Erection Instructions Tubular Steel Tower Up To 100 M

Erection instructions
Tubular steel tower up to 100 m

Wind turbine class K08 gamma
External transformer
K0801_031656_EN
Revision 04 / 2014-10-17
- Translation of the original instructions Document is published in electronic form.

Signed original at Nordex Energy GmbH, Engineering Department.
2015 by Nordex Energy GmbH
Technical modifications
This document was created with utmost care, taking into account the currently
applicable standards.
However, due to continuous development, the figures, functional steps and
technical data are subject to change without prior notice.
Copyright
Copyright 2015 by Nordex Energy GmbH.
This document including its presentation and content is the intellectual property
of Nordex Energy GmbH. The information in this document is intended
exclusively for Nordex employees and employees of trusted partners and
subcontractors of Nordex Energy GmbH and Nordex SE and must never (not
even in extracts) be disclosed to third parties.
Any disclosure, duplication or translation of this document or parts thereof in
printed, handwritten or electronic form without the explicit approval of Nordex
Energy GmbH is explicitly prohibited.
All rights reserved.
Contact details
For questions relating to this documentation please contact:
Nordex Energy GmbH
Langenhorner Chaussee 600
22419 Hamburg
Germany
http://www.nordex-online.com
info@nordex-online.com
2015 by Nordex Energy GmbH
Inhaltsverzeichnis
Revision 04 / 2014-10-17
1.
Scope ................................................................................................................... 7
2.
Safety information .............................................................................................. 8
3.
Conventions ........................................................................................................ 9
3.1
Symbols and notes ............................................................................................... 9
3.2
Notes on text format............................................................................................ 10
4.
General notes on erection................................................................................ 11
5.
Completion of the foundation .......................................................................... 13
5.1
Checking the acceptance of the foundation........................................................ 13
5.2
5.2.1
5.2.2
5.2.3
5.2.4
Preparing the foundation.....................................................................................

Cutting the conduits to fit ..................................................................................
Preparing the anchor bolts ...............................................................................
Preparing the foundation screw connection .....................................................
Drawing in the center lines ...............................................................................
5.3
Marking the position of the tower door................................................................ 17
6.
Attachment of the tower section to the crane ................................................ 18
6.1
6.1.1
6.1.2
Assembling the LLA weldment............................................................................ 18

Inserting the flange bushings............................................................................ 18
Assembling the LLAs to the top tower flange ................................................... 19
6.2
Hook in the J hook .............................................................................................. 21
6.3
Attaching the tower section to the crane............................................................. 22
7.
Preparation of the tower section ..................................................................... 23
7.1
7.1.1
7.1.2
7.1.3
Unloading the tower section................................................................................

Storing the tower section ..................................................................................
Unpacking the tower section ............................................................................
Preparing the tower section..............................................................................
7.2
Checking the vertical ladder................................................................................ 28
7.3
Assembling the air vent....................................................................................... 29
7.4
Securing the service lift....................................................................................... 29
8.
Erection of the base section ............................................................................ 30
8.1
Preparing the electrical installation ..................................................................... 30
8.2
Establishing the power supply in the tower ......................................................... 31
8.3
Marking the tower door ....................................................................................... 32
8.4
Lifting the base section onto the foundation ....................................................... 32
8.5
Assembling the base section on the foundation ................................................. 33

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8.6
Grounding the base section ................................................................................ 36
9.
Assembly of the tower interiors ...................................................................... 37
9.1
9.1.1
9.1.2
Mounting the tower stairs.................................................................................... 37

Erecting a pad foundation ................................................................................ 37
Assembling the stairs to the pad foundation..................................................... 38
9.2
Disassembling the platform parts of the standard plus platform ......................... 39
9.3
9.3.1
9.3.2
Installing the main converter ............................................................................... 40

Attaching the main converter to the crane........................................................ 40
Assembling the main converter ........................................................................ 41
9.4
Assembling the platform parts of the standard plus platform .............................. 42
9.5
9.5.1
9.5.2
9.5.3
Installing the converter cooling ...........................................................................

Mounting the cooler ..........................................................................................
Assembling the water pump .............................................................................
Connecting the water pump to the main converter...........................................
9.6
Mounting the tower exteriors............................................................................... 45
10.
Completion of the erected tower section ....................................................... 46
10.1
Measuring the vertical alignment of the erected tower section ........................... 46
10.2
10.2.1
10.2.2
10.2.3
Preparing the screw connection for the next tower section ................................
Preparing the top platform ................................................................................
Equipping the toolbox .......................................................................................
Lifting the toolbox .............................................................................................
10.3
Sealing the tower flange ..................................................................................... 47
10.4
Grounding the tower flange................................................................................. 47
10.5
10.5.1
10.5.2
10.5.3
Providing the fall protection system ....................................................................

Preparing the vertical ladder.............................................................................
Connecting the fall arrest rail............................................................................
Installing the fall arrest rope .............................................................................
11.
Erection of the tower ........................................................................................ 51
11.1
11.1.1
11.1.2
Interruptions during tower erection ..................................................................... 51

Considering interruption periods in the assembly state.................................... 51
Bracing the tower.............................................................................................. 52
11.2
Lifting the tower section onto the tower .............................................................. 52
11.3
Establishing the power supply ............................................................................ 53
11.4
11.4.1
11.4.2
Assembling the tower section onto the tower ..................................................... 54

Screw connections for a 4-part tower ............................................................... 54
Screw connections for a 5-part tower ............................................................... 61
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Revision 04 / 2014-10-17
12.
Completion of the tower ................................................................................... 64
12.1
Operating the service lift ..................................................................................... 64
12.2
Removing the aluminum hollow section on the loop ........................................... 65
12.3
Completing the water cooling system for the main converter ............................. 67
12.4
Sealing the tower ................................................................................................ 68
12.5
Assembling the fire extinguisher ......................................................................... 69
12.6
Attaching the signs.............................................................................................. 69
13.
Installation of the main converter ................................................................... 71
13.1
13.1.1
13.1.2
Connecting the main converter to the transformer substation ............................ 72

Connecting the LV cables to the main converter.............................................. 72
Laying the LV cables ........................................................................................ 72
13.2
13.2.1
13.2.2
13.2.3
13.2.4
13.2.5
Grounding the components.................................................................................

Laying the grounding cables.............................................................................
Checking the grounding of the base section ....................................................
Grounding the main grounding bar...................................................................
Grounding components ....................................................................................
Grounding the tower interiors ...........................................................................
13.3
13.3.1
13.3.2
Completing work ................................................................................................. 74

Cleaning the working area................................................................................ 74
Preserving damaged areas .............................................................................. 74
14.
Quality notes on the installation of the electrical connections .................... 75
14.1
Labeling .............................................................................................................. 75
14.2
Laying the cables ................................................................................................ 75
14.3
Stripping cables .................................................................................................. 76
14.4
14.4.1
14.4.2
14.4.3
14.4.4
Pre-assembling the cables using mechanical connections.................................

Preparing mechanical connectors and cable lugs ............................................
Preparing aluminum cables ..............................................................................
Preparing copper cables...................................................................................
Assembling the mechanical connector or mechanical cable lug ......................
14.5
Pre-assembling copper cables using a crimp connection ................................... 83
14.6
Insulating cable connections with roll-on sleeves ............................................... 85
14.7
14.7.1
14.7.2
14.7.3
14.7.4
Connecting cables to the connection system in the main converter ...................

Pre-assembling cables outside the main converter..........................................
Pre-assembling the cables inside the main converter ......................................
Connecting the copper cables in the main converter .......................................
Connecting the aluminum cables in the main converter...................................
15.
Quality notes on the assembly of the screw connections ............................ 93
15.1
Fasteners ............................................................................................................ 93
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15.1.1
15.1.2
Differences in the fasteners.............................................................................. 93

Fasteners for special applications .................................................................... 93
15.2
15.2.1
15.2.2
15.2.3
15.2.4
15.2.5
Screw assembly.................................................................................................. 93
Torque-controlled tightening method................................................................ 94
Hydraulic tightening method ............................................................................. 96
Tightening torques up to K08 beta ................................................................... 98
Tightening torques from K08 gamma ............................................................... 99
Tightening torques for hand-tightening........................................................... 100
15.3
15.3.1
15.3.2
15.3.3
15.3.4
15.3.5
15.3.6
15.3.7
Marking the screw connection ..........................................................................

