Solutions for

Wind Turbine Systems

PHOENIX CONTACT
Communicating with customers
and partners worldwide
Phoenix Contact is a leading manufacturer
of electrical connection and industrial
automation technology. Founded more than
80 years ago, the company now has 9,300
employees, of which more than 5,200 are
located in Germany. A sales network of
40 subsidiaries and more than 30 sales
representatives guarantees proximity
to the customer.
The product range includes high-
grade components, systems and
services across a wide variety of
applications. The selection ranges from
modular terminal blocks to interface
technology, PCB connection technology
and solutions for surge protection to
hardware and software solutions for the
automation of industrial systems.
Global Player within close reach
of the customer
Phoenix Contact values in-house expertise.
The design and development departments
continuously implement innovative product
ideas and deliver special solutions to meet
customer requirements. Numerous patents
have resulted from products developed at
Phoenix Contact.

2 PHOENIX CONTACT
 Ensuring the power supply
for the future
The global energy demand
is continuously increasing.
Therefore, regenerative
energy within the energy mix
has become an increasingly
important energy source
from the ecological as
well as economical point
of view. In addition to
hydropower, biomass/gas and
photovoltaics, wind energy is
also fast gaining importance.
Taking into account the future
requirements, this rapidly
developing field is expected
to become an important
pillar in the field of power
supply. Join Phoneix Contact
in the challenge of ensuring
the power supply worldwide.
For years now, we have been
a reliable and
a competent
partner in this Economy is the base of
field. With ecological efficiency.
the aid of our
experience,
products, solutions and
services, we help you operate
your systems reliably and
economically.

PHOENIX CONTACT 3
A fresh breeze with Phoenix Contact
Your partner for wind power systems

In 1923, the first modular terminal block

of the world was developed in close
cooperation with a power supply company.
Gear
Even today, we have a close dialog with our
customers and also believe in a high degree
of manufacturing penetration in order to
ensure delivery reliability and consistent
quality. Thanks to our tightly meshed sales
network, we provide local as well as global
support to you and your customers.
With the same dynamics as the power
supply market has developed in the last few
years, Phoenix Contact has and will provide
innovations that give wings not only to
the wind power sector:
Automation and control technology
Electrical and electronic switch
Slip ring
components
Power supply units
Interface converters
Rotor blade control
Rotor hub system (e.g. pitch
Signal conditioning
control)
Wireless transmission systems
Rotor blade
Lightning and surge protection
Industrial connection and device
connection technology
Cabling systems Transformer station

4 PHOENIX CONTACT
Brake systems Innovative solutions From the
Wind speed rotor hub to the control room
(anemometer)

Wind turbine control system

Pages 6 7

Wind direction Windpark management

Generator Topbox
Pages 8 9
Aviation light
system Protection of persons and plants
Pages 10 11

Lightning and surge protection

Fundamentals
Pages 12 13
Comprehensive solutions
Nacelle Pages 14 15

Combine, network, connect

Device connection technology

Pages 16 17
Systems in the control cabinet
Pages 18 19

Technology and know-how

Cooling Certified quality
system
Pages 20 21

Planning, visualization, marking

Yaw drive
Pages 22 23

Engineering Service Training

Pages 24 25
Tower

Windpark Trends and developments

Pages 26 27

Main control
panel

Low-voltage
distribution panel

PHOENIX CONTACT 5
Wind turbine control system

Today, modern control systems for wind

turbines must fulfill high requirements, as
the systems with their high investment
volumes are expected not only to work
profitably but also for a long time in harsh
enviroments!

RFC 470

ETHERNET

ILC 150 ETH

Controllers

Our scalable control systems are the platform of a high-

performance management system designed to optimize
the rate of return PC-based or as embedded controller.
Innovative functions such as seamless Ethernet communication,
removable Flash storage for program and operating data
recording provide quick results in development. Industrial
design for harsh enviroments ensures high system availability.

