetization, even during fault situations the cabinets to be completely enclosed, with no openings
Reliable fastening of the magnets, optimized for all the keeping salty, sandy, and dusty air out. Converters over 2 MW
different rated speeds, for low, medium, and mechanically offer a design option to use parallel connected sub-converters
demanding high-speed applications for increased efficiency and optimized turbine installation.
The expertise in serial production of low, medium and high-
speed concepts involving assemblies of strong magnets 0.8 to 6 MW
Liquid-cooled, fully enclosed cabinets
High-speed generators Air-cooled model up to 1 MW
ABBs high-speed permanent magnet generators provide high Grid-side contactor or breaker for safe connection and
power from the smallest frame size, with the highest efficiency disconnection
over the whole speed range. ABB asynchronous generators IGBT power modules with integrated DC capacitors and
can also be used in this high-speed concept. control electronics
Reduces torsional oscillations (active drivetrain dampening)
Very low total harmonic distortion (THD)

12 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
 Wind turbine converter

DC

Generator-
Grid-side
side

Grid
transformer
Medium voltage
Converter control switchgear
Gearbox

Brake SCIM or PM generator

(up to 2000 rpm)

Wind turbine
control
Rotor bearing Pitch
drive

Rotor positioning Coordinated breaker and contactor solutions

Motorized generator test run Both grid disturbances and normal turbine operation result in
Installable in the tower base or nacelle frequent connection and disconnection of the turbines power
circuit. To maximize kilowatt-hour production throughout the
Medium voltage full power converters life time of the turbine, ABBs solution is to use a coordinated
Designed for larger turbines, ABBs medium voltage full breaker and contactor solution with ABB breakers for
power converters use IGCT semiconductor technology protection and ABB contactors for switching.
which reduces the part count and results in very low
converter losses. The converters are designed for tower base Specific surge protective devices (SPD)
installation and enable low cost and efficient cable installation Wind turbines are at a high risk for lightning strikes. Installing
to the generator. The converters provide fault ride-through surge protective devices in the electrical drivetrain increases
and grid code compliance. the reliability of the turbine. ABB developed specific surge
protection solutions to protect all the equipment within
2.5 to 10 MW the electrical drivetrain, including the generator, converter,
3.3 kV, 4-quadrant, 3-level topology contactor and breaker.
Liquid-cooled power modules
IGCT technology ABB services
Harmonic elimination control algorithm Implementing ABB services for generators and converters,
High efficiency such as preventive maintenance, extends the life time of the
Integrated cooling unit product and helps ensure continuous, optimized kilowatt-hour
Integrated generator breaker production and reduces turbine downtime. These services,
Smaller and lighter cables which include spare part management, onsite service,
Installed in the tower base refurbishment, and training, are available globally and support
Rotor positioning turbine manufacturers during turbine planning and construction,
Motorized generator test run as well as the wind power plant owner or operator throughout
the turbines life cycle. ABB service contracts are customizable,
tailored to meet the needs of manufacturers and operators.

Global products
ABB products, including the generators and converters, are
global products which are manufactured locally to the same
quality standards. This ensures that the high-volume, high-
quality products are available to meet customer expectations
and needs.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 13
ABB electrical drivetrain package
For medium-speed full converter concepts

