Item no.: 947596.

R1 Software Upload Manual for Turbines on Date: 2004-11-11

Class: II
Issued by: Technology dept. VMP 5000.02 and VMP 6000 Type: MAN

Software Upload Manual for Turbines

based on VMP5000.02 and VMP6000

History of this Document

Changes in this document:

Rev. no.: Date: Description of change

0 2003-09-26 First edition

1 2004-11-11 Document adjusted according to Upload Tool release 1.32

Contents ......................................................................................................Page
1. Background ..................................................................................................................... 2
1.1 CT318 / VCP........................................................................................................... 2
2. The Technology in VMP5000.02 and VMP6000.............................................................. 3
2.1 Operating System ................................................................................................... 3
2.2 Communication ....................................................................................................... 3
2.3 File System ............................................................................................................. 4
3. Physical Connection to the Turbine................................................................................. 4
3.1 IP numbering........................................................................................................... 4
4. Workflow at a new turbine. .............................................................................................. 9
5. Workflow at an operational turbine ................................................................................ 11
6. General use of Vestas Upload Tool............................................................................... 14
6.1 Preparatory Routines ............................................................................................ 14
6.2 Common uses of the Upload Tool......................................................................... 15
6.3 The Functions in Vestas Upload Tool ................................................................... 20

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1. Background
In many respects, VMP controllers based on VMP5000.02 and VMP6000 are similar to the
previous ”well known” VMP5000.01 mounted in V52/V66/V80, but they also differ in many
important respects.

In order to be able to install/update the software in such a turbine, it is necessary to have a

basic knowledge of how this controller is designed.

The physical connection to the VMP controller and the actual software upload procedure are
both completely new and different and therefore they will be described thoroughly.

VMP6000 is used in the V90 – 3MW turbine and will be used in future turbine types.
VMP5000.02 is used in the V52/V66/V80.

1.1 CT318 / VCP

The VCP module CT318 has not been modified from the .01 to the .02 controllers and
therefore it is not subject to the technology description in section 2. However, it is no longer
necessary to flash the VCP module separately, as this will happen automatically during
booting of the control system. A copy of the VCP software is to be found in the top processor
node.

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2. The Technology in VMP5000.02 and VMP6000

2.1 Operating System

The VMP controller is based on an operating system called VxWorks. Among other things,
the operating system gives access to the VMP controller via Ethernet. The operating system
runs the actual control system and manages the communication between processor modules
internally in the turbine and also to the surroundings.

2.2 Communication
The communication between the processor modules in the turbine is based on ArcNet over
optical fibers and copper cable but in addition, Ethernet access for the use of remote control
and software upload has been introduced. On the turbine’s internal ArcNet and the external
Ethernet, a “language” called the TCP/IP protocol is used, which among other things makes
the transfer of files possible. Ethernet access to the system I granted through the ground
controller (CT291).

File transfers to and from the VMP controller happen by means of a technology called FTP
(File Transfer Protocol).

Nacelle Hub

CT6001 CT316 CT6001

CT316 CT318 CT244 CT244
VCMP/27
VCMP/28
Top/20 Hub/22
VCPM/25

Tower Fiber Optics ArcNet

Bottom Electrical ArcNet
Ethernet
CT244 = Optics / Electrical Converters
yyyy/xx = Processor module/ArcNet Node Number

CT291
Laptop
Gnd/10 PC

Figure 1: The network set up in a V90 3MW turbine.

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Figure 1 outlines the communication nerwork connections in a V90 3MW turbine based on
the VMP6000 system. Basically the communication network is structured in the same way in
a VMP5000.02 system.

2.3 File System

Each processor module, excluding node 25 (VCPM) has a DOS file system where the
VxWorks operating system, the actual VMP program, standard parameters, log files etc. are
stored.

The file system functions like a hard drive in an ordinary PC but is based on integrated
circuits, so-called flash circuits, to avoid rotating hard drives that can break.