6 PHOENIX CONTACT
 Software development
Software development as per IEC 61131 for all variants is
carried out using the large-scale integrated engineering tool
PC WORX.
Comprehensive module libraries provide basic control
functions. The intelligent program code management in
modules and libraries allows easy re-use with different
performance classes.
You can also integrate your own algorithms that have been
developed in 'C' or 'C++'.
In addition, the flexible task system enables a variety of
control and regulation circuits, such as fast pitch adjustment
and slow charging state monitoring to be implemented
together with corresponding priorities.
Control system periphery
Fast regulation processes require fast recording and processing
input and output signals. INTERBUS as the realtime bus
for synchronous data transmission and PROFINET as the
Ethernet-based high-speed network provide the required
performance for fast process data exchange between the
control system and periphery.
HMI Human Machine Interface
A human-machine interface is important for setting up,
monitoring and servicing a system. You must also have online
options for switching the system to the service mode, calling
up current statuses of the units as well as power and history
data and adapting parameters. Our rugged touch panels and
the powerful SCADA software Visu+ make a strong team
here.
Simulation
If you optimize the control circuits of the wind turbine
systems with MATLAB Simulink, you can use PLC Link to
generate the results of your optimization directly as control
algorithms for PC WORX Design instead of programming!
PHOENIX CONTACT 7
Windpark management

An economical power generation requires

an optimized system operations. An
integral windpark management system is
indispensable in order to ensure smooth
operation of a windpark. High-performance
control technology
Our automation system reliably fulfills the
high time-related requirements for the
reaction times in the case of a voltage
failure, thanks to its realtime-capable,
failure-proof Ethernet communication and
high computing capacity. The visualization
on our industrial PCs constantly displays all
system statuses.

W-LAN

ETHERNET
PPC
Switch

M-Guard Com server

Firewall Modem GSM

RFC470
8 PHOENIX CONTACT
 Park communication and
realtime control
The high-performance controllers of the 400 series are highly
communicative and allow easy decentral access to the entire
windpark. Data transmission from the main control system
to the individual wind turbine is possible in realtime via
Profinet. The PC WORX automation software allows intuitive
system programming. Remote management is increasingly
carried out using a communication link via the Internet. Our
VPN gateways with integrated Firewall guarantee secure and
authorized access to the windpark network without loss of
speed. Remote access is possible either via ISDN or an analog
connection.
Our IT-powered automation increases the transparency during
the operation of your windpark, thus making a considerable
contribution to raising the productivity.
W-LAN
W-LAN
Redundant network
Redundant
park network
A wide range of infrastructure components is available for
structuring a redundant park network, right from cost-
effective switches to Gigabit components. A wide product
range enables reliable networking from the control system, to
I/O level and industrial connection technology. A redundant
network structure on the basiss of fiber optics technology
guarantees reliable monitoring and control of the system in
the windpark, as well as data exchange
between systems even under
adverse ambient conditions.
Switches andd
infrastructure components
Windpark visualization and
data archiving
Phoenix Contact offers a wide range of energy-saving
industrial PCs for constant monitoring and visualization
of weather, energy and operating data. The full-SCADA
visualization software Visu+ can be used to visualize and
process trends or alarms graphically. System statuses can be
constantly recorded and analyzed either using the operating
data recording and protocolling functions or by establishing
a connection to the database systems. Realtime archiving can
be done via SQL server. The connection to the control level
is implemented with OPC. The operating data of the wind
turbine is protocolled continuously so that information about
the availability and performance of
the system is available to you at all
times and you can also implement
the required preventive measures to
avoid a failure.
Energy-efficient
and industrial PCs
PHOENIX CONTACT 9
Protection of persons and systems