ABBs offering for medium-speed full converter concepts Wind turbine converters
includes permanent magnet generators and full power Full power converters isolate the generator from the grid and
converters. The generators and converters are suitable for provide the fault ride-through, low voltage ride-through, and
onshore or offshore turbines. Generator stator contactors dynamic and flexible grid code support including active and
and main circuit breakers complete the ABB drivetrain reactive power control. ABB offers a selection of both low
offering. voltage and medium voltage wind turbine converters. The
converters set and monitor the generators torque and speed
ABB permanent magnet generators reference, and guard against sudden jolts caused by grid
ABBs proven high voltage insulation technology and vacuum disturbances that would otherwise add mechanical stress on
pressure impregnation system maximize the operational life the drivetrain. ABB full power converters are suitable for both
time and enable a high momentary overload capacity. All of onshore and offshore turbines.
the ABB generators offer maximum efficiency at all speeds,
especially at low wind speeds with a robust design and low Low voltage full power converters
maintenance. ABBs direct torque control (DTC) monitors the generators
torque 40,000 times per second, enabling the most efficient
The extensive ABB permanent magnet generator design generator control, providing the foundation for grid code and
expertise and experience ensures: fault ride-through compliance. Liquid-cooling transfers the
heat from the converter to outside the turbine and enables
The specific magnetic circuit design necessary for each of the cabinets to be completely enclosed, with no openings
the low, medium or high-speed concepts keeping salty, sandy, and dusty air out. Converters over 2 MW
The selection of the right neodymium magnet properties offer a design option to use parallel connected sub-converters
available on the market for each individual case for increased efficiency and optimized turbine installation.
Correct dimensioning and low operating temperature
prevents demagnetization, even during fault situations 0.8 to 6 MW
Reliable fastening of the magnets, optimized for all the Liquid-cooled, fully enclosed cabinets
different rated speeds, for low, medium, and mechanically Air-cooled model up to 1 MW
demanding high-speed applications Grid-side contactor or breaker for safe connection and
The expertise in serial production of low, medium and high- disconnection
speed concepts involving assemblies of strong magnets IGBT power modules with integrated DC capacitors and
control electronics
Medium-speed generators Reduces torsional oscillations (active drivetrain dampening)
ABB medium-speed permanent magnet generators are Very low total harmonic distortion (THD)
integrated with the gearbox to provide a very compact design Rotor positioning
with the highest efficiency over the whole speed range. A Motorized generator test run
separate modular design is also available. Installable in the tower base or nacelle

1 to 6 MW
Typical rated speed 120 to 450 rpm
690 to 3300 V

14 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
 Wind turbine converter

DC

Generator- Grid-side
side

Grid
transformer
Integrated Medium voltage
gear or modular Converter control switchgear
system

Brake
PM generator Wind turbine
(up to 450 rpm) control
Rotor
bearing Pitch
drive

Medium voltage full power converters Coordinated breaker and contactor solutions
Designed for larger turbines, ABBs medium voltage full Both grid disturbances and normal turbine operation result in
power converters use IGCT semiconductor technology frequent connection and disconnection of the turbines power
which reduces the part count and results in very low circuit. To maximize kilowatt-hour production throughout the
converter losses. The converters are designed for tower base life time of the turbine, ABBs solution is to use a coordinated
installation and enable low cost and efficient cable installation breaker and contactor solution with ABB breakers for
to the generator. The converters provide fault ride-through protection and ABB contactors for switching.
and grid code compliance.
Specific surge protective devices (SPD)
2.5 to 10 MW Wind turbines are at a high risk for lightning strikes. Installing
3.3 kV, 4-quadrant, 3-level topology surge protective devices in the electrical drivetrain increases
Liquid-cooled power modules the reliability of the turbine. ABB developed specific surge
IGCT technology protection solutions to protect all the equipment within
Harmonic elimination control algorithm the electrical drivetrain, including the generator, converter,
High efficiency contactor and breaker.
Integrated cooling unit
Integrated generator breaker ABB services
Smaller and lighter cables Implementing ABB services for generators and converters,
Installed in the tower base such as preventive maintenance, extends the life time of the
Rotor positioning product and helps ensure continuous, optimized kilowatt-hour
Motorized generator test run production and reduces turbine downtime. These services,
which include spare part management, onsite service,
refurbishment, and training, are available globally and support
turbine manufacturers during turbine planning and construction,
as well as the wind power plant owner or operator throughout
the turbines life cycle. ABB service contracts are customizable,
tailored to meet the needs of manufacturers and operators.