Screws with screw lock...................................................................................
Hydraulically tightened stud bolts ...................................................................
Screws tightened with the torque-controlled method......................................
Maintenance type 1 ........................................................................................
Test marking of the screw connection ............................................................
100
100
101
101
101
102
102
102
15.4
15.4.1
15.4.2
15.4.3
15.4.4
Srv fasteners.....................................................................................................
Lubricating srv fasteners ................................................................................
Assembling srv fasteners ...............................................................................
Re-using srv fasteners....................................................................................
Documenting the use of the srv fasteners ......................................................
104
104
105
105
106
16.
Quality notes on the preservation ................................................................. 108
16.1
16.1.1
16.1.2
Preserving the nacelle ...................................................................................... 108

Preserving parts outside of the nacelle .......................................................... 108
Preserving parts inside the nacelle................................................................. 109
16.2
16.2.1
16.2.2
Preserving the fasteners ................................................................................... 109

Cleaning fasteners before assembly .............................................................. 110
Preserving fasteners after assembly .............................................................. 110
16.3
Repairing paint damage at low temperatures ................................................... 112
17.
Revision index................................................................................................. 113
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K0801_031656_EN
1.
Revision 04 / 2014-10-17
Scope
The present erection instructions describe the erection of wind turbines of
turbine class K08 gamma.
The work steps in these erection instructions must only be carried out by
appropriately qualified, trained and commissioned specialized personnel.
K0801_031656_EN
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2.
Safety information
OBSERVE DOCUMENT
Safety manual NALL01_011010 Rules of conduct on, in and around wind
turbines
Documented procedure HSE12 Works in, at and on wind turbines
The Safety Manual NALL01_011010 must be read and understood. The safety
notes must be observed.
A prerequisite for carrying out the work described is the compliance with all
national and Nordex GmbH-defined safety-relevant standards and
specifications.
The extensive health and safety regulations implemented at Nordex Energy
GmbH form the basis of occupational health and safety and environmental
protection.
The valid accident prevention regulations must be observed.
If operating materials are used, always observe and adhere to the
manufacturer's information on existing health risks.
Always use a PPA when working where a fall hazard is, e.g. on the nacelle roof
or when climbing into the hub Secure yourself at the corresponding personal
attachment points.
General safety instructions (e.g., how to handle respective tools and hoists),
references to corresponding guidelines and occupational health and safety
regulations, as well as generally accepted handling procedures are not
mentioned.
Page 8 of 116
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3.
Conventions
3.1
Symbols and notes

Hazard of personal injury
DANGER
Failure to comply with the instructions and notes will result in life-threatening
injury.
WARNING
Failure to comply with the instructions and notes may result in serious injury.
CAUTION
Failure to comply with the instructions and notes will result in injury.
Warning of material damage
NOTICE
Warning of damage to components or material

Notes and information
NOTE
Additional information, notes and hints
OBSERVE DOCUMENT
Reference to information in other documents
Integrated safety notes and information

Information and safety notes integrated into the text. Indicated by the signal word
in bold: Note, Notice, Caution, Warning.
Example
Symbols and notes
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Notice: To prevent damage to the paintwork, the tower sections must not
touch the ground.
3.2
Notes on text format

Lists and work steps
Work step
Result of a work step
List
- Subordinate list
Italic text
Identification of proper names: e.g., manufacturer names, document titles.
SAP no. with revision
An SAP no. with revision digits is written as follows, e.g.:
SAP no. 1036116-XX
- 1036116: leading digits of the SAP number
- -XX: extension for the revision digits
Note: For the complete SAP no. refer to the applicable bill of materials and/or
the production order.
Page 10 of 116
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Notes on text format
4.
Revision 04 / 2014-10-17
General notes on erection

OBSERVE DOCUMENT
Current erection report
Document any work that has been carried out during the erection in the
current Erection report
Once the erection has been completed, submit the completed and signed
Erection report to Nordex
Document any damage and repairs with photos that are true to scale.
OBSERVE DOCUMENT
All applicable documents
Observe all documents specified in the relevant chapters
The content and all safety notes in the applicable documents must be read
and understood by all individuals involved in the erection.
NOTE
The following chapters contain general qualitative and professional
requirements to the execution of the work described:
see chapter 14 "Quality notes on the installation of the electrical
connections"
see chapter 15 "Quality notes on the assembly of the screw connections"
see chapter 16 "Quality notes on the preservation"
NOTE
All tools, equipment and consumables required for the erection are provided in
erection containers.
WARNING
RISK OF INJURY
Proper functioning of the tools, lifting tackle and fasteners cannot be
guaranteed at temperatures below -20 C. A safety-relevant erection is thus
not possible.
In frosty conditions, tools and lifting tackle must be thawed and dried in a
heated container
Only perform erection and assembly work at temperatures above -20 C
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DANGER
DANGER TO LIFE FOR UNAUTHORIZED PERSONS
No unauthorized individuals may be present on the construction site during the
entire erection work.
Cordon off a large area around the construction site
Install warning signs around the construction site
Stop all activities if unauthorized persons gain access to the area of the
construction site
Remove unauthorized persons from the construction site
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5.
Completion of the foundation
5.1
Checking the acceptance of the foundation

OBSERVE DOCUMENT
Inspection instructions K0801_036711 Measuring the electrical safety
Measurement report NALL01_036727 Foundation grounding
Erection instructions K202_032 Anchor cage
Logbook K404_142_A02 Record of ground resistance measurements
Non-conformity report
The foundation (including conduits, load-spreading plate and grouting mortar)
has completely been built, leveled and released for tower erection.
Check the erection report K202_032 for completeness
Check the logbook K404_142_A02 for completeness
Check the 4 grounding leads in the foundation
4 grounding leads are available
Each grounding lead is at least 2 m long
Toward the concrete foundation, each grounding lead is sealed with a
heat-shrink tube
Randomly inspect the foundation
Component
Foundation
Damage
Description
Visible damage
Flaking
Cracks
Contaminations
Horizontal position
Load-spreading plate
Cavities
Checking the acceptance of the foundation
K0801_031656_EN
Faults
Concrete adhesions
Welding spatter
Visual inspection
Leveling instrument
Layer structure of the
grouting mortar
Flaking
Knock test
Sound test
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Component
Anchor bolts
Damage
Description
Contaminations
Faults
Concrete adhesions
Welding spatter
Vertical position
1.1 test with angle

2 mm/100 mm
Thread damage
Faults
Concrete adhesions
Welding spatter
Complete and send the non-conformity report for foundation damage
5.2
Preparing the foundation
5.2.1
Cutting the conduits to fit

Drain the water
Cut the conduits individually to the required length
Length of conduits approx. 200 mm above the foundation
Fig. 1
Conduits (similar to figure)
Clean the load-spreading plate with a brush, wire brush or tool
5.2.2
Preparing the anchor bolts

Sweep out the gaps between the anchor bolts
Clean the anchor bolt threads with a wire brush
Lubricate the anchor bolt threads completely with Molykote G-Rapid Plus
immediately before erection
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Revision 04 / 2014-10-17
Note: Molykote G-Rapid Plus determines the friction coefficient of the screw
connection and is used for lubrication and corrosion protection.
5.2.3
Preparing the foundation screw connection
Fig. 2
Screw connection foundation (similar to figure)

1 Anchor bolt
2 HV washers and hexagon nuts
Prepare the screw connection for the foundation, see fig.2

Lubricate the contact surfaces of the HV washers with the hexagon nuts with
Molykote G-Rapid Plus
Apply 1 bead of UV resistant silicone between the 2 parts of the loadspreading plate
Apply 1 bead of UV resistant silicone between the two rows of anchor bolts
Apply 1 bead of UV resistant silicone all around the two rows of anchor bolts,
see fig.3
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1
2
3
Fig. 3
Applying silicone (similar to figure)

1 Between the 2 sections of the load-spreading plate
2 Between the two rows of the anchor bolts
3 To the outer radius of the two rows of the anchor bolts
5.2.4
Drawing in the center lines

Draw in the vertical center line on the foundation
The vertical center line is parallel to the conduits
Draw in the horizontal center line on the foundation
The horizontal center line runs centrally to the conduits
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2
1
3
Fig. 4
Drawing in the center lines

1 Conduits
2 Vertical center line
3 Horizontal center line
5.3
Marking the position of the tower door

Mark the center line of the tower door position
The vertical center line of the foundation and the tower door line up with
each other, see fig.4
The marking is clearly visible on the load-spreading plate at the external
flange
Marking the position of the tower door
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6.
Attachment of the tower section to the crane

Abbreviation
6.1
EWL
Effective working length
LLA
Load lifting attachment
WLL
Working load limit
TAP
Tower attachment point
Assembling the LLA weldment

OBSERVE DOCUMENT
Engineering drawing 07020-1008650 LLA tower section for the top right
tower
Engineering drawing 07020-1021907 LLA tower section for the top left tower
flange
Operating instructions NALL20_024847 Superbolt preloading system
Attachment point
Load lifting attachment

LLA tower section for top right tower flange
Top tower flange
6.1.1
Main crane
LLA tower section for top left tower flange
Inserting the flange bushings
Flange
bushing
Length
l [mm]
ERP 1025352
39
ERP 1025343
59
ERP 1052689
97
ERP 1025688
123
ERP 1036707
71
ERP 1052874
127
ERP 1025344
143
ERP 1067562
100
ERP 1042489
122
ERP 1028096
142
Page 18 of 116
Crane
Outer
do [mm]
Inner
di [mm]
Washer
Drill hole
flange
Bolt
LLA
44
38
ERP 1036679
M42
M36
50
38
ERP 1036679
M48
M36
57
38
ERP 1036679
M56
M36
K0801_031656_EN
Flange
bushing
ERP 1042490
Revision 04 / 2014-10-17
Length
l [mm]
Outer
do [mm]
Inner
di [mm]
Washer
Drill hole
flange
Bolt
LLA
167
64
38
None
M64
M36
da
di
Fig. 5
Flange bushings
Select a suitable flange bushing and washer, if required

Length and diameter of the flange bushing fills out the hole
Notice: Flange bushing must not protrude.
Insert the flange bushings into the drill holes of the tower flanges, see fig.6
Slightly grind down the flange bushings at the edge if they do not fit easily into
the drill holes
Fig. 6
6.1.2
Flange bushings
Assembling the LLAs to the top tower flange

Hold the spirit level vertically to the bolt circle
Mark the center hole on both sides
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Attach the LLA to the auxiliary crane