The file system in each processor module is shared on the internal network to make it
possible to access these via the Ethernet access to the ground controller. The technology is
almost similar to the one used to share folders with other users on a PC.

In a PC, the different disks are typically called A: or C, whereas they are typically called /20
or the like in the VMP controller. According to Table 1:, the ArcNet node number of each
processor module determines the name of the disk (as set on the module’s dipswitch).

Module Disk name

Gnd /10
Top/Nacelle /20
Hub /22
VCMP top /28
VCMP hub /27
Table 1: Relation between module and disk name.

3. Physical Connection to the Turbine

The primary means of communication with a turbine based on VMP5000.02 or VMP6000 is
via the Ethernet plug on the ground controller CT291.02/03.

During normal operation, this plug is connected to the remote control system via an ordinary
(straight) UTP patch cable. At software upload locally in the turbine, CT291.02/03 is
connected to the laptop PC via a crossed UTP patch cable. A crossed UTP cable typically
has a specific color, e.g. red. Remember that the key switch must be in RCS position in order
for the Ethernet connection to work.

3.1 IP numbering

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All computers connected to a network via the TCP/IP protocol have a unique identification
number, an IP address. This applies to PCs as well as to control systems.

The IP address can be compared to a phone number and in many ways; a computer network
can be compared to a telephone system consisting of telephones communicating through a
telephone exchange.
An IP address consists of 4 numbers separated by a dot, e.g. 10.83.101.10. Each number is
between 0 and 255.

For two computers to communicate, e.g. a laptop PC and a ground controller in a turbine,
they must be on the same network – both physically and as regards the addresses. This
corresponds to the situation where you call an extension number internally in a company; the
telephones must be electrically connected, and the receiver on the other end must belong to
the same telephone exchange as the one that makes the call.

3.1.1 The IP address of a turbine in boot mode

If the turbine is put into boot mode, the ground controller’s IP address is automatically set to
the following known and fixed address: 169.254.254.254. This can be very convenient if you
inserted a panel with an unknown IP-address: Switch it into boot mode and it will have the IP-
address 169.254.254.254.

3.1.1.1 How to put the Turbine in Boot mode

Cut the power supply to the turbine controller for about 5 sec.
Press button 1 and switch on the supply to CT291 again.
Keep button 1 pressed for about 5 sec. until all 8 light diodes switch on at the same time.
Wait for about 15 sec. until the ground controller starts and light diodes 5 and 7 are on
constantly.
If necessary, wait for about 1 more minute to be sure that the nacelle processor toggles the
watchdog. Otherwise, the power to the VMP controller will disappear.

3.1.2 The operational turbine’s IP address

11.1a:ENTER IP NUMBERS (FUNC: Enter IDs)

IP ADDR 10. 83.101. 10
IP MASK 255.255. 0. 0
GATEWAY 10. 83. 1. 1 On (#: Off)

Figure 2: Display 11.1a showing the turbines IP address

During normal operation, the turbine has a site-specific IP address. This address can be read
and changed when the turbine is in its service mode in display image 11.1a. Press <FUNC>
in display image 11.1 to go to display image 11.1a.

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As shown, two other parameters, besides the IP address, can be changed.

IP ADDR: The IP address of the turbine. This is unique to each turbine on the site.
IP MASK: The IP mask shows which part of the IP address is the “extension number” and
which part is the master number. E.g. a typical Vestas phone number is 96 75 23 18, 96 75
being the master number and 23 18 the extension number. The master number cannot vary
only the extension. The IP ADDR and the IP MASK apply to all turbines on the site.

GATEWAY: The gateway address is the switchboard “phone number” used to communicate
with a computer outside the turbine. In some cases, this address is automatically set but
sometimes it has to be entered and activated by pressing <#>. The GATEWAY applies to all
turbines on the site.

The turbine will keep these IP settings even if the application does not start up. The only
exception is when it is put into boot mode, section 3.1.1.

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3.1.3 The PC’s IP address

In order to communicate with a ground controller, as mentioned earlier, necessary to set the
PC’s IP address within the same address area.