Conventional safety solutions are sufficient

for safeguarding health and preventing
damage to the wind turbine systems. Taking
this background into account, Phoenix
Vibration monitoring
Contact has developed trendsetting safety
components and systems. Our easy-to- Our PSR switching devices can be used to integrate the latest
safety technology into your signal path easily and monitor the
handle solutions that have been developed
circuit between the vibration sensor system and the switch-off
in cooperation with many users as well line using our GL (Germanischer Lloyd) certified PSR-ESP4 for
example.
as with certified bodies such as TV and
BGIA fulfill all relevant safety standards
such as EN 954-1, ISO 13849-1 and
IEC 62061. The implementation of safety
applications requires special competence
and know-how. We therefore support the
users in planning and programming, startup
and in after-sales-service over the entire life
cycle of the wind turbine systems. Join up
with our experts to develop the technically
and economically best solution that will
adapt to your requirements with flexibility.

Downtime and
speed monitoring
The comprehensive safety switching device range from
Phoenix Contact provides the PSR-RSM4 module for the
monitoring of safely reduced speeds and/or a safe downtime.
This relay records the speeds with maximum reliability, either
using proximity switches or using an incremental encoder.
The PSR-RSM4 switches off safely if the freely parameterized
speeds are exceeded.

10 PHOENIX CONTACT
 System protection with safety relay System protection with safety control system

Our PSR safety relays prove that innovative safety solutions
do not necessarily have to be complex to meet the high
safety requirements. Besides simple integration and handling,
our modules are characterized by their compact, space-
saving design, as well as top quality, safety and reliability. The
innovative connection technology and the comprehensive
approvals perfect the range.
With Interbus Safety and Profisafe, you have two systems that
have been specially designed for these and other requirements.
The main feature of the system is its simplicity: It is easy
to integrate into existing networks, easy to operate over
the entire lifecycle of the system and easy to
adapt to suit your changing application
requirements. Short startup
times, high availability
and maximum safety
complete the scope
of service.

Position control

When a defined position is left and the relevant signal is

given, a safe switch-off is carried out using our modules as
per cat. 4 EN 954-1, PLe as per EN ISO 13849-1 or SIL3 as
per IEC 62061.

PHOENIX CONTACT 11
Lightning and surge protection
Fundamentals

The goal of wind turbine operators is

to break even as soon as possible and
guarantee profitable system operation by
means of reliable management. Experts
estimate a minimum life time of 20 years.
The high investment costs must be
amortized in the minimum possible time.
Uninterrupted availability of all system
components are the basis.
Malfunctions and downtime due to damage
caused by lightning and surge voltages are
The comprehensive
ruled out by planning and implementing a TRABTECH protective
circuit concept
comprehensive surge protection concept.

Protected volume LPZ 0A LPZ 0A

LPZ 0A

LPZ 0B
LPZ 1 or LPZ 0B LPZ 2

LPZ 2

LPZ 0A

LPZ 0A LPZ 1

LPZ 0B LPZ 2

12 PHOENIX CONTACT
 Design of the surge protection concept

Due to their exposed locations and

height, wind turbine systems are
particularly at risk from lightning
discharges. Effective surge protection
begins by assessing the potential risk
and identifying all the devices within
the object to be protected.
In addition, IEC 61400-24 Wind
turbines Lightning protection,
directives of Germanischer Lloyd (GL)
and IEC 62305 Protection against
lightning form the base for the
necessary definition of the LPZ
(Lightning Protection Zone) for
wind power plants:
Source: GDV

LPZ 0A describes a zone that is

endangered by direct lightning strikes
and the unattenuated electromagnetic
lightning field. The inner systems can be
exposed to the entire lightning current.
LPZ 0B describes a zone that is
protected against direct lightning
strikes but is endangered due to the
unattenuated electromagnetic lightning
field. The inner systems can be exposed
to the partial lightning currents.
between lightning protection zones
(e.g. for the protection of power
supply units):
LPZ 0A > LPZ 1:
Lightning arrester, class I
LPZ 0B > LPZ 1:
Surge arrester, class II
LPZ 1 > LPZ 2:
Device protection, class III