- Transport brackets
- Weight 44.9 kg
Position the LLA to the top tower flange, see fig.7
- Rating plate outside
- Lifting lug inside
Fasten the top tensioning nut
- LLA: Drill hole 39 mm top
- Tower flange: Drill hole above the marked drill hole
Fasten the bottom tensioning nut
- LLA: Slotted hole 39 mm bottom
- Tower flange: Drill hole below the marked drill hole
Assemble the LLA to the top tower flange
HV nut M36
Designation
Quantity SAP no.
HV washer EN 14399-6-36-tZn
HV nut EN 14399-4-M36-10-tZn
Torque wrench
Tightening torque 500 Nm
Superbolt tensioning nut
Designation
Quantity SAP no.
Tensioning nut Superbolt MR-M36x4
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32682
Lubrication with the lubricant delivered

Torque wrench
1 x crosswise with a tightening torque of 45 Nm
With a tightening torque of 90 Nm in several turns until all DRK screws are
evenly tightened
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Fig. 7
LLA on top tower flange

1 Lifting lug inside
2 Rating plate outside
6.2
Hook in the J hook

OBSERVE DOCUMENT
Operating instructions K0820_060038 operating manual Axzion J hook for
construction number 514010028-1 to -28
Valid for all tower sections:
Hook in the Axzion J hook into the bottom tower flange according to operating
instructions K0820_060038
Fig. 8
Hook in the J hook
Axzion J hook hooked in
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6.3
Attaching the tower section to the crane

OBSERVE DOCUMENT
Attaching the tower section to the auxiliary crane with the J hook
Attach the tower section to the crane with the Axzion J hook according to
operating instructions K0820_060038
Attaching the tower section to the main crane
Connect 2 lifting lugs of the LLAs on the top tower flange to the main crane
- 2 bow shackles WLL 55 t
- 2 webbing slings WLL 40 t; EWL 6 m
Fig. 9

1 Bottom tower flange, auxiliary crane
2 Top tower flange, main crane
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7.
Revision 04 / 2014-10-17
Preparation of the tower section

DANGER
FALL HAZARD
Fall hazard if work is performed on the tower section without protection.
Work must only be carried out using a leaning ladder and a working platform
with officially tested operator protection.
7.1
Unloading the tower section
7.1.1
Storing the tower section

WARNING
RISK OF TILTING AND ROLLING OFF
On sloping ground the tower section can tilt, slip or move off.
Always store the tower section on a stable support.
Prepare stable supports with squared timber and support from the transport
vehicle or crane mats
Place a piece of clean textile, e.g. carpet, onto the stable support
Notice: If the tower section comes into contact with the ground, paint
damage may result.
Lift the tower section onto a stable support
Notice: When storing a tower section always place the support under the
flange of the tower section, not under the weld seam.
Transport vehicles with hydraulic holding device
Lower the top tower flange of the tower section onto a stable support using
the hydraulic holding device
Detach the tower section from the hydraulic holding device
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Fig. 10
Hydraulic holding device
Transport vehicle without hydraulic holding device

Remove the transport securement from the tower section
7.1.2
Unpacking the tower section

Remove the protective covers from the front and rear
Put aside the protective covers to be returned to the tower manufacturer
Disassemble lifting and lashing plates
Remove all wooden transport supports and transport brackets
7.1.3
Preparing the tower section

Check the tower interiors for completeness and transport damage
- Vertical ladder
- Platforms
- Lighting
- Cable brackets
- Service lift, etc.
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Fig. 11
Revision 04 / 2014-10-17
Tower interiors (similar to figure)
Check the tower interiors randomly for correct fastening

Remove or securely fasten loose items
Clean the tower sections inside and outside
Repair paint damage properly
- Grind
- Clean
- Apply primer
- Apply paint
Complete and send a non-conformity report for incomplete or damaged base
section
Top section
Check the round Hydac cable clamps for breaks
Replace broken round Hydac cable clamps
Check the braced Hydac cable clamp for proper fastening and positioning
Note: The braced Hydac cable clamp is positioned in the center of the tower
with the Hydac bracing set. 3 guy wires are attached to the 3 eyebolts on the
braced Hydac cable clamp.
The length of the guy wires of the Hydac bracing set is adjusted as follows:
- With 2 snap hooks for rough adjustment
- With a turnbuckle for fine adjustment
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Fig. 12
Braced cable clamp with guy wire

1
2
3
4
Eyebolt on braced Hydac cable clamp

1st (inner) snap hook
2nd (outer) snap hook
Turnbuckle
Check the following:

- 1st (inner) snap hook of the guy wire is hooked into braced Hydac cable
clamp
Note: The 2nd (outer) snap hook continues to hang freely.
DANGER
COLLISION HAZARD
The service lift may collide with the guy wires during yawing of the nacelle if
the wires are not tight enough.
Adjust the guy wires to the correct length.
Guy wires adjusted to correct length

Braced Hydac cable clamp in central position
Tight guy wires without any slack
Guy wires without tensile stress, i.e., the guy wires do not hold the cable
weight
Turnbuckle secured against unscrewing with cable ties
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Fig. 13
Revision 04 / 2014-10-17
Turnbuckle secured with cable ties
Remove the fastening of the dampers between the aluminum hollow section
and the Hydac cable clamps
Note: The dampers will fall out during the erection of the top section.
Fig. 14
Damper between aluminum hollow section and Hydac cable clamp

(similar to Fig.)
Remove the cable support from the aluminum hollow section

Remove the 2 short ratchet straps
Note: The long ratchet strap is only removed after the erection of the top
section.
K0801_031656_EN
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1
Fig. 15
Removing cable support and ratchet straps

1 Short ratchet strap
2 Long ratchet strap
3 Cable support
7.2
Checking the vertical ladder

OBSERVE DOCUMENT
Operating instructions NALL02_005046 (MA 5017 d/e) Haca - fall protection
rails
Inspection report NALL02_014263 Haca - fall protection system
Check the vertical ladder for secure fastening
The ladder is connected throughout
All screw connections are tight
Vertical ladder with fall arrest rail
Check the stopper at the fall arrest rail
At each termination of the fall arrest rail a metal plate must be assembled
as a stopper.
Page 28 of 116
K0801_031656_EN
Checking the vertical ladder
Fig. 16
7.3
Revision 04 / 2014-10-17
Metal plate as a stopper
Assembling the air vent

Assemble the air vent to the tower wall
1
Fig. 17
Air vent
1 Position of the air vent
2 Assembled air vent
7.4
Securing the service lift

Secure the service lift to a ladder rung in accordance with the manufacturer's
instructions
Assembling the air vent
K0801_031656_EN
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8.
Erection of the base section
8.1
Preparing the electrical installation
Abbreviation
Designation
RCD
Residual-current device
(previously: residual-current protective device)
SPE-PRCD
(PRCD-S)
Switched protective earth portable residual current devices

(SPE-PRCD) for class I and battery powered vehicle
applications
according to DIN IEC 62335, VDE 0661-20
OBSERVE DOCUMENT
- Current circuit diagram Electrical installation - Tower
- Test report K0801_053535 PE conductor continuity test K08 gamma
Let a qualified person check the grounding of the emergency power
generator
All electrical feeding points are operated as TN or TT network, i.e. the
generator neutral point is connected to the grounding system of the WT
(PE rail or equivalent connection)
If power distribution systems of the WT in erection are used for the supply of
the electrical devices:
Check the PE continuity before and document the result in the test report
K0801_053535
Notice: If this is not possible electric devices must only be operated via
PRCD-S with IN 30 mA. In error cases it is not possible to connect the
power supply via PRCD-S.
Going on working is not permitted until the error has been rectified by an
electrically skilled person
Check the protective devices
- RCD circuit breaker for emergency power generator
- RCD circuit breaker for temporary power distribution box
Prepare the connector for the tower lighting
- 16 A / 230 V
- Cable 3 x 2.5 mm
- Europlug or plug with grounding contact
Page 30 of 116
K0801_031656_EN
Preparing the electrical installation
Revision 04 / 2014-10-17
Prepare the connectors for tools

- 16 A / 400 V
- Cable 5 x 2.5 mm
- Europlug
Topbox power supply cable
Prepare connectors for pitch power supply, on-board crane and yaw system
Note: The cable is already installed by the tower manufacturer. Only connect
the CEE plugs after the individual tower sections have been erected.
- In each tower section separately
- 32 A / 400 V
- Cable 5 x 6 mm
- CEE connector
Prepare the connectors for lighting
- 16 A / 230 V
- 2 cables 4 x 1.5 mm
- Harting connector
8.2
Establishing the power supply in the tower

Establish a connection from the PE terminal of the emergency power
generator to the tower grounding system
Connect the temporary power distribution box to the emergency power
generator
- Cable
Lay 2 cables for the voltage supply between the tower and the temporary
power distribution box
- Tower power supply cable
- Topbox power supply cable
If necessary, assemble 2 connectors to the 2 cables
- 230 V lighting
- 400 V tools
Establishing the power supply in the tower
K0801_031656_EN
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Fig. 18
Temporary power distribution box
Connect the tower power supply to the temporary power distribution box
Pitch/yaw system
Connect an isolation transformer between the emergency power generator and
the Topbox supply cable
Tools for 110 V
Connect an isolation transformer for 110 V between the emergency power
generator and the temporary power distribution box
8.3
Marking the tower door

Apply a marking for the center line of the tower door to the base section
- Use a colored and removable marking, e.g., colored tape
The marking is applied from bottom edge tower door to top edge tower
flange and clearly visible
The marking applied to the outer tower must be clearly visible
8.4
Lifting the base section onto the foundation

