LICAP Wind Retrofit

LICAP's ultracapacitor based retrofit solution replaces the existing lead-acid battery back-up system for pitch control in GE 30Nm and 20Nm wind turbines. Our solution is a drop-in replacement that is designed to fit in the same location as the existing batteries, and will not require any operating system modifications. We designed the solution to be common across the different pitch box versions with only wire harness, bracket and mounting accommodations.

  • Ultracapacitor Expertise & Direct Manufacturer of Cells
  • Patented Activated Dry Electrode Process
  • Modular Ultracapacitor Energy Storage Solutions for GE 30Nm & 20Nm Turbines.
  • 20 Years of Pitch Control Expertise
  • ~3GW Installed Base
  • Modular Capacitor Charging Unit (CCU) Manufacturer for GE 30Nm & 20Nm Turbines
  • Bracket & Wire Harness Supplier
  • Certified Technicians Available to Climb & Troubleshoot
  • Made in USA

GE-30Nm Battery Box Configurations

There are 4 variations of thebattery box (shown here).  Wiringharnesses vary significantly between the A & B designs, with minordifferences between the B1, B2, & B3 versions. Drop-in replacement cableand hardware solution adapts natively to all the OEM's component configurationswithout modification required.

LICAP Installed Retrofit Solutions for GE-30Nm Battery Box Configurations

GE2.X – 30Nm Ultracapacitor Energy Storage System

There are 4 variations of the battery box (shown here). Wiring harnesses vary significantly between the A & B designs, with minor differences between the B1, B2, & B3 versions. Drop-in replacement cable and hardware solution adapts natively to all the OEM's component configurations without modification required.

See the different variations here

B1 - Box
B2 - Box
B3 - Box
A - Box

GE-30Nm Battery Box Configurations

LICAP Installed Retrofit Solutions

GE-30Nm Battery Box Configurations

LICAP Installed Retrofit Solutions for GE-30Nm Battery Box Configurations

GE2.X – 20Nm Ultracapacitor Energy Storage System

Major Components & Functionally - Existing System

The GE 20Nm battery box is shown here. There is only one version of the 20Nm battery box. Wiring harness will be similar to the existing harness and mounting bracket for capacitor charging unit (CCU).

GE-30Nm Battery Box Configurations

LICAP Installed Retrofit Solutions for GE-30Nm Battery Box Configurations

Ultracapacitor Energy Storage System

Energy Storage Requirement

  • 6 cells in series, 3000F 2.7V cells (Operating at 2.42V / cell)
  • 500F Module (6 modules per axis)
  • 14.5V per module
  • IEC 60529, IP20 – No exposed PCBA’s

Balancing

  • Passive balancing system
  • Turn-off voltage at 2.4V per cell

Note

  • GE 20Nm uses 4 ultracapacitor modules, same charger box (CCU).
  • Mounting bracket hardware for charger box CCU (Not Shown) - TBD

Value Proposition

Lower maintenance cost

  • Retrofit is a drop-in replacement
  • Retrofit interfaces with the existing Emergency Power Unit (EPU) and Turbine controller (SCADA System)
  • Eliminates costly maintenance and battery replacements
  • Reduces battery related pitch faults

Increased reliability

  • Approximately 10-15-year life
  • Wider operating temperature range  -40oC to+65oC
  • Minimizes turbine downtime

Improved safety

  • Reduces operational safety concerns
  • Can be fully discharged to provide safer working conditions
  • Reduces number of climbs for technicians
  • No lead or acid
  • No change to lock-out tag-out procedures
  • IP20 rated – No exposed PCBA’s

Lower maintenance cost

  • The 6 cell ultracapacitor modules are the same dimensions and use the same mounting locations as the batteries.
  • Each blade pitch system will use 6 modules for GE 30Nm and 4 modules for GE 20Nm.
  • LICAP ultracapacitor modules feature laser welded bus bar connections to ensure a robust and reliable connection for the life of the installation VS. threaded cells with nuts that can be over torqued or come loose over time.
  • Loose nuts can cause higher resistance which can lead to increased temperatures at the terminal. Increased temperature can shorten life and/or lead to failure of the module.

Windurance Capacitor Charging Unit (CCU)

  • The Windurance CCU is designed to monitor and manage 4 or 6 ultracapacitor modules
  • 1 Charging Unit per blade pitch actuator vs. 1 per ultracapacitor module. A cost-effective solution.
  • Fewer parts + fewer connections = higher reliability
  • The CCU can be used either for GE 30Nm or GE 20Nm interchangeably.
  • Drop-in replacement conveniently interfaces to existing cables, harnesses and RS-485 communication protocol.
  • IP20 rated – no exposed PCBA’s.
Value PropositionDocumentation

Documentation & Field Installation Manuals (FIM)

PDF - GE 20Nm
PDF - GE 30Nm A-BoxPDF - GE 30Nm b1/b2 BoxPDF - GE 30Nm b3 Box
PDF - Reliability questionsPDF - Installation picturesPDF - Life and replacement