Deif AWC 500 Quick start guide

ADVANCED WIND TURBINE CONTROLLER
AWC 500

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Turbine controller, AWC 500
Designed to last for more than 20 years
Designed to solve all challenges regarding turbine control,
DEIF’s Advanced Wind Turbine Controller, AWC 500, can be
installed in on- and o󰀨shore turbines ranging from small kW
up to the biggest 6-8 MW turbines.
Robustness
The AWC 500 is second-to-none the most robust controller
fully operational in extreme temperatures from -40 °C to +70
°C and at altitudes of 4,000 metres. Is immune to electrical
noise and designed specically with robustness in mind, the
AWC 500 is extremely protective against destroying surge
pulses and conforms to CE acceptance tests.
Pitch and turbine control
Applied as both turbine main controller and pitch controller,
especially in the Chinese market, DEIF’s AWC 500 has
been installed in more than 4,000 turbines. Characterised
by extremely cold winters and very hot summers, China is
perfectly illustrates why controller robustness is crucial.
High-level PLC programming or C/C++
Challenged by premature breakdowns, traditional automation
PLCs used as wind turbine controllers result in added spare
part and repair costs and, not least, lost production during
repairs.
PLCs designed for factory automation were simply not
designed for the tough conditions in wind turbines.
DEIF’s controller platform conforms to IEC 61131-3
programming with the widely used CODESYS V3 for high-
level programming or as embedded controller in C/C++ with
full power from our real-time Linux operating system. Via our
PLC Link, we deliver support for automatic code generation
from MathWorks MATLAB/Simulink & Stateow.
Park control and SCADA
DEIF applies the AWC 500 unconditionally as the most
preferred controller platform for complete control solutions.
Delivered as a standard solution for park control, the AWC
500 integrates the complete Park Control algorithm and also
serves as a platform for data collection and storage to control
large scale wind parks with reliable data gateways.
Controller retrot
The AWC 500 is a perfect t for the challenging conditions
o󰀨ered in older turbines due to their less advanced protection
and climate-controlled control cabinets. We can deliver
complete retrot solutions including control strategy, software
and component package, or open controller solutions.
DEIF collaborates with an open partnership approach and
can also provide technology transfer for software.

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AWC 500
Designed to last for more than 20 years
Introducing an unprecedented level of robustness within
wind turbine control systems, the AWC 500 (PLC-based
PAC) is the latest addition to DEIF’s range of AWC
controllers.
With it’s ability to execute application software awlessly
under all conditions, the AWC 500 can be applied in all
sites, be they located in cold or hot climates, onshore or
o󰀨shore or at high altitudes.
AWC 500 features
►Designed for a lifetime of no less than 20 years
►5 years warranty
►100 % production-tested system units
►Full traceability
▪ Operating temperature: -40 to 70 °C (cold start-
up!)
▪ Storage temperature : -40 to 85 °C
▪ Climate: 55 °C 97 % RH condensing
▪ Coated PCBs
▪ Altitude: Up to 4,000 m
▪ Vibration: 2.1 g (3.2 to 50 Hz) 1.0 g (13.2 to 100
Hz)
▪ Shock: 50 g, 11 ms, half sine
▪ Bump: 25 g, 6 ms, half sine
►Fully EtherCAT-based I/O
►TCP/IP, CAN, CANopen, SSI, RS-422/485
communication interfaces
►Direct 3-phase 690 V voltage and 1/5 A current
measurement, with class 0.5 power measurement
►Real-time embedded Linux operating system
software maintained 100% in-house
▪ <5 second startup-time from power on
▪ Fail-safe remote update
▪ Fault-tolerant le system (self-monitoring and
error-correcting)
▪ Secure protocols (SSL, SCP, HTTPS, built-in
VPN etc.)
▪ Hot standby controller redundancy
►Open software development with Linux, C/C++,
CODESYS (IEC 61131-3)

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“Defacto” standard communication protocols
The AWC 500 has fully EtherCAT-based I/O architecture:
► On internally backplane
► Between distribued racks
► As eldbus to external sensors and systems
The AWC 500 supports control loop cycles down to 1 ms.
Supported eldbuses
► Ethernet (TCP/IP, Modbus)
► EoE (Ethernet over EtherCAT)
► CAN (layer II), CANopen
► SSI
► Serial RS-422/485
► Probus DP slave
► Pronet (on request)
► NTP (Network Time Protocol) client for automatic clock
synchronisation
Integrated grid measurement
The accuracy of the control algorithms relies on a class
0.5 power measurement which denes a new standard in
the wind turbine controller industry. Up until now, the norm
has been class 0.5 voltage and current measurements
(multiplying to a lower accuracy of the power measurement).
Support for fast and precise LVRT reaction:
► Direct 690 V voltage, 1/5 A current and power
measurement (Class 0.5)
► No delay reading external transducer
► Calculates Energy (E), Power (P), Reactive Power (Q),
Phase angles etc.
► All values are directly available on GPM module for use
in the software
Simple digital frequency counter interface for HTL
sensor and encoders
► Values directly available on IOM module (DIF input)
► Only conguration and conversion
► No module communication required
AWC 500
A variety of congurations…