OBSERVE DOCUMENT
Page 32 of 116
K0801_031656_EN
Marking the tower door
Revision 04 / 2014-10-17
DANGER
SUSPENDED LOAD
The base section may fall or pass into uncontrolled pendular movement. If the
base section is turned loose objects may fall from the base section.
Maintain an adequate safety distance from the suspended base section.
Lift the base section at both ends up to a height of approx. 1.5 m
Erect the base section, see fig.19
- The main crane pulls up
- The auxiliary crane moves along
Fig. 19
Erecting the base section
Loosen Axzion J hook from the bottom tower flange according to operating
Measure the weight of the base section and record it in the erection report
NOTICE
RISK OF DAMAGE TO COMPONENTS

When the base section is moved over the transformer, damage may result in
case of collision.
Ensure that the base section is precisely positioned.
Align the base section above the foundation
The markings of the tower door/foundation and base section line up with
each other
The holes are flush with the anchor bolts
Slowly and carefully lift the base section onto the load-spreading plate
Connect the power supply in the tower
8.5
Assembling the base section on the foundation

OBSERVE DOCUMENT
Repair instructions I402_010 Tower flange gaps Repair procedures
Record the serial number of the load-spreading plate in the erection report
Provide the base section tower flange with the available washers and nuts
K0801_031656_EN
Page 33 of 116
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NOTE
Use XLCT8 Hytorc with special tool in case the welded sockets of the support
for the stairs impair the base section assembly.
Fig. 20
Hytorc with special tool
Mount the base section onto the foundation, see fig.21

R75 MT, R80 MT
Designation
Quantity SAP no.
HV washer DASt Rili 021 -42-tZn
160
Hexagon nut ISO 4032-M42-8 m=d-tZn
160
Chamfer of the HV washer points towards hexagon nut

Torque wrench
Preload torque 1000 Nm
No later than after 48 hours

Torque-controlled tightening method
Spray protective wax against corrosion onto the internal screw connections
Lubricate the outside screw connections with Molykote G-Rapid plus
Press the black protective cap onto the external screw connection
R91 MT
Designation
Page 34 of 116
Quantity SAP no.
160
Hexagon nut ISO 4032-M42-8 m=d -tZn
160
K0801_031656_EN
Revision 04 / 2014-10-17
Designation
Quantity SAP no.

Torque wrench

R100 MTR
Designation
Quantity SAP no.
200
Hexagon nut ISO 4032-M42-10 m=d -tZn
200

Torque wrench

K0801_031656_EN
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Fig. 21
8.6
Assembling the base section
Grounding the base section

4 connector bases for the grounding leads have been welded on the tower wall.
Danger: Ground the base section immediately after erection.
Remove paint and contamination from the connector base
Surface of the connector base is smooth, level and free of paint
Spray the connector base with zinc spray
Install the 4 grounding leads from the foundation to the 4 connector bases of
the tower wall
- Extend the grounding leads, where required
Page 36 of 116
Component
Grounding point
Foundation
Tower wall
K0801_031656_EN
Cable
Quantity
Strip steel 1x120 mm
Grounding the base section
9.
Revision 04 / 2014-10-17
Assembly of the tower interiors

CAUTION
RISK OF INJURY
Risk of injury due to loose screw connections on the tower interiors.
Glue in all screws in the threaded bushes using medium-strength screw lock.
9.1
Mounting the tower stairs

OBSERVE DOCUMENT
Engineering drawing 01423-1034706 Tower stairs transformer external
DANGER
FALL HAZARD
Work must only be carried out using ladders and working platforms officially
tested for personal protection, working height approx. 3.0 m
Secure yourself to the personal attachment points located at the right and left
side of the tower door
9.1.1
Erecting a pad foundation

OBSERVE DOCUMENT
Engineering drawing Tower interiors bottom
Erect 2 frost resisting pad foundations at the two bottom support points of the
tower stair
- Height = height tower foundation
- Width: 1500 mm
- Depth: 500 mm
- Distance to the tower (X): Engineering drawing Tower interiors bottom
K0801_031656_EN
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Fig. 22
9.1.2
Pad foundation: X = distance to the tower
Assembling the stairs to the pad foundation

Mount the tower stairs, see fig.23
- 2 hexagon socket screws M16
- 2 washers
Screw the threaded bolts down to the pad foundation
Fig. 23
Page 38 of 116
Tower stairs
K0801_031656_EN
9.2
Revision 04 / 2014-10-17
Disassembling the platform parts of the standard plus

platform
OBSERVE DOCUMENT
Engineering drawing 01421-1046111 Platform standard plus
DANGER
FALL HAZARD
Fall hazard from removed platform parts.
Prior to removing the platform parts, secure yourself to the personal
attachment points using the safety rope.
Disassemble 6 platform parts
- Hexagon socket head cap screws M10
Securely assemble 6 platform parts to the edge of the standard plus platform
2
Fig. 24
Platform parts of the standard plus platform

1 Platform parts assembled
2 Platform parts disassembled
Disassembling the platform parts of the standard plus platformK0801_031656_EN
Page 39 of 116
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9.3
Installing the main converter

NOTICE

Electrical components may be damaged by dirt, moisture or vibrations.
Only remove the protective cover from the main converter when the nacelle
has been mounted onto the tower.
Lift the main converter carefully and avoid jerky movements.
Always store the main converter on a dry and stable support.
9.3.1
Attaching the main converter to the crane

Abbreviation
Designation
WLL
Working load limit
EWL
Effective working length
WARNING
FALLING MAIN CONVERTER
The webbing slings may be damaged due to sharp edges at the cabinet base.
Protect the webbing slings by padding.
Attach the main converter to the main crane, see fig.25
- 4 lifting lugs of the transport cross beams
- 2 x 2-leg chain sling WLL 2 t, EWL 3 m
- Extension of the crane hooks
Page 40 of 116
K0801_031656_EN
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Fig. 25
9.3.2
Attaching the main converter to the crane
Assembling the main converter

DANGER
FALL HAZARD
Fall hazard due to removed floor plates.
When working on the platforms secure yourself with the safety rope at the
personal attachment points
Lift the main converter onto the platform tower access
Align the main converter
Doors are not located in the area of the railing for the service lift, see
fig.26
Fig. 26
Aligning the main converter
K0801_031656_EN
Page 41 of 116
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Assemble the main converter onto the platform tower access

Designation
Quantity SAP no.
Hexagon screw M10
Washer 11
Torque wrench
Tightening torque 40 Nm to 45 Nm
Only GE main converter:
Remove the transport cross beams
Close the drill holes of the cross beam with plug screws
- Plug screws are at the main converter
- 18 hexagon screws M10
9.4
Assembling the platform parts of the standard plus

platform
OBSERVE DOCUMENT
Engineering drawing 01421-1046111 Platform standard plus
DANGER
FALL HAZARD
Fall hazard from removed platform parts.
Prior to removing the platform parts, secure yourself to the personal
attachment points using the safety rope.
Assemble the 6 platform parts
- Hexagon socket head cap screws M10
- Tightening torque 35 Nm
Page 42 of 116
K0801_031656_ENAssembling the platform parts of the standard plus platform
Revision 04 / 2014-10-17
2
Fig. 27
Platform parts of the standard plus platform

1 Platform parts disassembled
2 Platform parts assembled
9.5
Installing the converter cooling

OBSERVE DOCUMENT
Assembly instructions K0809_026457 Converter cooling for tower revision 5
Note: Observe the flow direction marked on the water pump and the main
converter.
9.5.1
Mounting the cooler

Mount the cooler above the tower door
Fig. 28
Cooler above the tower door
K0801_031656_EN
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9.5.2
Assembling the water pump

Assemble the water pump on the bracket above the tower door
Designation
Quantity SAP no.
Hexagon screw ISO 4017-M12x60-8.8.tZn
Torque wrench
Fig. 29
Assembling the water pump
Connect the two hoses to the water pump, if necessary, with the angled ends
- To cooler
- From cooler
9.5.3
Connecting the water pump to the main converter

Route the two hoses from the water pump/bypass valve to the main converter
Connect the two hoses to the main converter
- As an option, the elbow fitting can be used
Note: Observe the flow direction. The labeling can be found in the converter
cabinet.
Page 44 of 116
K0801_031656_EN
9.6
Revision 04 / 2014-10-17
Mounting the tower exteriors

DANGER
FALL HAZARD
Work must only be carried out using ladders and working platforms officially
tested for personal protection, working height approx. 4.0 m
Secure yourself with the safety rope to the personal attachment points
located at the right and left side of the tower door
Mount the fan
Mount the lamp
1
2
Fig. 30

1 Fan
2 Lamp
K0801_031656_EN
Page 45 of 116
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10.
Completion of the erected tower section
10.1
Measuring the vertical alignment of the erected tower

section
OBSERVE DOCUMENT
Operating instructions NALL01_019122 Leica Builder
Operating instructions NALL01_019120 Electronic theodolite DT series
Erection report NALL01_019137 Remeasuring the tower
NOTE
Observe local conditions and lighting.
Only carry out the measurement in daylight
The tower door frame must not be within the position finding range
Measure the vertical alignment of the base section and record in the Erection
report
10.2
Preparing the screw connection for the next tower

section
10.2.1
Preparing the top platform

Lay out wood planks on the unloading surface for the toolbox
Note: Always align the wood planks transversely to the 2 platform beams
which are assembled parallel to the ladder.
10.2.2
Equipping the toolbox

Fill the toolbox with all the necessary materials and tools for the tower flange
connection:
- Screws, washers and nuts
- Impact wrench with suitable socket
- Wrench
- Silicone gun
- 2 cartridges of sealant
- Grounding cables
- Crimping sleeves, crimping pliers
- Heat-shrink tube
Page 46 of 116
K0801_031656_ENMeasuring the vertical alignment of the erected tower sec-
10.2.3
Revision 04 / 2014-10-17
Lifting the toolbox