1 Enter the PC’s control panel.

2 Start “Network and Dial-up Connections”.
3 Double-click the “Local Area Connection”.
4 Click ”Properties”.
5 Choose “Internet Protocol (TCP/IP)”.
6 Click ”Properties”.
7 Mark ”Use the following IP address:”.
8 Enter an IP address in the turbine’s address area.
The first 3 numbers shall be the same as the first 3 numbers in the turbine’s
IP address. Pick the last number from the turbine plus or minus 1, but never
0 or 255 as these have special meaning.
Example: 169.254.254.253
9 Enter a Subnet mask: 255.255.255.0.
10 Leave the rest of the fields empty and it should look like Figure 3:
11 Click ”OK”.
12 Click ”Close”.
13 If you use Windows 98 or earlier you have to reboot your machine.

Figure 3: Computer IP properties.

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3.1.3.1 Check the PC’s IP address

Check that the PC has had the correct IP address by starting a command prompt in Windows
and entering ipconfig

A correct result will look something like this:

C:\>ipconfig

Windows 2000 IP Configuration

Ethernet adapter Local Area Connection:

Connection-specific DNS Suffix . :

Autoconfiguration IP Address. . . : 169.254.254.253
Subnet Mask . . . . . . . . . . . : 255.255.255.0
Default Gateway . . . . . . . . . :

3.1.3.2 Test of the connection

You can verify the contact with the ground controller by using the Windows program
Ping.exe.

Start a command prompt in Windows and enter the following:

ping 169.254.254.254

The result of this command tells much about the connection to the ground controller. Some
possibilities are listed below:

1. If the connection has been established correctly, the result will typically look like this:

C:\>ping 169.254.254.254

Pinging 169.254.254.254 with 32 bytes of data:

Reply from 169.254.254.254: bytes=32 time<10ms TTL=64

Reply from 169.254.254.254: bytes=32 time<10ms TTL=64
Reply from 169.254.254.254: bytes=32 time<10ms TTL=64
Reply from 169.254.254.254: bytes=32 time<10ms TTL=64

Ping statistics for 169.254.254.254:

Packets: Sent = 4, Received = 4, Lost = 0 (0% loss),
Approximate round trip times in milli-seconds:
Minimum = 0ms, Maximum = 0ms, Average = 0ms

2. The ground controller is turned off; the cable connection is defect, etc.:

C:\>ping 169.254.254.254

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Pinging 169.254.254.254 with 32 bytes of data:

Request timed out.

Request timed out.
Request timed out.
Request timed out.

Ping statistics for 169.254.254.254:

Packets: Sent = 4, Received = 0, Lost = 4 (100% loss),

Approximate round trip times in milli-seconds:

Minimum = 0ms, Maximum = 0ms, Average = 0ms

3. The IP address of the PC is not set correctly. To verify, use the command “ipconfig” from a
prompt:

C:\>ping 169.254.254.254

Pinging 169.254.254.254 with 32 bytes of data:

Destination host unreachable.

Destination host unreachable.
Destination host unreachable.
Destination host unreachable.

Ping statistics for 169.254.254.254:

Packets: Sent = 4, Received = 0, Lost = 4 (100% loss),

4. Workflow at a new turbine.

1. Dismount the UTP cable from the Ethernet plug in the ground controller.
2. Restart the ground controller in boot mode, see section 3.1.1.1.
3. Make sure the key is in RCS.
4. Connect the crossed UTP cable between the laptop PC and the ground controller.
5. Start your PC.
6. Set the PC’s IP configuration as in 3.1.3. Set your PC’s IP address to
169.254.254.253.
7. Start Vestas Upload Tool.
8. In target IP type 169.254.254.254.
9. In Turbine Number type 0.
10. Press Connect. The output should be
Trying to connect to 169.254.254.254…Warning: Turbine number not available
for checking
Ok

If messages pops up see section 6.2.4.1.