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Unsurpassed durability
The AWC 500 is designed for high durability and veried
by HALT (Highly Accelerated Life Test) testing. Built to last
for more than 20 years, the controller has been constructed
using a selection of highly durable components with a long
supply life time. We provide a 5 year warranty on the AWC
500 controller - the longest in the wind industry.
Hot and cold climate
Handling cold starts from a guaranteed -40ºC, the AWC 500
secures a safe and controlled turbine start-up in very low
temperature environments.
The highest operating temperature for the AWC 500 is 70 ºC.
This is an advantage to the controller life-time. For every 10
degree the temperature is higher, the life-time is extended - a
general rule of thumb.
Surge power on the AWC 500 is DM 2 kV, CM 4 kV. Twice
the industrial standards on both power supply and I/O
terminals. These high standards improve robustness of the
controller enabling it to toleratefor instance lightning strikes
on the turbine.
All PCB modules are coated with an eco-friendly protective
layer.
High altitude installations
The controller is designed for full operation on all I/Os and
communication interfaces without requiring additional cooling
in high altitude installations up to 4,000 m.
Tolerance to voltage dips
If the power supply suddenly drops, the complete AWC 500
system including all I/O modules within the AWC 500 rack(s)
will continue to operate for a minimum of 50 milliseconds up
to 1 second.
If power supply returns within this period, the AWC 500
system will continue uninterrupted operation. If power is still
absent after the power-loss protection period, the AWC 500
will enter its safe shutdown cycle in which it will prioritize
as clean shutdown amongst writing data to FRAM and
dedicated areas of the le system cache to the internal ash.
This ensures that all data from the application is sent to the
power-loss protected data storage and will be available to
the application, when power supply returns.
Watchdogs on 4 di󰀨erent hardware and software
levels
To monitor the operation of the AWC 500 system, watchdogs
on di󰀨erent levels are featured, from each individual module
EtherCAT slaves, EtherCAT master, Operating system
services running to application watchdog.
AWC 500
Designed for robustness in every detail

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AWC 500
System software
Linux with PREEMPT_RT real-time patch
The operating system completes start-up within
5 seconds from power turned on. The system
it based on the latest open source Linux kernels real-time
patched with the widely accepted PREEMPT_RT patch,
and features Busybox (the Switch Army Knife of Embedded
Linux), Dropbear (Secure shell (SSH) client) etc.
Remote update with fault-back
Two OS images are included to ensure fail-safe update of
software, both separated from the Application File System.
Secured access and communication
Customer manages all credentials (root and user passwords)
and can add individual users.
All access to AWC 500 is authenticated communication using
standard communication protocols:
► Secure Shell (SSH), version 2, server and client
► Secure Copy (SCP), server and client
► Secure/SSH File Transfer Protocol (SFTP), server
► Build-in VPN client
► Congurable Ethernet broadcast storm rejection lter
Other network protocols supported are:
► File Transfer Protocol (FTP), server and client
► Trivial File Transfer Protocol (TFTP), client
► Network Time Protocol (NTP), client
► Dynamic Host Conguration Protocol (DHCP), client
Webbased conguration and managed update
procedure
The same, simple and safe update procedure is used for:
► Operating System
► Firmware
► CODESYS runtime
► User scripts and
► Application
Simply drag and drop the compressed les .dupdates
packages (DEIF updates) to the AWC 500 lesystem,
automatically initiating update of the system.

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AWC 500
System software
Robust data storage
Proven fail-safe le system (UBIFS – Unsorted Image File
System) to ensure data on the AWC 500:
► Tolerates sudden power interrupts and unclean reboots
► Recoverability – May be fully recovered if the indexing
information gets corrupted.
► Ensures data integrity – Everything written to the ash
media gets checksums.
Instant and long life storage of persistent variables is ensured
with FRAM (ferro magnetic RAM) as NOVRAM :
► High Endurance type guaranteeing 100 trillion read/
writes cycles
► 10 years storage without battery power necessary
Our new PCM5.2 relies on the ext4 le system and features
a lesystem cache that is written periodically every few
seconds, and a dedicated data area of persistent variables
is guaranteed to be persisted automatically to the mass
storage on power loss.
Primary
image
Boot
modes
Root File System (RFS)
Linux kernel
Boot loader (U-Boot)
Boot
D ownl oa d
Service
Run
Backup
image
Po wer loss
protected
data storage
Root File System (RFS)
Linux kernel
Application File System (AFS)
NAND NOR FRAM
Storage technologies:

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Software development
Choose your software packages:
► CODESYS (IEC61131-3 PLC)
► ANSI C/C++
► Linux scripting (BASH)
► Web server-side programming (CGI/BASH)
► Create pages in HTML, HTML5, JavaScript
► PLC Link (MATLAB/Simulink Interface)
C/C++ programming
► Eclipse based
► GNU C/C++ compiler
► GNU gdb debugger
► AWC 500 SDK
► Programming templates
CODESYS (IEC 61131-3 programming)
► IEC61131-3 PLC programming (ST,FDB,SFC,IL,LD)
► CODESYS V3.5 based (compliant with other PLCs.)
► Integrated HMI/Webvisualization
► Graphical PLC conguration
► Online debugging
► Multilanguage programming editor and help in Chinese,
German, Russian, French and English
► Integration of C/C++ libraries with DEIF External C lib
development package
Customized production – 100 % production-tested
system units
Controllers are delivered as ready-to-install, assembled and
congured according to customer specications. You will
benet from optimum logistics and maximum quality as each
controller delivered has been subjected to a cyclic burn-in
test in climate chambers with -40 to 70 ºC for 6 hours before
being delivered, testing CPU, memory, communication, I/O.
During the complete temperature cycle all measurements
must be within listed specications. This guarantees hassle-
free commissioning of our controller. We provide a 20 year
supply guarantee based on our decades of experience from
the marine industry.
Product traceability
DEIF secures full traceability on all units in all production
steps from sourcing of components to customers
congurations. And each modules unique id-code and
software versions can be read out from the system software
in the controller.
Ready-to-install controller
The AWC 500 provides compact, exible and service-friendly
solutions. The controller is delivered: tested, assembled
and ready to install in the turbine even preinstalled with the
customer applications software, if required.
AWC 500
Software development and customized production
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Tool chain
AWC 500
MATLAB
Simulink
interface
CoDeSys V3
C++
PLC Link
Code
generator
Linux
tools
Vizualization
• WEB
• DEIF HMI

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Rack sizes
Available rack sizes are from 0 (PCM module only) to 8 modules:
Module overview
Power and Control module
PCM5∙1 – Industrial grade 333 MHz Power-based CPU with real-time patched (PREEMPT_RT) Linux OS
PCM5∙2 – Extreme temperature (-40 to 70 ºC) 1 GHz dual core NXP CPU with real-time patched (PREEMPT_RT) Linux OS
PDM5∙1 - Power and Distributed communication Module for EtherCat network - Fiber
PDM5∙2 - Power and Distributed communication Module for EtherCat network – Electrical
I/O modules
IOM5∙1 - 40 channel multifunction I/O module
DIM5∙1 - 46 channel digital I/O module
Communication modules
IFM5∙1 - RS-422/485, CAN, CANopen, SSI interface
IFM5∙2 - 4 port Ethernet router
Grid protection module
GPM5∙1 - Direct 690 V 3-phase voltage, current and power measurement (class 0.5)
AWC 500
Product line

Cross-cultural project
partnership
DEIF Wind Power Technology
has taken part in the project
of commissioning 30 new GL
certied turbines with a total
capacity of 75MW for one of
Europe’s largest wind farms
Blaiken Wind in Sweden.
Together the partners Dongfang,
the utility Skelleftåe Kraft and
DEIF Wind Power Technology
have e󰀩ciently commissioned
30 turbines within a year. The
complete electrical system is
delivered and integrated by
DEIF Wind Power Technology
and Dongfang has delivered the
turbines, which have been GL
certied in China, based on a
collaboration between DEIF and
TÜV SÜD certifying body. With
the technological know-how,
DEIF on-site team of engineers
have integrated the pitch and
turbine control system including
a de-icing system for sustaining
full functionality in very cold
temperatures.
Complete system integration
& technological know-how
DEIF Wind Power Technology
constitutes a strong competence
in securing the turbine
components for the complete
system in Dongfang’s turbines
for the wind park. The entire
system is built on integration of
DEIF Wind Power Technology’s:
Turbine and Pitch Control,
Park Control and SCADA for
successful. An important part
of the integrated technology is
the Wind Park Control System,
which secures a stable and
reliable power production to be
transferred to the grid after the
commissioning of the turbines.
In order to secure this, the Wind
Park Control System has been
built to comply with the Swedish
criteria and local grid code
demands for energy production
and integration to the electrical
grid. The entire purpose is
to secure a safe and reliable
production of clean energy for
thousands of households in
Northern Sweden.
Control technology for 75 MW
Wind Farm in Sweden
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FACTS, DEIF Wind Power Technology:
• Develop and build State-of-the-art
solutions for complete integration of
the electrical system in wind turbines
• Commission 1500 turbines per year
World Wide, that makes 4 turbines a day!
• Commission wind parks with the capacity of
>200 MW
• Supply turbine control system designs for
turbines of 50 kW up to 7 MW
• Global partner in Europe, US and Asia
Our business model is typically where DEIF Wind Power
Technology delivers critical key components such as the
pitch drives and the main turbine controller. We make a big
dierence for our customers by being an active partner in
designing and approving the electrical system in the turbine.
A process that should be fast and fulll all new safety
standards, but without adding unnecessary cost or delays«.
– Christian Nielsen, Managing Director
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DEIF A/S
Frisenborgvej 33, 7800 Skive, Denmark
Tel. [phone]
LEARN MORE AT DEIFWINDPOWER.COM