Global products
ABB products, including the generators and converters, are
global products which are manufactured locally to the same
quality standards. This ensures that the high-volume, high-
quality products are available to meet customer expectations
and needs.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 15
ABB electrical drivetrain package
For low-speed full converter concepts

ABBs offering for low-speed full converter concepts 1.5 to 3 MW, higher powers are available
includes permanent magnet generators and full power Typical rated speed14 to 30 rpm
converters. The generators and converters are suitable for 690 to 3300 V
onshore or offshore turbines. Generator stator contactors
and main circuit breakers complete the ABB drivetrain Wind turbine converters
offering. Full power converters isolate the generator from the grid and
provide the fault ride-through, low voltage ride-through, and
ABB permanent magnet generators dynamic and flexible grid code support including active and
ABBs proven high voltage insulation technology and vacuum reactive power control. ABB offers a selection of both low
pressure impregnation system maximize the operational life voltage and medium voltage wind turbine converters. The
time and enable a high momentary overload capacity. All of converters set and monitor the generators torque and speed
the ABB generators offer maximum efficiency at all speeds, reference, and guard against sudden jolts caused by grid
especially at low wind speeds with a robust design and low disturbances that would otherwise add mechanical stress on
maintenance. the drivetrain. ABB full power converters are suitable for both
onshore and offshore turbines.
The extensive ABB permanent magnet generator design
expertise and experience ensures: Low voltage full power converters
ABBs direct torque control (DTC) monitors the generators
The specific magnetic circuit design necessary for each of torque 40,000 times per second, enabling the most efficient
the low, medium or high-speed concepts generator control, providing the foundation for grid code and
The selection of the right neodymium magnet properties fault ride-through compliance. Liquid-cooling transfers the
available on the market for each individual case heat from the converter to outside the turbine and enables
Correct dimensioning and low operating temperature the cabinets to be completely enclosed, with no openings
prevents demagnetization, even during fault situations keeping salty, sandy, and dusty air out. Converters over 2 MW
Reliable fastening of the magnets, optimized for all the offer a design option to use parallel connected sub-converters
different rated speeds, for low, medium, and mechanically for increased efficiency and optimized turbine installation.
demanding high-speed applications
The expertise in serial production of low, medium and high- 0.8 to 6 MW
speed concepts involving assemblies of strong magnets Liquid-cooled, fully enclosed cabinets
Air-cooled model up to 1 MW
Low-speed generators Grid-side contactor or breaker for safe connection and
ABB low-speed permanent magnet generators form a disconnection
structurally integrated unit with the wind turbine. Inner and IGBT power modules with integrated DC capacitors and
outer rotor designs are available. They enable the smallest low- control electronics
speed design with the highest efficiency in the whole speed Reduces torsional oscillations (active drivetrain dampening)
range. Very low total harmonic distortion (THD)

16 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
 Wind turbine converter

DC

Generator-
Grid-side
side

Grid
transformer
Medium voltage
Converter control switchgear

Wind turbine
control
Brake
Pitch
drive

PM generator
(up to 30 rpm)

Rotor positioning Rotor positioning

Motorized generator test run Motorized generator test run
Installable in the tower base or nacelle
Coordinated breaker and contactor solutions
Medium voltage full power converters Both grid disturbances and normal turbine operation result in
Designed for larger turbines, ABBs medium voltage full power frequent connection and disconnection of the turbines power
converters use IGCT semiconductor technology which reduces circuit. To maximize kilowatt-hour production throughout the
the part count and results in very low converter losses. The life time of the turbine, ABBs solution is to use a coordinated
converters are designed for tower base installation and enable breaker and contactor solution with ABB breakers for
low cost and efficient cable installation to the generator. The protection and ABB contactors for switching.
converters provide fault ride-through and grid code compliance.
Specific surge protective devices (SPD)
2.5 to 10 MW Wind turbines are at a high risk for lightning strikes. Installing
3.3 kV, 4-quadrant, 3-level topology surge protective devices in the electrical drivetrain increases
Liquid-cooled power modules the reliability of the turbine. ABB developed specific surge
IGCT technology protection solutions to protect all the equipment within
Harmonic elimination control algorithm the electrical drivetrain, including the generator, converter,
High efficiency contactor and breaker.
Integrated cooling unit
Integrated generator breaker ABB services
Smaller and lighter cables Implementing ABB services for generators and converters,
Installed in the tower base such as preventive maintenance, extends the life time of the
product and helps ensure continuous, optimized kilowatt-hour
production and reduces turbine downtime. These services,
which include spare part management, onsite service,
refurbishment, and training, are available globally and support
turbine manufacturers during turbine planning and construction,
as well as the wind power plant owner or operator throughout
the turbines life cycle. ABB service contracts are customizable,
tailored to meet the needs of manufacturers and operators.