11. Press Set time.
12. Press the Browse besides File to upload:
13. Pick the right turbine release and press Open.
14. Press Upload.

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15. After a while a window like Figure 4: will pop up. Check that there are the right nodes
present for the given turbine. For instance node 28 (VCMS) is not present on many
turbines. On a V52 you should only see node 10 and 20.
Press Ok.

Figure 4: Selection of which node to upload to

16. If you get the error shown in Figure 5 proceed by
a. Press OK.
b. Update the boot sector(s) as in section 6.2.3.
c. Press Stop Toggle Watchdog to make the turbine reboot. It will take 30 seconds,
approximately.
d. Set the ground controller in boot mode as in section 3.1.1.1.
e. Go back to 14.

Figure 5: Error message “Boot sector needs update”.

17. A normal upload will take about 5-20 minutes. Wait for the Upload finished message
shown in Figure 6 and press Ok.

Figure 6: Upload finished message.

18. Make the turbine reboot by pressing Stop Toggle Watchdog.
Wait about 1 minutte and the turbine software should start up.
19. In order to coldboot the controller keep button 1 and 2 pressed until all 8 lights diodes
switch on at the same time.
20. Change the parameters.
21. Restart the controller.

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5. Workflow at an operational turbine

1. Dismount the UTP cable from the Ethernet plug in the ground controller.
2. Connect the crossed UTP cable between the laptop PC and the ground controller.
3. Start your PC.
4. Go into picture 11.1a on the turbine and read the IP address.
5. Make sure to switch the key back into RCS mode.
6. Set the PC’s IP configuration as in 3.1.3.
Set your PC’s IP address to be the same as the turbines IP address except for the
last number which have to be plus or minus one compared to the last number in
the turbine’s IP address but never 0 nor 255.
7. Start Vestas Upload Tool.
8. At Target IP type in the turbines IP address.
9. At Turbine Number type in the turbines number.
10. Press Connect.
It will print
Trying to connect to <IP address>…
and a little while after
Trying to connect to <IP address>…Ok

If messages pops up see section 6.2.4.1.

11. Press Full Ramdump. This will usually take a while.
12. Press Set Fail Safe.
13. Press Stop Toggle Watchdog.
Wait until the turbine has rebooted (30 seconds to a minute).
14. Press OS stati.
Be aware that you don’t get a reliable answer before the turbine has fully rebooted.
Until that happens you will get the errors in 6.2.4.1. Verify that each processor
node is in “No application mode”, like in Figure 7. If not go back to 12.

Figure 7: Window showing the state of each node.

15. Press the Browse next to Upload. Pick the right turbine release archive and press
Open.
16. Press Upload.
17. After a while a window like Figure 8 will pop up. Check that there are the right
nodes present for the given turbine. Many turbines do not have a node 28 (VCMS)
and V52 does only have node 10 and 20.
Press Ok.

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Figure 8: Selection of which node to upload to.

18. If you get the error in Figure 9 then press OK and update the boot sector(s) as in
section 6.2.3 and go back to back to12.

Figure 9: Error message “Boot sector needs update”.

19. A normal upload will take about 5-20 minutes. Wait for Upload finished message
shown in Figure 10 and press Ok.

Figure 10: Upload finished message.

20. Press Reset startup fail.
21. Make the turbine reboot by pressing Stop Toggle Watchdog.
Wait about 30 seconds.
22. Press OS stati to verify the turbine is in Normal application mode. This might fail a
few times because the turbine has to be ready to answer first, see 6.2.4.1. Keep
pressing OS stati again until a window with a message like Figure 11 appears. The
number of nodes depend of the configuration of the turbine.

Figure 11: Window showing the state of each node.

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23. Check the ground panel and wait until the controller displays the overview picture1.
24. Press Reestablish.
25. Choose the latest setup.zip file made from the current turbine and press Open.
The reestablish takes several minutes.
26. At some point the parameter restore dialog box shown in Figure 12 will appear.
Press Ok unless you have uploaded the same software version as the one from
which you have the ramdump. Otherwise you have to type in the parameters
manually.