LPZ 1 describes a zone in which surge

currents are restricted by current
distribution and SPDs (Surge Protective
Devices) at the zone transitions. The
electromagnetic lightning field can be Phoenix Contact provides
attenuated using physical shielding. not only the relevant surge
protective devices but also
LPZ 2 describes a zone in which surge provides support in creating
currents are further restricted by protection concepts and
current distribution and additional SPDs offers sector-specific seminars
(Surge Protective Devices) at the zone in close cooperation with our
transitions. The electromagnetic lightning customers.
field can be attenuated using additional
physical shielding.

The following surge protective devices

should be installed at the transitions

PHOENIX CONTACT 13
Lightning and surge protection
Comprehensive solutions

FLASHTRAB VALVETRAB PLUGTRAB-PT

FLT-PLUS-CTRL VAL-CP and VAL-MS PT2 and PT4

Class I Class II Class III

Lightning arresters for power supply.
AEC technology enables direct parallel
connection to the corresponding
varistor-based surge arresters
Surge arresters for 230/400 V, 690 V
and 1000 V systems for the protection
of power supply, the generator and the
inverter system, etc.
Device protection for power supply
(e.g. aviation light systems)
and secondary side protection of
the 24 V DC power supply units
(e.g. control voltage)

CHECKMASTER
CHEC
Arrester test

Professional testing off surge

protective devices within
hin the Transformer station
scope of the repeat test
est of
lightning protection systems
ystems
as per IEC 62305-3

Power supply unit

14 PHOENIX CONTACT
 4 20 mA (intensity)
4 20 mA (wind direction)
0 10 V (wind speed)

UPS
Bus system
230 / 400 V

Stator
Rotor
690 V
230 / 400 V
Bus system

PLUGTRAB PT DATATRAB DT

Signal protection Data protection

Protection of the bus system and sensor Protection of infrastructure

and actuator system (e.g. ambient (e.g. Ethernet, Profinet)
parameters)

LVDP Low-Voltage Distribution Panel

MCP Main Control Panel

Communication

PHOENIX CONTACT 15
Combine, network, connect
Device connection technology

Irrespective of whether you need the

connection system for signal, data or
power transmission In the PLUSCON
and COMBICON product ranges from RJ45 industry-friendly
for Ethernet and
Phoenix Contact you will find the ideal PROFINET

solution for your application. The spectrum

Fiber optics
ranges from PCB connection with IP20, connection for
every fiber type
intelligent power distributors to circular (POF, HCS, GOF)
connectors for motors with
150 A in IP67.
The option of customer-specific
development makes it possible for
you to realize completely new and M12, M8, M5
Up to 17-pos.
innovative connection solutions.

Extremely flat
connectors with high
packing density

Impressive range of Compact PCB terminal

sensor/actuator cabling blocks with universal screw
connection

16 PHOENIX CONTACT
 Stranded and fieldbus-
compatible,
D-SUB 9 to 44-pos.

Twin bus connectors

For computer periphery with a fast direct plug-
(USB, Firewire) in technology

High-current
connectors for real
600 V UL applications

Optimal connection for

maximum power

Modular connection for

power and signals with
EMC protection

Direct connectors
Rugged power connections for increased ambient
for drives conditions

PHOENIX CONTACT 17
Combine, network, connect
Systems in the control cabinet

With CLIPLINE complete, the unique

modular terminal block system from
Phoenix Contact, the user has choice
of connection method. Irrespective
of whether the user chooses screw,
spring-cage, push-in, fast or bolt
connections. All connection systems
can be combined using the same
accessories.

CLIPLINE complete all

connection technologies,
one system

18 PHOENIX CONTACT
 Pluggable wiring with COMBI

The COMBI connectors can be combined with each other

independent of the connection technology.
tech
chno
nology. The
Thhe contact
co
ont
ntact
system meets the most stringent of
vibration requirements
ents due to the
integrated overspring
ng and the
different engagement
nt
options.