Global products
ABB products, including the generators and converters, are
global products which are manufactured locally to the same
quality standards. This ensures that the high-volume, high-
quality products are available to meet customer expectations
and needs.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 17
Grid connection products

Grid connection products enable the distribution of the Switchgear

generated power from the turbine to the wind power ABBs SafeWind is a compact switchgear solution for all
plants collection network. The turbines transformer and voltage levels. It provides switching and protection of wind
switchgear are the main components of this system. power plant networks in harsh operating environments. It has
both IEC and Chinese GB approval, and is the only product
Transformers approved for the 40.5 kV GB standard. The slim design width
ABB transformers have a compact design that allows the of 420 mm for a 36 kV circuit breaker module allows it to fit
transformer to be installed through the tower door, without through tower doors during installation. Both compact and
disassembly. They are engineered to reduce losses and modular solutions are available in a variety of configurations.
operate in environments with high vibrations as well as harsh
ambient conditions where salt, sand, dust, and relative Solutions available for 12 kV, 24 kV, 36 kV and 40.5 kV
humidity of 100% are common. Suitable for onshore and offshore wind turbines
Combination of standardized modules provides full
Dry transformers up to 72.5 kV and 40 MVA application flexibility
Liquid filled transformers up to 72.5 kV and 40 MVA Switch fuse or circuit breaker protection
Classes E2, C2, F1 Advanced solutions for arc protection available
Multiple forced cooling system solutions Wide scope of protection and communication solutions
Insulation system temperature up to 180 C for dry Optional sequential closing system for T-off (turbine)
transformers
Organic liquid cooling options
Suitable for onshore and offshore wind turbines

18 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
ABB products and services for wind turbines| Electrical drivetrain and turbine systems 19
Turbine control and protection products

The turbine control and protection system ensures that

the turbine operation is within defined values. The PLC is
used for overall turbine control logic.

PLC
The ABB AC500 PLC is the key component for wind turbine
control. The PLC provides the fastest program execution
available, and enables a high level of protection to safeguard
the control programs intellectual property. The PLC is used to
set the reference speeds, turbine orientation to the wind, and
for turbine startup and shutdown operations.

Industry leading program execution times PLC and system interface products
Programming in accordance with international standards ABB offer the largest selection of electronic products and
(IEC 61131) relays in one product family, including timers, measuring and
Multiple communication (fieldbus) options monitoring relays, signal converters, relays, optocouplers,
Very flexible I/Os configurable as either inputs or outputs power supplies and safety solutions. The ABB low
Modular design, saves control cabinet space temperature signal converter is the only one with a low
temperature rating of -40 C.

Wind turbine control using ABBs AC500 PLC

Switch Pitch control

PROFINET
PROFINET

CANopen
Ethernet
Optical link

Nacelle

Tower Switch

Local Ethernet
network
Ethernet
Ethernet
PROFINET

e.g.Serial
Converter

20 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
Motor control and protection DIN-rail products
ABB produces safe and reliable products and solutions for all DIN-rail mounted electrical parts are used in many of the
motor applications. These solutions are available for different electrical cabinets in the turbine. The ABB range of DIN-
motor types, and enable different starting methods as well as rail products includes high performance miniature circuit
coordinated solutions for protection and control of motors. breakers, miniature circuit breakers, residual current devices,
Products include AC and DC drives, softstarters, contactors, surge protective devices, contactors, pilot devices, timers,
manual motor starters, back-up breakers/short-circuit and electricity meters. These products are available in a wide
limiters, temperature monitoring relays, and overload relays. In range of power ratings and voltages.
addition, motor starters can be integrated on the SMISSLINE
plug-in system to reduce space, wiring complexity and
installation time.