Figure 12: Parameter restore.

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6. General use of Vestas Upload Tool

Software upload for a VMP5000.02 or VMP6000 turbine takes place by means of a special
program called Vestas Upload Tool, Figure 13. This tool can automatically transfer the
program files to the different processor modules in the turbine and can also perform other
different tasks such as backup of the existing application in the turbine, ramdump,
reestablishment and rebooting of the turbine.

Figure 13: Vestas Upload Tool user interface.

6.1 Preparatory Routines

6.1.1 Connect PC and Ground Controller

1. Dismount the UTP cable from the Ethernet plug in the ground controller.
2. Connect the crossed UTP cable between the laptop PC and the ground
controller.
3. Set the PC’s IP configuration as in 3.1.3.

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6.1.2 Starting the upload tool

1. Start Upload Tool.
2. Type in the IP address and the turbine number.
3. Press Connect. It will print
Trying to connect to <IP address>…
and a little while after
Trying to connect to <IP address>…Ok
If the turbine software is not loaded it will print
Trying to connect to <IP address>…Warning: Turbine number not
available for checking
Ok

If messages pops up see section 6.2.4.1.

6.2 Common uses of the Upload Tool

Here we describe some common operations in detail. Software upload is described in the
sections 4 and 5.

6.2.1 Making a ramdump

Before changing processor boards or updating it the VMP software it is very important to get
all data out of the turbine before you start.
1. If not already done, start upload tool and connect as in section 6.1.2
2. Press Full Ramdump. A box like Figure 14 will come up at the end if the Ramdump
has succeeded.

Figure 14: Ramdump finished successfully.

If there is a difference between the turbine time and the PC time a window like Figure 15
will appear. Check the time of the turbine. If the time is ok press OK. If the time of the PC
is ok press Cancel, then Set time and try the ramdump again.

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Figure 15: Mismatch in the turbine time and the PC time.

6.2.2 Reestablish
After a software upload or after a processor module has been changed it is important to
reestablish all old data on a turbine.

1. If not already done, start upload tool as in section 6.1.2.

2. Press Reestablish. When it asks for a file choose your latest setup.zip-file from the
current turbine and press Open.
Notice that reestablish will fail until the turbine application has fully started. Errors like
in Figure 16 might appear. Press OK and try again.

Figure 16: Error message due to the turbine application isn’t fully started.

3. At some point the point the parameter restore dialog box shown in Figure 17 might
appear. Press Cancel unless you have uploaded the same software version as the
one from which you have the ramdump. Otherwise you have to type in the parameters
manually.

Figure 17: Parameter restore.

6.2.3 Updating the bootsector

WARNING: Updating the bootsector has to be handled with care. It is a good idea to have
replacement processor modules available. If the power is cut during an update the processor
module has to be replaced.

1. Press Update boot sector.

2. After a while you get the boot sector update window shown in Figure 18.

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Figure 18: Update of the boot sector.

Press Update for each of the processor modules that need to be updated. In the above
example processor nodes 10, 22 and 28 needs to be updated. The update takes a while.
3. Each boot sector update should end with a window like Figure 19, to which you press
OK.

Figure 19: Successful boot sector update on node 10.

4. When the boot sector has been updated at all the needed processor modules press
Done.

6.2.4 Common error messages in Vestas Upload Tool.

6.2.4.1 Errors when trying to connect

The error message shown in Figure 20 will cone up if you have misspelled the Target IP.
Look at it again and try again.

Figure 20: Error message due to misspelled target IP.

If there is no connection between the PC and the turbine the error message shown in Figure
21. This can happen when the turbine is rebooting. Press Ok and try again. If the problem is
still there after 3 tries see section 3.1.3.1.

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Figure 21: Error message due to missing connection between pc and turbine.

If you are trying to connect to the turbine while the application is loading, the error message
shown in Figure 22 will come up. Press Ok and try again.