Lay wood planks across platform beams
Lift the box of screws onto the wood planks
Take out the required materials and tools
Take out the screw connection for the next tower section
- Counted for each tower flange
- Separated by a cardboard layer
10.3
Sealing the tower flange

Apply 1 continuous bead of silicone to the tower flange of the erected tower
section, see fig.31
- Approx. 3 mm thick
- Approx. 30 mm from the outer edge
Fig. 31
10.4
Silicone bead on the tower flange
Grounding the tower flange

4 connector bases for grounding cables are welded to each tower flange.
Danger: Ground each tower section immediately after erection.
Remove the grease from the cleaned surface with cleaning agent
Sealing the tower flange
K0801_031656_EN
Page 47 of 116
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Fig. 32
Grounding the tower flange
Install the pre-assembled grounding cables 70 mm to the connector bases

Minimum bending radius: 5 x d
Attach grounding symbols
Designation
Quantity SAP no.
Hexagon screw M12
Conical spring washers or washer with spring lock

washer
Torque wrench
10.5
Providing the fall protection system

Abbreviation
PPE
Personal protective equipment
OBSERVE DOCUMENT
Operating instructions NALL02_005046 (MA 5017 d/e) Haca fall arrest rails
Inspection report NALL02_014263 Haca fall arrest system
Page 48 of 116
K0801_031656_EN
Revision 04 / 2014-10-17
DANGER
FALL HAZARD
Fall hazard resulting from incorrect assembly and approval of the fall arrest
system.
The fall arrest system must only be assembled by specially trained
personnel. The training must be provided either by the manufacturer or a
company authorized by the manufacturer.
After the assembly is complete, the fall arrest system must be certified and
approved by an external certification authority.
DANGER
FALL HAZARD
Fall hazard if the safety instructions are not observed.
Do not use the vertical ladder without PPE
Always secure yourself with the corresponding fall arrester to the fall arrest
system
If the fall arrest system is not yet operational, use the two lanyards of the
PPE in alternation for safety
Attach yourself to the uprights of the vertical ladder only
Before moving the snap hook always secure yourself with the 2nd lanyard
10.5.1
Preparing the vertical ladder

Remove the connectors from the railing
Press the connectors into the ends of the vertical ladder
Fig. 33
Connectors of the vertical ladder
K0801_031656_EN
Page 49 of 116
Revision 04 / 2014-10-17
10.5.2
Connecting the fall arrest rail

OBSERVE DOCUMENT
Engineering drawing 03011-1002760 Haca fall arrest system, assembly
DANGER
FALL HAZARD
Fall hazard due to material fatigue of the fall arrest rail
The joints of the fall arrest rails must only be reworked by persons who hold a
certificate from the manufacturer.
Connect both ends of the fall arrest rails with rail connectors verbinden
Fig. 34
10.5.3
Rail connector
Installing the fall arrest rope

DANGER
FALL HAZARD
Fall hazard resulting from incorrect assembly and approval of the fall arrest
rope.
The fall arrest rope must only be assembled by specially trained personnel.
The training must be provided either by the manufacturer or a company
authorized by the manufacturer.
After the assembly is complete, the fall arrest rope must be certified and
Page 50 of 116
K0801_031656_EN
11.
Revision 04 / 2014-10-17
Erection of the tower

DANGER
DANGER OF COLLAPSE
Danger of life-threatening injuries resulting from collapse of the tower due to
tower vibrations and incorrect assembly of the tower screw connections.
The following rules of assembly must be observed for tower erection:
All tower screw connections must be fully tightened to the required tightening
torque (100 %), see "Assembling the tower section onto the tower" page 54:
- After each interruption of the tower erection
- No later than after the erection of the top section
Consider periods of interruption during tower erection, see chapter 11.1.1
"Considering interruption periods in the assembly state"
11.1
Interruptions during tower erection
11.1.1
Considering interruption periods in the assembly state

NOTICE
CORROSION DAMAGE
Corrosion damage from moisture can result if the tower erection is interrupted.
If the tower erection is interrupted cover the top tower section with a protective
tarpaulin against moisture.
After each interruption of the tower erection:
Fully tighten all tower screw connections to the required tightening torque
(100 %), see "Assembling the tower section onto the tower" page 54
Consider the following interruption periods in the assembly state:
Interruption periods in the assembly state
Tower
N90 HS R80MT5.1 IEC 1a
Without
nacelle
Without
top section
7 days 16,7 m/s
365 days
N100 R80MT5.1 IEC 2a
76 days
N100 R80MT5.1 TAT IEC 2a L flange
76 days
N100 R100 MTR5.1 IEC 2a
76 days
Interruptions during tower erection
K0801_031656_EN
Page 51 of 116
Revision 04 / 2014-10-17
Tower
N100 R75MT TAT IEC 2a
N117 R91MT TAT DIBt2; IEC 3a
Without
nacelle
Without
top section
7 days 18,6 m/s
100 days
5 days
365 days
If the interruption periods have been exceeded:

Disassemble the top tower section or brace the tower, see "Bracing the
tower" page 52
11.1.2
Bracing the tower

Barely varying wind direction
Brace 1 rope from the tower top vertically to the wind direction
- Angle between ground anchor and rope: 30
Strongly varying wind direction
Brace 1 rope from the tower top vertically to the wind direction
Brace 1 rope from the tower top into the wind direction
11.2
Lifting the tower section onto the tower

OBSERVE DOCUMENT
DANGER
SUSPENDED LOAD
The tower section may fall or pass into uncontrolled pendular movement.
When the tower section is turned loose objects may fall from the tower section.
Maintain an adequate safety distance from the suspended tower section.
Lift the base section at both ends up to a height of approx. 1.5 m
Erection of the tower section
- The main crane pulls up
- The auxiliary crane moves along
Page 52 of 116
K0801_031656_EN
Lifting the tower section onto the tower
Revision 04 / 2014-10-17
Loosen Axzion J hook from the bottom tower flange according to operating
Lift the tower section above the erected tower section
Position the tower section
Ends of the vertical ladder are flush
Insert 2 guide pins from above through the holes in the tower flange, see
fig.35
Fig. 35
Guide pin
Slowly lower the tower onto the erected tower section

Connect the ends of the vertical ladder
11.3
Establishing the power supply

OBSERVE DOCUMENT
Current circuit diagram
Connect the supply cable to the terminal box in the tower

Commission the lighting in the tower
Establishing the power supply
K0801_031656_EN
Page 53 of 116
Revision 04 / 2014-10-17
Fig. 36
11.4
Tower terminal box
Assembling the tower section onto the tower

OBSERVE DOCUMENT
Repair instructions I402_010 Tower flange gaps Repair procedures
NOTE
Safety-relevant screw connection
The signature of the safety-relevant screw connection must be visible for clear
identification.
Provide the tower section flange with the available washers and nuts
Assemble the tower section onto the erected tower section
11.4.1
Screw connections for a 4-part tower

N90 HS R80MT5.1 IEC 1a
Tower sections 1 and 2
Designation
Page 54 of 116
Quantity SAP no.
Srv HV screw DASt Rili 021-M42x320-10.9-tZn
132
HV washer DASt-Rili 021-42-tZn
264
HV nut DASt-Rili 021-M42-10-tZn
132
K0801_031656_EN
Revision 04 / 2014-10-17

Designation
Quantity SAP no.
Insert the HV screws from below through the tower flanges

The chamfer of the HV washer must point towards the screw head or
towards the HV nut
Torque wrench
Designation
Quantity SAP no.
Srv HV screw EN 14399-4-M36x250-10.9-tZn
152
304
HV nut EN 14399-4-M36-10-tZn
152

towards the HV nut
Torque wrench
Designation
Quantity SAP no.
138
276
HV nut EN 14399-4-M36-10-tZn
138

towards the HV nut
Torque wrench
K0801_031656_EN
Page 55 of 116
Revision 04 / 2014-10-17

Designation
Quantity SAP no.

N100 R75MT TAT IEC 2a
Designation
Quantity SAP no.
132
264
132

towards the HV nut
Torque wrench
Designation
Quantity SAP no.
Srv HV screw DASt-Rili 021-M42x280-10.9-tZn
120
240
120

towards the HV nut
Torque wrench
Page 56 of 116
K0801_031656_EN
Revision 04 / 2014-10-17

Designation
Quantity SAP no.
138
276
HV nut EN 14399-4-M36-10-tZn
138

towards the HV nut
Torque wrench
N100 R80MT5.1 IEC 2a
Designation
Quantity SAP no.
168
336
168

towards the HV nut
Torque wrench
Designation
Quantity SAP no.
120
240
K0801_031656_EN
Page 57 of 116
Revision 04 / 2014-10-17

Designation
Quantity SAP no.
120

towards the HV nut
Torque wrench
Designation
Quantity SAP no.
138
276
HV nut EN 14399-4-M36-10-tZn
138

towards the HV nut
Torque wrench
N100R80MT5.1 TAT IEC2a L flange
Designation
Page 58 of 116
Quantity SAP no.
108
216
108
K0801_031656_EN
Revision 04 / 2014-10-17

Designation
Quantity SAP no.

towards the HV nut
Torque wrench
Designation
Quantity SAP no.
120
240
120

towards the HV nut
Torque wrench
Designation
Quantity SAP no.
138
276
HV nut EN 14399-4-M36-10-tZn
138

towards the HV nut
Torque wrench
K0801_031656_EN
Page 59 of 116
Revision 04 / 2014-10-17

Designation
Quantity SAP no.