Limit switches
ABB limit switches are used as part of the turbine control
system to monitor and protect against excessive vibrations.
Used for electrical signaling of a mechanical position, the limit
switches are activated when vibration in the turbine exceeds
the switchs limits, signaling the PLC to activate protective
turbine controls.

Push buttons, switches and pilot lights

ABBs offering of push buttons, switches and pilot lights are
used throughout the turbine for control and visual indications. Terminal blocks
ABB terminal blocks are used in electrical panels and boards
within the turbine. They provide the connection point for
systems where point-to-point connection between systems is
used.

Switch mode power supplies

Switch mode power supplies are used for systems requiring
reliable DC power supplies. ABB power supplies use primary
switch mode technology that reduces heat loss and increases
efficiency. A power reserve of up to 50% protects against
loads that have high startup draws on power.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 21
Yaw and pitch system products

The yaw and pitch systems are responsible for Yaw system drives
mechanical movement of the turbines nacelle, turning the ABB drives are used either individually, or as part of a master/
nacelle into the wind, as well as the blades orientation to follower solution to adjust the turbines yaw. The drives are
the wind. connected to the turbines control PLC. Using drives to control
the yaw motors reduces mechanical stress and excessive
PLC vibrations during movement.
The ABB AC500 PLC is the key component for wind turbine
control of the yaw and pitch systems. The ABB PLC provides Back-up breaker/Short-circuit limiter
the fastest program execution available, and enables a ABBs short-circuit limiter breakers, WT63 and S800S-SCL-SR,
high level of protection to safeguard the control programs are used for coordinated protection in motor applications up
intellectual property. to 690 V, enabling selectivity and minimized installation space
when used as back-up for several motor starters.
Brake motors for yaw and pitch control
ABB brake motors are tailored to meet the needs of the yaw Softstarters
system and are used to drive gears that adjust the orientation ABB softstarters are used for reducing mechanical stress from
of the turbine. Pitch systems (often hydraulic) use motors to yaw and pitch motor startup. They reduce initial motor starting
adjust the pitch of the blades. current draw and enable smooth motor acceleration and
deceleration.
Typically 6-pole motors
1.1 to 4 kW, larger sizes available

22 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
Lightning protection products

Unprotected electrical system inside a turbine can be

damaged as a result of direct lightning strikes on the
turbine. To protect against damage and loss of production
as a result of a lightning strike, ABB protection products
are used throughout the turbine.

Surge protection
ABBs surge protection devices (SPD) protect systems
throughout the turbine from direct lightning strikes, both
Type 1 and Type 2. ABBs SPDs also protect from switching
impulse current.

From 24 V to 690 V electrical systems

Provides equipment protection
Reduces downtime resulting from equipment reset
Helps prevent damage due to over voltage and impulse
currents

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 23
Electrical protection and disconnect
products

Turbine electrical protection and disconnect products are High current ratings, up to 2,050 A
used to protect the turbines equipment from electrical Electronic coil is less sensitive to voltage drops
damage caused by faults or other failures of one or Low voltage ride-through version available
another system. They are also used to safely disconnect Modern, compact design
the turbine to enable maintenance or service within the Easy installation, wiring and maintenance
turbine.
Breakers
Arc Guard Tmax moulded case circuit breakers and Emax air circuit
ABBs Arc Guard system provides arc fault protection for breakers are designed for standard wind turbine and variable
medium voltage switchgear, transformers and low voltage frequency (0 to 200 Hz) applications. They are used for main
switchgear panels. The modular system provides fast circuit and sub distribution protection, up to 6,300 A. They
protection, using optical sensors and optical communication are available according to the main international certifications
to monitor up to 30 sensors connected in the system. It has and standards, including IEC 60947, UL 489, UL 1066, GOST
a functional safety rating of SIL2. The system can be wall or and CCC.
DIN-rail mounted.
Modular protection system and DIN-rail products
Functional safety SIL2 ABBs modular SMISSLINE plug-in system of protection
Increased safety products uses integrated bus bars to reduce system wiring
Full text display complexity, installation time and space. Both replacement
Up to 30 detectors can be connected of devices and expansion are easily managed. SMISSLINE
devices include supply terminals, miniature circuit breakers,
Safety residual current operated circuit breakers, surge arrestors,
ABB products and solutions for turbine safety systems include switch disconnectors, motor protection circuit breakers,
safety controller and safety relays for machine safety, as well auxiliary and signal contacts.
as various monitoring and protection products.
In addition to the SMISSLINE products, ABB products include
Contactors traditional DIN-rail mounted high performance miniature circuit
ABB contactors offer the most modern design on the market, breakers, miniature circuit breakers, residual current devices,
and provide a coordinated and tested solution with ABB surge protective devices, and electricity meters.
breaker products. The contactors are highly reliable and can
handle large variations in control voltage. A low voltage ride- Insulation monitoring relays
through version works without a separate UPS for control Wind turbines are unearthed systems, and both 3-phase
voltage. mains or DC mains may be monitored for insulation faults.
ABBs monitoring relays are used to directly measure the
insulation resistance in unearthed AC and DC electrical
systems with voltage levels up to 690 VAC and 1000 VDC.