Figure 22: Error message when the turbine is starting up.

If you are trying to connect to the turbine while it is rebooting, the error message shown in
Figure 23 will come up. Press OK and try again.

Figure 23: Error message when the turbine is rebooting.

If the IP connection to the turbine unmotivated has been closed down, the error message
shown in Figure 24 will come up. This happens most often because the turbine has been
rebooted. It can also mean that somebody else is connected to the turbine or the controller is
too busy handling your request. Press OK and restart your operation.

Figure 24: Error message when IP connection to the turbine is closed.

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Figure 25: Error message when IP connection to the turbine is closed.

6.2.4.2 Other common errors

The error message shown in Figure 26 will appear if the Upload Tool program is working
while a new task is trying to be started. Please be patient and wait until Upload Tool is ready
or interrupt the running task by pressing “Disconnect” and restart the wanted task.

Figure 26: Error message when Upload Tool is busy.

If reestablish is started before the turbine application have fully booted the error message
shown in Figure 27. Press Ok and try again.

Figure 27: Reestablish is started before the turbine application is fully booted .

When trying to make a ramdump and there is a mismatch in the turbine time and your PC
time the error message shown in Figure 28 will appear. Check which of the two clocks that
are correct. If the turbine time is ok press OK. If the PC time is ok press Cancel, press Set
time and try to make a ramdump again.

Figure 28: Mismatch in the PC clock and the turbine clock.

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6.3 The Functions in Vestas Upload Tool

Figure 29: Vestas Upload Tool user interface.

Ramdump. Takes a usual ramdump from a turbine in operation and puts it as a file under
C:\Vmp\<turbine number> on the PC’s hard disk. These ramdumps are the same as those on
VMP3500 and VMP5001. However, these are not sufficient to reestablish a VMP5002 or
VMP6000 turbine. Do instead use Full Ramdump below to get a backup of the state of the
turbine to be used in reestablish.

Full Ramdump makes a full ramdump in a .setup.zip file under C:\Vmp\<turbine number>.
The .setup.zip file will contain the old style ramdump along a lot of files which also needs to
be restored after a software upload.

Set Fail Safe disables the application the next time the turbine reboots. This will prevent the
controller from starting the application.

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Reboot Ground. If something goes wrong during upload, e.g. if the ”Stop Toggle Watchdog”
does not work, you can press this button. This will only reboot the ground controller, though.
Do not use this on a running turbine, as it will cause a crash.

Stop Toggle Watchdog will ask the controller to stop triggering the watchdog. This will make
the turbine reboot soon after. This can safely be used even if the turbine is running, as the
turbine application will stop the turbine before rebooting.

WorldMap. Is used to troubleshoot the ArcNet by showing which nodes the ground panel can
see on the ArcNet. Usually nodes on the network are marked with a green square. If you see
yellow squares the network is reconfigurating. Red squares means that the controller does
not even answer the query. This happens if the controller reboots or crashes.

OS stati is used to see in what status the various processors on the turbine are.

Reset Startup Fail. Resets the reboot counter. If the turbine reboots too often, it will avoid
starting. With the Reset Startup Fail button, you can reset the counter in order for the turbine
to reboot normally again. Use it if the turbine for some reason does not start and nothing
appears in the display.

Read Contoller State. Reads the state of the controller software. “Not implemented” means
that either no application is loaded or the loaded application is so old that it does not support
this functionality. “Running” means the turbine controller is running, i.e.the turbine is in
emergency or higher.

Set Time copies the PC’s watch to the turbine’s processor. Should only be used on turbines
that are not already in operation or turbines where the watch is wrongly set.

Update bootsector is used to update the bootsector on the processor nodes, see section
6.2.3. Do not do this unless it is required as it might ruin the processor boards if the power is
cut during the operation.

Reestablish uploads the content of a setup.zip file from your hard drive. Used to reestablish
the data of the turbine after a software upload or a module replacement.

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