N117 R91MT TAT DIBt2; IEC 3a
Designation
Quantity SAP no.
132
264
132

towards the HV nut
Torque wrench
Designation
Quantity SAP no.
152
304
HV nut EN 14399-4-M36-10-tZn
152

towards the HV nut
Torque wrench
Page 60 of 116
K0801_031656_EN
Revision 04 / 2014-10-17

Designation
Quantity SAP no.
138
276
HV nut EN 14399-4-M36-10-tZn
138

towards the HV nut
Torque wrench
11.4.2
Screw connections for a 5-part tower

N100 R100 MTR5.1 IEC2a
Designation
Quantity SAP no.
200
400
200

towards the HV nut
Torque wrench
K0801_031656_EN
Page 61 of 116
Revision 04 / 2014-10-17

Designation
Quantity SAP no.
200
400
200

towards the HV nut
Torque wrench
Designation
Quantity SAP no.
Srv HV screw DASt Rili 021 M56x370-10.9-tZn
80
160
80

towards the HV nut
Torque wrench
Designation
Page 62 of 116
Quantity SAP no.
138
276
HV nut EN 14399-4-M36-10-tZn
138
K0801_031656_EN
Revision 04 / 2014-10-17

Designation
Quantity SAP no.

towards the HV nut
Torque wrench
K0801_031656_EN
Page 63 of 116
Revision 04 / 2014-10-17
12.
Completion of the tower
12.1
Operating the service lift
OBSERVE DOCUMENT
Operating instructions K0802_058498 Hailo TOPLift L
Operating instructions K0802_058530 Hailo TOPLift CCV
Operating instructions NALL02_015216 Tower service lift Zarges
DANGER
FALL HAZARD
Fall hazard resulting from incorrect assembly and commissioning of the
service lift.
The service lift must only be assembled by specially trained personnel. The
training must be provided either by the manufacturer or a company
authorized by the manufacturer.
The service lift must only be commissioned for test purposes. The test must
be indicated by a sign.
After the assembly is complete, the service lift must be certified and
The commissioning report must be stored in the place provided in the service
lift.
DANGER
RISK OF INJURY
Risk of injury when entering the area under the service lift.
The area under the service lift must be marked and secured by a rail.
Do not deposit items in the area under the service lift.
Do not enter or stay in this area under the service lift.
Strain relief for the service lift cables:
Hailo and Zarges
- Arrangement of the strain relief on the railing of the platform Standard
Half the travel distance of the service lift serves as basis: The strain relief
is arranged on the railing of the next higher platform Standard, see the
engineering drawing for the respective tower section
Page 64 of 116
K0801_031656_EN
Operating the service lift
12.2
Revision 04 / 2014-10-17
Removing the aluminum hollow section on the loop

NOTE
The loop is secured with an aluminum hollow section during transport and
erection. The aluminum hollow section serves to hold the cables in a
horizontal position and to keep the specified clearances between the round
Hydac cable clamps.
After erection of the top section the aluminum hollow section must be removed
from the loop.
Attach the aluminum hollow section to the crane with a ratchet strap
Note: There are 2 options:
Variant 1
- Attach the top end of the aluminum hollow section to the lifting eye of the
crane with a 2nd ratchet strap
- Remove the ratchet strap from the round ladder
Variant 2
- Secure the aluminum hollow section by sliding a bar horizontally through
the round ladder and the aluminum hollow section
- Remove the ratchet strap from the round ladder. Use it to attach the top
of the aluminum hollow section to the lifting eye of the crane
- Remove the bar from round ladder and aluminum hollow section
Fig. 37
Ratchet strap on round ladder for securing the aluminum hollow section
Undo the aluminum hollow section from the fastening points, see fig.39
With a crane, carefully pull the aluminum hollow section upwards out of the
round Hydac cable clamps
Notice: There is the risk that the screw connections of the aluminum hollow
section will get caught in the Hydac cable clamps.
If necessary during removal, guide the aluminum hollow section by hand from
the service lift platform.
K0801_031656_EN
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Revision 04 / 2014-10-17
Fig. 38
Screw connections on aluminum hollow section
Note: Return the assembly tools for the loop (aluminum hollow section, ratchet
straps, brackets) to the tower manufacturer.
Fig. 39
Aluminum hollow section fastened in top section (similar to figure)

1
2
3
4
Page 66 of 116
Ratchet strap to round ladder

Bracket below topmost platform
Eyebolt and short ratchet strap below lift platform
Ratchet strap to eyebolt below lift platform
K0801_031656_EN
12.3
Revision 04 / 2014-10-17
Completing the water cooling system for the main

converter
OBSERVE DOCUMENT
Retrofit instructions I403_077 Converter drain hose
Assembly instructions NALL01_011878 Antifreeze for CCV
Note: The water pump is located on the bracket above the tower door.
Lay the cables of the fan motor and the standstill heater to the main converter
- Fan motor: Windflex 7 G 1.5 mm; 20 m
- Standstill heater: Windflex 3 G 1.5 mm; 20 m
Lay the cables along the hoses
Protect the cables from damage
Lay the cables through the provided openings
Fasten the cables using cable guides (cable brackets, cable trays or ducts)
Notice: Always route the cables in the external area in cable ducts.
Connect the water pump to the power supply
- Windflex 4 G 1.5 mm; 10 m
Connect the temperature and pressure sensor of the water pump to the main
converter
- TRONIC-CY 4 x 0.75 mm; 10 m
- TRONIC-CY 2 x 0.75 mm; 10 m
Connect the heater for the converter cooler (only D2013)
- NCV: 1 x Windflex 4 G 1.5 mm; 10 m
- CCV: 2 x Windflex 4 G 1.5 mm; 10 m
Fasten the cable for the standstill heater to the cooler
Fasten the cable for the pole-changing fan motor to the cooler
NOTE
Cables are part of the cable set Bottom K08_D2013_TIT or cable set cooler
Bottom K08_RxxMT(R)_5_TIT.
Completing the water cooling system for the main converterK0801_031656_EN
Page 67 of 116
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Filling the water cooling system

Prior to filling the water cooling system, check the self-sealing screw
connections for correct assembly
- Maximum tightening torque 250 Nm
Fill the cooling circuit completely with antifreeze (2.5 bars)
Note: The system can be completely filled via the port of the bypass valve.
- NCV: 45 % antifreeze Varidos FSK 45 % (USA: LCE-50)
- CCV: 50% antifreeze Varidos FSK 50% (USA: LCE-50)
Run the water pump for a while; if required, briefly remove the protective cap
on the vent valve
The water cooling system is vented
If the pressure drops to < 2.5 bars, refill cooling water
After assembly is complete, check the cooling system for leaks
12.4
Sealing the tower

OBSERVE DOCUMENT
Assembly instructions K0802_027277 Tower door Nordex Rev.5
Replace the temporary locking cylinders, see assembly instructions
K0802_027277
Seal uncovered holes with silicone
Seal all connecting joints and drill holes between the air inlet hood and the
tower wall
- Adjust the provided material to fit
- Seal the existing gaps and holes with silicone
Page 68 of 116
K0801_031656_EN
Sealing the tower
Fig. 40
12.5
Revision 04 / 2014-10-17
Tower door
Assembling the fire extinguisher

OBSERVE DOCUMENT
Engineering drawing 801_02_00301 Fastening board at the tower base
The number of required fire extinguishers depends on the country and is
specified in the contract.
Observe the country-specific and contractual specifications
Always assemble 1 fire extinguisher to the fastening board in the tower base
next to the door
NOTE
A special bracket is provided for each fire extinguisher
12.6
Attaching the signs

OBSERVE DOCUMENT
Operating instructions I501_050_A01 WT signs wind turbine class NALL
Operating instructions I501_050_A02 WT sign list wind turbine class NALL
Assembling the fire extinguisher
K0801_031656_EN
Page 69 of 116
Revision 04 / 2014-10-17
Attach missing signs according to the operating instructions I501_050_A01

and I501_050_A02
Page 70 of 116
K0801_031656_EN
Attaching the signs
13.
Revision 04 / 2014-10-17
Installation of the main converter

Abbreviation
Designation
LV
Low voltage
MV
Medium voltage
TAT
External transformer (transformer is located outside of the

tower)
TIT
Internal transformer (transformer is located inside the tower)
WT
Wind turbine
OBSERVE DOCUMENT
Inspection instructions K0801_036711 General inspection instructions for
measuring the electrical safety
VDE standard 0100 (IEC 60364) Erection of power installations with nominal
voltages up to 1000 V
VDE standard 0101-1 (IEC 61936-1) Power installations exceeding 1 kV
VDE standard 0105 (EN 50110-1) Operation of power installation
DIN EN 61238 Compression and mechanical connectors for power cables
for nominal voltages up to 36 kV (Um = 42 kV)
DANGER
HAZARDOUS VOLTAGE
Electric shock from incorrect handling of electrical equipment.
The electrical installation must be carried out by electrically skilled persons
The following 5 safety rules must be observed
- Disconnect the WT
- Secure the WT against reconnection
- Verify that the WT is dead
- Ground and short-circuit the WT
- Provide protection against adjacent live parts
K0801_031656_EN
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13.1
Connecting the main converter to the transformer

substation
13.1.1
Connecting the LV cables to the main converter

WARNING
FIRE HAZARD
There is a risk of fire when using connection terminals for aluminum cables.
Only use approved mechanical cable lugs for aluminum cables.
Hand-tighten the mechanical cable lugs to the copper rail
Install the LV cables to the copper bar using mechanical cable lugs
Caution: Do not allow torn screw heads to fall into the main converter.
Label the LV cables on the main converter
13.1.2
Laying the LV cables