24 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
Hydraulic and cooling system products

Turbine systems are supported by hydraulic pumping and Motors for generator cooling
cooling systems that are used to transfer heat losses from ABBs motors are used to power the generators heat
equipment, such as converters and generators, outside of exchange and ventilation systems. They are tailored for
the turbine. ABB products such as motors and drives are the operating requirements unique to the installation in the
used in these systems. turbines nacelle.

Motor control and protection Typically 0.75 to 7.5 kW

ABB produces safe and reliable products and solutions for all 2, 4, or 6 pole motors
motor applications. These solutions are available for different Two speed 2/4, 4/8, or 4/6 pole motors available
motor types, and enable different starting methods as well as
coordinated solutions for protection and control of motors. Low voltage AC drives for pumps and fans
Products include AC and DC drives, softstarters, contactors, ABB has developed drives with built-in pump and fan
manual motor starters, back-up breakers/short-circuit applications that are designed to improve pump and
limiters, temperature monitoring relays, and overload relays. In fan performance and efficiency. The drives also reduce
addition, motor starters can be integrated on the SMISSLINE mechanical wear on systems by providing pump and fan
plug-in system to reduce space, wiring complexity and protection functions such as soft pipe filling, multi-pump
installation time. control, preventing pump dry-run, and configurable fan
application settings.
Motors for pumping
ABB AC motors are used in hydraulic pump applications Softstarters
in the turbine. They are available from 2 to 8 poles, 0.06 to ABB softstarters are used for reducing mechanical stress
55 kW, for all common voltages, and are available with IE3 from motor startup. They are used with motors for hydraulic
premium efficiency requirements. systems. They reduce initial motor starting current draw and
enable smooth motor acceleration and deceleration.

Back-up breaker/Short-circuit limiter

ABBs short-circuit limiter breakers, WT63 and S800S-SCL-SR,
are used for coordinated protection in motor applications up
to 690 V, enabling selectivity and minimized installation space
when used as back-up for several motor starters.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 25
Auxiliary system products

There are many smaller supporting systems in a turbine, Back-up breaker/Short-circuit limiter
from lift systems used to bring equipment and parts to ABBs short-circuit limiter breakers, WT63 and S800S-SCL-SR,
the nacelle, to circulation fans and internal lighting & are used for coordinated protection in motor applications up
electrical connections. ABB products are used throughout to 690 V, enabling selectivity and minimized installation space
these systems. when used as back-up for several motor starters.

Motor control and protection Push buttons, switches and pilot lights
ABB produces safe and reliable products and solutions for all ABBs offering of push buttons, switches and pilot lights are
motor applications. These solutions are available for different used throughout the turbine for control and visual indications.
motor types, and enable different starting methods as well as
coordinated solutions for protection and control of motors. Enclosures
Products include AC and DC drives, softstarters, contactors, ABB metal structure enclosures enable easy integration
manual motor starters, back-up breakers/short-circuit limiters, of electrical components especially ABB products. They
temperature monitoring relays, and overload relays. In addition, are available in a variety of sizes, from small wall mounted
motor starters can be integrated on the SMISSLINE plug-in models to floor standing cabinets. Customization options for
system to reduce space, wiring complexity and installation doors, cable entry, mounting holes and other items enable
time. manufactures to design optimal installation plans.