Quick and economical KEL

The modular structure of the KEL system allows you to route

pre-assembled conductors into the control
cabinet flexibly, safely and inn a space-saving
manner. Up to 40 conductors ors with
IP54 protection can be routed ted
into the control cabinet through
rough
a standard cutout for a heavy- vy-
duty connector.

F
Flexible for all measuring transducer
ccircuits
T
The patented test disconnect terminal
bblocks in the CLIPLINE complete system in
ccombination with the PACT Analog current
ttransformer range make it easy to build Power networking
iindividual current transformer measuring sets. with bolt connection
T
The practical accessories are used to realize all
m
measuring transducer circuit tasks The rugged bolt connection is characterized
terized by
iin a cost and time-savingg manner. maximum reliability and no maintenance
ance in all
applications. Thanks to their high current
urrent
carrying capacity, these terminal blocks
ocks
are especially suitable for wiring
primary circuits.

PHOENIX CONTACT
T 19
Technology and know-how
Certified quality

Salt mist test IEC 60068-2-11/-52

In particular in wind turbine systems, to a finely dosed spray of 5% sodium

technical components have to be marked
and function permanently in a corrosive
atmosphere. The salt content of the
air in combination with the increased
humidity places high demands on the
labeling and materials used. On the basis
of the above standard, it is possible to
simulate the influence of a sea climate.
The resistance of the materials in a
corrosive atmosphere is tested using
salt spray. The test objects are placed
in the test chamber and subjected
chloride solution (NaCl; pH 6.5 7.2)
at a temperature of 35C for a period
of 96 h. The test is followed by a visual
check. In the IEC 60068-2-52, testing
is also performed using 5% sodium
chloride, but under conditions with
different specifications.
Phoenix Contact marking materials fulfill
these high requirements.

Protection level monitoring IEC 61643-1

Availability of all system components of (1.2/50) s surge voltage and the

is necessary for an uninterrupted and (8/20) s surge current. The resulting
safe operation of wind turbine systems. protection level Up is a parameter that
Surge protective devices are therefore characterizes the performance of the
of particular importance when designing surge protective device; abbreviated
systems. as SPD.
An important component of a qualified
test is the protection level monitoring
as per IEC 61643-1. The response
behavior and the course of the residual
voltage is recorded during application

20 PHOENIX CONTACT
 Corrosion test IEC 6988

The contact area of high-quality, gas- A visual check and the measurement of
proof connections remains free of the contact resistance follows the drying
corrosion with a consistently low period, in order to assess the effects
ohmic characteristic even under the of the corrosive environment on the
effects of aggressive media. contact point.
In the so-called Kesternich test, the test
object is exposed to an atmosphere
containing sulfur-dioxide at an ambient
temperature of 40C.

Vibration tests IEC 60068-2-6

The vibration resistance of an electrical The test object may not incur any
connection is verified with this test. damage that would inhibit the further
Harmonic, sinusoidal vibrations are use or negatively influence the constant
applied to the test object to simulate electrical values.
rotating, pulsating or oscillating forces.
A frequency range of 10 2000 Hz, for
example, is covered at a speed of one
octave per minute in all three axes (xyz).
The r.m.s. value of the acceleration is
50 m/s2.

Temperature shock test IEC 60512-11-4, test 11d

In wind turbine systems, temperature the product and usually stay there for
changes resulting from the processes 45 minutes. There should be no damage
may occur. Electrical connections in here which can affect further use.
the climatic chamber are subjected to
extreme temperature changes for the
simulation of such ambient conditions.
In a two-chamber procedure, the test
objects are moved within a few seconds
between the lower and the upper limit
temperature (e.g. -50C to +85C) of

PHOENIX CONTACT 21
Planning Visualization Marking

Thanks to our universal tools,

implementation of an automation
solution has now become more
convenient for you. The transition
between tools is seamless and data
once generated can thus be easily
used in other tools.