Lay the LV cables from main converter to foundation
Fig. 41
Laying the LV cables
13.2
Grounding the components
13.2.1
Laying the grounding cables

Cut the grounding cables to length
Label the grounding cables green/yellow
Provide conical spring washers or washers with spring lock washers to all
grounding cable terminals
Page 72 of 116
K0801_031656_EN Connecting the main converter to the transformer substa-
Revision 04 / 2014-10-17

Attach grounding symbols
13.2.2
Checking the grounding of the base section

The base section must be grounded to the tower wall with 4 grounding leads.
Check the correct installation of the grounding leads
13.2.3
Component
Grounding point
Foundation
Tower wall
Cable
Quantity
Strip steel 1x120 mm
Grounding the main grounding bar

Connect 1 grounding cable to the main grounding bar and the tower wall
Component
Grounding point
Main grounding bar
Tower wall
Fig. 42
13.2.4
Cable
Quantity
H07BN-F 1x240 mm
Grounding of the main grounding bar (similar to figure)
Grounding components
Designation
Main converter grounding bar
Grounding the components
Grounding point
Cable
Quantity
Main grounding bar
H07BN-F 1x240 mm
K0801_031656_EN
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Revision 04 / 2014-10-17
Fig. 43
13.2.5
Main converter grounding
Grounding the tower interiors

Ground all metallic components which become live in case of fault
13.3
Completing work
13.3.1
Cleaning the working area

Dispose of all remaining packaging, tools, cleaning cloths, cable ties etc.
Sweep and vacuum foundation and access platform
Remove oil and grease residue using an engine cleaner
Remove chips from the coils
13.3.2
Preserving damaged areas

Repair paint damage properly
- Grind
- Clean
- Apply primer
- Apply paint
Page 74 of 116
K0801_031656_EN
Completing work
14.
14.1
Revision 04 / 2014-10-17
Quality notes on the installation of the electrical

connections
Abbreviation
Designation
Al
Aluminum
Cu
Copper
CC2
Stranded conductor class
CC5
Flexible conductor class
FO cable
Fiber optic cable
TAT
Transformer outside tower
TIT
Transformer inside tower
Labeling
Label power cables and control cables in accordance with the cable list and
the circuit diagram
Note: Labels must be attached to each cable end, approx. 50 cm before the
cable gland or the cable entry slot.
14.2
Laying the cables

Fasten the cables to the cable ladder using cable ties
- Always use the ladder rung for fastening
- Secure the cable crosswise to each ladder rung
When laid without cable guides, fasten the cables in bundles of 3 with cable
ties
- Always L1 together with L2 and L3
- Intervals of approx. 50 cm
Avoid pressure and abrasion marks on the cable insulation
- Use edge protection, where required
Observe minimum bending radius in accordance with DIN VDE 0298, part 3
Labeling
Cable type
Ladder
Signal cables
Supply cables
Copper
FO cable
Fiber optics
Outer diameter [D]
Bending
radius
8 mm 12 mm
3xD
12 mm 20 mm
4xD
9 mm
25 x D
K0801_031656_EN
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Cable type
Ladder
Power cable
Copper
Aluminum
Outer diameter [D]
Bending
radius
more than 20 mm
4xD
6xD
Always use U-bolt clamp (BBS) with clamping saddle

Observe the tightening torque of the aluminum U-bolt clamp
- Tightening torque 1 Nm
Observe the tightening torques of the screw connections
14.3
Stripping cables
NOTICE
CABLE FIRE HAZARD

Cable fire from damaged aluminum or copper conductors.
Note the following when stripping the cables:
Always use a suitable tools when stripping the cables
Check aluminum or copper conductor for damage after stripping
Determine the stripping length
Mark the stripping length with a marker or cable stripping knife
Always use a suitable tools when stripping the cables, see fig.44
Fig. 44
Page 76 of 116
Stripping the cable
K0801_031656_EN
Stripping cables
14.4
Revision 04 / 2014-10-17
Pre-assembling the cables using mechanical

connections
SAP no.
Designation
35747
Mechanical connector GPH M185 CU Nordex, Cu 185 mm
35748
Mechanical connector GPH M300 Nordex, Al 300 mm
35749
Mechanical cable lug GPH C185 x 12 Nordex, Al 185 mm
35750
36821
36822
38001
WARNING
FIRE HAZARD
Overheating of the mechanical connector may occur due to oxide layer on the
aluminum conductor.
Remove the oxide layer of the aluminum conductor before inserting the
conductor into the mechanical connector.
Table 1:
Cable type and mechanical connection
Connection
Nacelle/top section (loop)
Tower flange Cu
Tower flange Al
Cable type
Mechanical connection
Cu 240 LK5 / Cu 240 LK5
M240 CU Nordex
Cu 185 LK5 / Cu 185 LK5
M185 CU Nordex
Cu 95 LK5 / Cu 95 LK5
M95 CU Nordex
Anti-icing
Al 300 LK2 / Al 300 LK2
M300 Nordex
Al 185 LK2 / Al 185 LK2
M185 Nordex
Cu 95 LK5 / Cu 95 LK5
M95 CU Nordex
Anti-icing
Foundation grid TAT
Al 300 LK2 / Cu 300 LK2 NYY /

M300 Nordex
N2XY
Converter stator Al
Al 300 LK2
C300 x 12 Nordex
Converter stator Cu
Cu 240 LK5 / Cu 185 LK5
C240 x 12 Cu5 /
C185 x 12 Cu5
Converter rotor Al
Al 185 LK2
C185 x 12 Nordex
Pre-assembling the cables using mechanical connections K0801_031656_EN
Page 77 of 116
Revision 04 / 2014-10-17
Connection
Cable type
Mechanical connection
Converter rotor Cu
Cu 240 LK5 / Cu 185 LK5
C240 x 12 Cu5 /
C185 x 12 Cu5
Converter grid
Al 300 LK2 / Cu 300 LK2 NYY /

C300 x 12 Nordex
N2XY
Transformer TIT
Al 300 LK2
14.4.1
C300 x 12 Nordex
Preparing mechanical connectors and cable lugs

NOTICE
NO ELECTRICAL CONNECTION
Aluminum forms an oxide layer at the surface when in contact with oxygen.
Remove the oxide layer on the aluminum conductor to make the electrical
connection at the contact surfaces of the aluminum conductor.
Check the mechanical connector or the mechanical cable lug
Mechanical connector or cable lug is in its original packaging
Contact grease has not leaked
Contact grease has not dried out
Only unpack the mechanical connector or mechanical cable lug immediately
before use
1
Fig. 45
Checking the mechanical connector and mechanical cable lug

1 Mechanical connector
2 Mechanical cable lug
Stripping the cable

The stripping length for the cable is stated in the below table
Page 78 of 116
K0801_031656_EN Pre-assembling the cables using mechanical connections
Revision 04 / 2014-10-17
Cable cross section
Stripping length
300 mm
240 mm
67 mm
185 mm
56 mm
95 mm
35 mm
Determine the stripping length where applicable, see fig.46

- Cable length in mechanical connector + small gap
Mark the stripping length with a marker or cable stripping knife
Fig. 46
Determining the stripping length
Strip the cable using a cable stripping knife
14.4.2
Preparing aluminum cables

Remove the film on the aluminum conductor
Fig. 47
Removing the film
Remove the oxide layer on the aluminum conductor using a wire brush
Page 79 of 116
Revision 04 / 2014-10-17
Fig. 48
Removing the oxide layer
Immediately insert the aluminum conductor up to the barrier into the

mechanical connector or mechanical cable lug to prevent a new oxide layer
from forming
A small gap remains between the mechanical connector or the
mechanical cable lug and the cable insulation
1
Fig. 49
Aluminum conductor in the mechanical connector

1 Inserting the aluminum conductor
2 Gap between mechanical connector and cable insulation
14.4.3
Preparing copper cables

Insert the copper cable up to the barrier into the mechanical connector
A small gap remains between the mechanical connector or the
mechanical cable lug and the cable insulation
14.4.4
Assembling the mechanical connector or mechanical cable lug

First screw in the screws by hand to ensure that the cable sits centered
between the screws attached in a V shape
Page 80 of 116
Revision 04 / 2014-10-17
Fig. 50
Tightening the screws from the outside in

1 Outside
2 Inside
Tighten the screws from the outside in until the screw head tears off
Caution: Do not allow torn screw heads to fall into the tower.
Designation
Quantity SAP no.
Screw in mechanical connector
Screw in mechanical cable lug
Cordless impact wrench approved by GPH

- Nexans ASKO Compact Type BTW250RFE
- Nexans ASKO Type BTW 151 RJEX
- Milwaukee C18 IW
- Hitachi IT-1000-023
Wrench with holding tool GPH GH 40 I-V
The tightening torque is reached when the screw head tears off
Page 81 of 116
Revision 04 / 2014-10-17
2
Fig. 51
Tightening the screws

1 Cordless impact wrench
2 Socket wrench with holding tool
Remove the protruding bur at the mechanical connector after the screw
heads have torn off
Fig. 52
Bur at mechanical connector
Smoothen sharp edges if necessary

Remove any leaked contact grease
Note: The mechanical connectors and cable lugs have been packed with
contact grease that improves the electrical contact properties and prevents
oxygen reaching the contact surfaces.
Page 82 of 116
Fig. 53
14.5
Revision 04 / 2014-10-17
Leaked contact grease
Pre-assembling copper cables using a crimp

connection
SAP no.
Designation
2750
Compression joint DIN 46267, 185 mm
5711
Compression cable lug RSRD A12-185 galvanized, 185

mm
8790
Compression joint DIN 46267, 240 mm
8792
Compression cable lug RSRD A12-240 galvanized,