Low voltage motors Terminal blocks

ABB has a large selection of AC motors that are used ABB terminal blocks are used in electrical panels and boards
in turbines. ABB motors are used for hydraulic pumping within the turbine. They provide the connection point for
systems, cooling systems, winches and lift systems, systems where point-to-point connection between systems is
compressors and fan systems. used.

Low voltage drives DIN-rail products

AC drives are used to efficiently and accurately control AC DIN-rail mounted electrical parts are used in many of the
motors. With the widest selection of drives on the market, electrical cabinets in the turbine. The ABB range of DIN-
and support for all fieldbus communication used in turbines, rail products includes high performance miniature circuit
the drives can be intelligently integrated into systems. Using breakers, miniature circuit breakers, residual current devices,
drives reduces startup stresses, and enables precise control surge protective devices, contactors, pilot devices, timers,
of the motor. This results in a more efficient system with and electricity meters. These products are available in a wide
reduced mechanical wear helping to increase turbine uptime. range of power ratings and voltages.

Softstarters
ABB softstarters are used for reducing mechanical stress from
motor startup. They reduce initial motor starting current draw
and enable smooth motor acceleration and deceleration.

Switch mode power supplies

Switch mode power supplies are used for systems requiring
reliable DC power supplies. ABB power supplies use primary
switch mode technology that reduces heat loss and increases
efficiency. A power reserve of up to 50% protects against
loads that have high startup draws on power.

Wide range of DC output voltages

Wide range of AC or DC supply voltages
Suitable for ambient temperature range of -25 to 70 C

26 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
ABB products and services for wind turbines| Electrical drivetrain and turbine systems 27
Expertise
Grid codes

Increasing generation drives regulation Controlled testing with custom software

As the installed capacity of wind power plants increases, the Laboratory engineers are able to test ABB products in a
share of power they provide to the transmission network also controlled and repeatable environment. Customized testing
increases. This means that during times of grid fault, the way software is used to configure the test conditions, which may
a wind power plant is able to respond with the fault has a be taken from individual grid code specifications. Tests may
significant impact on the stability of transmission grid. include three-phase, two-phase, or single-phase voltage dips,
or even a sequence of faults developing from single-phase
To regulate these conditions, utility companies have earth faults to three-phase short circuits.
developed regional grid code specifications wind power
plants must meet. These grid codes, which outline grid This laboratory testing helps reduce on-site testing costs by
fault conditions and the expected wind turbine behavior in replacing the variability of the wind with a speed controlled
response to these conditions, are becoming more demanding, motor driving the generators.
and vary from country to country. The wind turbine converter
plays an important role in helping the wind turbine meet Turbine certification support
these grid code requirements and to obtain the necessary Turbine certifications are based on the grid codes used
operational certification. in the region the turbine will be installed. When turbine
manufacturers are applying for turbine certification, ABB
Fault ride-though laboratory engineers can help the turbine manufacturer use and
A common requirement for all grid codes is a fault ride-though maximize the converters technology to meet the requirements
capability where the wind power plant and the turbines must of the grid code.
be capable of operating continuously at reduced voltage, and
must not trip off-line because of transient voltages. Globally active
ABB stays globally active in grid code working groups and
To test these grid codes, ABB developed a multi-megawatt standards definition to ensure ABBs products continue to
fault ride-through laboratory. It is designed to replicate both meet manufacturers needs.
doubly-fed and full converter turbines. The test equipment
includes generators, converters, transformers, switchgear,
and is connected to a 20 kV transmission line.