22 PHOENIX CONTACT
 Project planning with CLIP PROJECT

CLIP PROJECT allows you to plan automation and

interface components, as well as surge protection
and modular terminals quickly and easily. Labels
can be attached easily. Integrated interfaces allow
export of data to electrical planning systems such
as EPLAN.

Programming and
parameterization using PC WORX
PC WORX is the automation software for all
PC-based and embedded control systems from
Phoenix Contact. This software is based on
IEC 61131-3 and has an integrated bus configurator.

Visualization with Visu+

Data projected in PC WORX can be processed

further for visualization purposes, for instance,
in the Visu+ visualization software from Phoenix
Contact. Visu+ is connected to the control system
through OPC and is therefore not manufacturer
dependent.

MARKING system

MARKING system Software and hardware Moreover, Phoenix Contact also offers a worldwide
optimally adapted to each other for quick and labeling service. We provide you with the desired
easy labeling of your applications. A wide range of labeled marking materials anywhere in the world in
software-controlled terminal blocks, conductor next to no time.
and device marking materials are available for the
labeling of your entire application, irrespective of
which printer system you opt for.

PHOENIX CONTACT 23
Engineering Service Training

Using an integrated, fast and simple

approach, we realize solutions for specific
applications on the basis of comprehensive
project experience in wind turbine
technology.
Contact us at the first stage of your project
planning. Your personal contact will be
there to help you with sound competence 1. Pre-sales and sales
in the specific sector, right from the start
and through to commissioning.
During operation, our service team is
available via the 24x7 hotline. If on the
phone support is not sufficient, we will
be over immediately.
To qualify your employees we will join you
to design application-specific courses and
coordinate locations and dates.
We will provide practical support for your
application worldwide.

Complete pre-sales/after-sales
service
The worldwide certified integrated
management system from Phoenix
Contact and our closely knit
international sales network will support
you effectively in attaining your goals
anywhere in the world.

24 PHOENIX CONTACT
2. Planning and development 3. Training and seminars

4. Production and distribution 5. After-sales

PHOENIX CONTACT 25
Trends and developments

Offshore The use of constant winds

Environmental protection and reduction of CO2

Sufficient space
Constant energy production
Higher efficiency provides a balance of costs as
compared to onshore systems
Nature conservation
Feed-in consumption and
stable electricity prices
Independence and secure supply
Regional added value

26 PHOENIX CONTACT
 Repowering Less is more

Larger but less wind turbines

Increase in efficiency
Landscape
Better network integration
Nature conservation
Stable domestic market
Feed-in consumption and stable electricity prices
Halving the number of systems
Up to three times higher capacity
Up to four times higher power generation

PHOENIX CONTACT 27
Further information on the products
presented here and on the world of solutions
from Phoenix Contact can be found at
www.phoenixcontact.com

Industrial Connection Technology,

Marking Systems and Mounting Material
CLIPLINE

Industrial Connectors
PLUSCON

Or, contact us directly:

PCB Connection Technology

and Electronic Housings
COMBICON

Surge Protection

PHOENIX CONTACT 2008

TRABTECH

USA:
Signal Converters, Switching Devices,
PHOENIX CONTACT Inc.
Power Supplies
P.O. Box 4100
Harrisburg INTERFACE

Printed in Germany
PA 17111-0100
Fax (717) 944-1625
Phone (717) 944-1300
www.phoenixcon.com Components and Systems
AUTOMATION
Canada:
MNR 52004521/01.09.2008-00

PHOENIX CONTACT Ltd.

235 Watline Avenue
Mississauga, Ontario
L4Z 1P3
Fax (905) 890-0180
Phone (905) 890-2820
Toll Free 1-800-890-2820
www.phoenixcontact.ca