28 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
Expertise
Permanent magnet generator technology

ABB has been developing permanent magnet applications Standard generator designs
since the mid 1990s, for both the wind industry and the ABB builds on proven technical solutions and offers standard
very demanding marine industry. This experience provides generator designs for all of the main full converter concepts.
the foundation for ABBs know-how, ensuring the most These high, medium, and low-speed designs are totally
critical factors for the efficient and long operation of unique from each other leading to different mechanical and
a permanent magnet generator are addressed. This magnetic circuit designs. Turbine manufacturers benefit from
expertise is used for each of the high, medium, and low- these standard solutions, which are used as the basis for
speed generators ABB develops. each custom application, reducing development costs and
time, as well as the increasing the reliability and success of
Electrical and mechanical design the turbines project execution.
There are many factors that ABB addresses in the design
that affect the quality, and proper operation of the generator, Series production
as well as the maximum kilowatt-hour production. These High-strength permanent magnets present unique challenges
include the magnetic circuit design itself, the magnet material during manufacturing. ABB has developed special procedures
selection, the correct positioning in each individual case, and tools that enable safe and fast series production of high-
stabilizing and aging of the magnets, corrosion protection and quality products for low, medium, and high-speed concepts.
the reliable fastening of the magnets in these mechanically
demanding applications. An experienced global partner
The low and medium speed concepts involve a high degree
Magnetic circuit design of integration into the turbine construction, which is a very
The magnetic circuit design is the most critical factor for the challenging task. Selecting the right partner to build the
proper operation of a permanent magnet generator. ABB generator has a direct affect on the turbine development
has experience in designing many different low, medium and schedule, budget and delivery. ABB has been developing and
high-speed applications up to 6 MW. This expertise is used to delivering permanent magnet generators for wind turbines
ensure correct dimensioning and a low operating temperature, since 2000. This experience helps turbine manufacturers
preventing demagnetization, even during fault situations, and remain both on schedule and within budget.
also to ensure the correct positioning and fastening of the
magnets for the different rated speeds. Leading wind turbine manufacturers trust ABB expertise,
and today most of the megawatt-class permanent magnet
generators operating in Europe and North America were built
by ABB.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 29
Services
ABB life cycle services provide investment peace of mind

ABBs portfolio of life cycle services is designed to Custom made service contracts
increase a customers return on investment and keep ABB Each turbine manufacturer or wind power plant operator has
products operating a highest efficiency levels throughout a unique need for services. ABB helps provide customers with
their individual product life cycles. the right mix based on service contracts. ABB can bundle
individual services into one contract. Contracts can be made
Comprehensive services portfolio at any stage of product ownership, throughout the products
ABBs services span the entire product ownership life life cycle. Contracts may be comprised of a mix of services,
cycle, from pre-purchase engineering, installation and including spare parts agreements, preventive or corrective
commissioning, technical support, online and classroom maintenance agreements, technical support, and training.
training, preventive maintenance schedules, spare part kits,
spare parts management, to retrofit and refurbishment. Service contracts provide customers with improved cost
controls, increased operational efficiency, lower capital
expenditures, reduced downtime and extended product life
time.

30 ABB products and services for wind turbines | Electrical drivetrain and turbine systems
Training improves efficiency and performance Regional service hubs
Wind turbines are complex machines. Understanding how to ABB has positioned regional service hubs around the world
efficiently integrate and operate ABB products provides the to provide certified service for ABB products. The service
basis for improved product quality and reduced production hubs perform repair, refurbishment, and retrofit work. These
costs. ABB training is available for many products. Wind services help wind power plant owners improve turbine
turbine manufacturers, power plant operators and service production and reliability.
providers may attend training at ABB training centers, online
through e-learning classes, or even at their own site. Training Highlights
also helps keep wind turbine manufacturers and wind power Global services for the complete life cycle
plant operator engineers up-to-date with the latest product Tailor made service contracts
developments and information. Classroom and online training
Pre-sales engineering
Engineering and technical support Regional service hubs
Wind turbines require sophisticated engineering. ABBs Spare parts management
engineers work with turbine manufacturers during the product
specification phase to ensure all of the technical questions
and issues are addressed. Engineering and technical support
is available by phone, email, or on-site visits, as agreed in an
ABB services contract.

ABB products and services for wind turbines| Electrical drivetrain and turbine systems 31
Contact us

3AUA0000080942 REV A 18.5.2010 #14995

www.abb.com/windpower Copyright 2010 ABB. All rights reserved.
Specifications subject to change without notice.