240 mm
Note: DIN compression cable lugs and DIN compression joints can be
recognized by a double continuous line on the surface
Strip the copper cable considering the insertion length +10 %
Insert the copper cable up to the full insertion length into the compression
cable lug/compression joint
For crimping, only use the appropriate tool inserts in accordance with DIN
46267
Select the appropriate crimping tool in accordance with the specifications on
the compression cable lug/compression joint
- 5 narrow lines: Crimp 5 times using a narrow tool
- 2 wide lines: Crimp 2 times using a wide tool
Note: 5 narrow and 2 wide lines mean: Crimp 5 times using a narrow tool or
twice using a wide tool, see fig.54
Start crimping at the connection flange of the compression cable lug and the
center of the compression joint towards the end of the compression cable lug/
compression joint
Pre-assembling copper cables using a crimp connection K0801_031656_EN
Page 83 of 116
Revision 04 / 2014-10-17
Fig. 54
Assembling the compression cable lug/compression joint

1 Assembly direction
2 1st crimping
3 Crimping specifications
Compacted cables
For compacted cables, e.g. NYY >50 mm, special crimping sleeves are used.
These sleeves ensure an adequate filling volume in the compression cable lug.
Slide the crimping sleeve over the compacted cable
Crimp the sleeve and the compacted cable with the compression cable lug or
compression joint
1
4
Fig. 55
Crimp connection
1
2
3
4
Page 84 of 116
Crimping sleeve
Compression joint
Crimp connection
Crimp connection with heat-shrink tube
K0801_031656_EN Pre-assembling copper cables using a crimp connection
14.6
Revision 04 / 2014-10-17
Insulating cable connections with roll-on sleeves

SAP no.
Designation
41836
Roll-on sleeve RS70-240_0.6kV, Cu 95 mm, Cu 185 mm
41837
Roll-on sleeve RS300-500_0.6kV, Al 300 mm, Cu 240 mm
Assemble a roll-on sleeve over the mechanical connection in order to insulate

the cable connection
Remove the cable insulation in line with the depth of the sleeve
Fig. 56
Removing the cable insulation
Attach the roll-on sleeve to a cable and roll back to the parking position
Assemble the mechanical connector
3
B
A
Fig. 57
Assembling the roll-on sleeve

A
B
1
2
3
4
Attaching the roll-on sleeve

Assemble the mechanical connector
Cardboard sleeve
Roll-on sleeve
Cable
Mechanical connector
Roll the roll-on sleeve over the connector in a central position
K0801_031656_EN
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Revision 04 / 2014-10-17
B
Fig. 58
Assembling the roll-on sleeve

A Rolling the roll-on sleeve over the mechanical connector
B Insulated cable connection
Secure the top end of the roll-on sleeve with cable tie
- Hand tighten
Notice: Take care not to damage the roll-on sleeve.
Fig. 59
Page 86 of 116
Roll-on sleeves with cable ties
K0801_031656_EN
14.7
Revision 04 / 2014-10-17
Connecting cables to the connection system in the

main converter
NOTICE

Dirt particles may damage the electrical components in the main converter.
Ensure the correct assembly of the components for sealing the main
converter:
Foam seals are straight
Foam seals must not have moved during installation
There should be no gaps
Only connection terminals and mechanical cable lugs delivered by the
manufacturer were used
DANGER
HAZARDOUS VOLTAGE
Electric shock from incorrect handling of electrical equipment.
Verify that the cable system is dead prior to the assembly:
Rotor and stator cables must be dead
Busbar system must be dead
Busbar system in the main converter
Triple busbar system
4-part plate system for power and grounding cable leadthrough
Seal of the gaps between the cable entry plates and the foam seals
Connecting cables to the connection system in the main converterK0801_031656_EN
Page 87 of 116
Revision 04 / 2014-10-17
11
6
10
7
1
Fig. 60
Grid connection layout in the main converter, power field

1
2
3
4
5
Cable entry plate 1

Cable entry plate 2
Cable entry plate 3
Cable entry plate 4
Connection with cable lugs
GE (Converteam) N80-2: Connection terminals
6 Aluminum cable clamps M6; 3034 mm
7 Clamp rail
8 Foam seals
9 Base frame
10 Switch cabinet housing
11 Busbar system
Preparing the cable connection

Check that all connection systems are uniquely marked
Check the pre-assembled cable entry plates and foam seals for
completeness
Check the grid cable
- Copper cable: For each phase 7 LV cables 240 mm, cable type H07BN4F or equivalent
- Aluminum cable: For each phase 6 LV cables 300 mm
Start the cable connection with the rearmost busbar system
Page 88 of 116
K0801_031656_EN
Connecting cables to the connection system in the main
14.7.1
Revision 04 / 2014-10-17
Pre-assembling cables outside the main converter

WARNING
FIRE HAZARD
In the case of aluminum cables, remove any connection terminals from the
copper bar in the main converter
Disassemble the cable gland
Slide the screw of the cable gland over the cable
Insert the cable through the opening of the cable gland and determine the
required length
Cut the cable outside the converter to the required length
Pre-assemble the cable
- Pre-assemble the aluminum cables using mechanical cable lugs
- Pre-assemble the copper cables using compression cable lugs
Route the cable through the hole of the cable gland to the copper bar into the
main converter
Assemble the union nut onto the cable gland
Fig. 61
Cable glands on the main converter
Page 89 of 116
Revision 04 / 2014-10-17
14.7.2
Pre-assembling the cables inside the main converter

WARNING
FIRE HAZARD
In the case of aluminum cables, remove any connection terminals from the
copper bar in the main converter where required
Lay the cables through the cable glands to the copper bar into the main
converter
Shorten the cables to the required length
Fig. 62
Removing the connection terminals
In the case of aluminum cables, hand-tighten the mechanical cable lugs to

the copper rail in the main converter, see fig.62
14.7.3
Connecting the copper cables in the main converter

Connecting the copper cables using a connection terminal
WARNING
FIRE HAZARD
Page 90 of 116
K0801_031656_EN
Revision 04 / 2014-10-17
NOTE
Only use connection terminals if:
- Connection terminals have been pre-assembled at the copper bar in the
main converter
- Only copper cables are connected to the connection terminals
Strip off approx. 40 mm of the cable insulation
Fasten the cable to the connection terminal
Fig. 63
Rittal connection terminal
Connecting the copper cables using compression cable lugs

Install the copper cables to the copper bar using compression cable lugs
- M12 x 240 mm; M16 x 240 mm
Fig. 64
Compression cable lug at the connection system Rittal PLS system
Page 91 of 116
Revision 04 / 2014-10-17
14.7.4
Connecting the aluminum cables in the main converter

Connecting the aluminum cables using mechanical cable lugs
If necessary, assemble the cables in the mechanical cable lugs
Notice: Tighten screws from the outside in.
Caution: Do not allow torn screw heads to fall into the main converter.
Fig. 65
Installing the aluminum cables in the mechanical cable lugs

1 Outside
2 Inside
Install the aluminum cables to the copper bar using mechanical cable lugs
- Rotor cable:
M12 x 185 mm with C185 x 12 Nordex
- Stator cable:
Page 92 of 116
K0801_031656_EN
Revision 04 / 2014-10-17
15.
Quality notes on the assembly of the screw

connections
15.1
Fasteners
15.1.1
Abbreviation
Designation
srv
safety-relevant
HV
High strength, pre-loaded as specified
Differences in the fasteners

Standard fasteners
Fasteners meet the generally applicable standard
Srv fasteners
Fasteners meet the additional requirements of the Nordex specifications
15.1.2
Fasteners for special applications

HV fasteners
Coated fasteners
Prelubricated fasteners
Note: Prelubricated fasteners are delivered lubricated and assembled as
delivered
15.2
Screw assembly
OBSERVE DOCUMENT
Current instructions for assembly, erection, maintenance etc.
Current assembly and engineering drawings
WARNING
RISK OF INJURY
There is a risk of injury from faulty preload force of the screw connections.
Tighten all screw connections with a calibrated tightening tool.
To apply the necessary preload force during screw assembly, 2 methods are in
use:
Torque-controlled tightening (e.g. Hytorc)
Fasteners
K0801_031656_EN
Page 93 of 116
Revision 04 / 2014-10-17
Hydraulic tightening (e.g. ITH)

NOTE
Tightening torque, unless specified differently in the current documentation:
Up to K08 beta, see "Tightening torques up to K08 beta" page 98
- VDI 2230 sheet 1/edition 1986
- Head coefficient of friction K = 0.10
- S70, S77: Head coefficient of friction tot = 0.08
Ab K08 gamma, see "Tightening torques from K08 gamma" page 99
- VDI 2230 sheet 1/edition 2003
- Head coefficient of friction K = 0.10
Hand tightening, see "Tightening torques for hand-tightening" page 100
15.2.1

NOTE
For torque-controlled tightening, the entire screw connection is tightened 1 x
with the required tightening torque after preloading.
In the torque-controlled tightening the preload force of the screw is applied via a
tightening torque.
Tool
- Mechanical torque wrench
- Hydraulic torque wrench (e.g. Hytorc)
Fasteners
- Hexagon screws
- Hexagon nuts
- Hexagon socket head cap screws
Lubrication or screw lock
- Lubrication required to achieve the preload force
- No lubrication if screw lock is used
Note: Use medium strength screw lock, unless specified differently in the
current documentation.
Treating the threads
Clean the tap hole
- Weldotec brake cleaner (acetone-free)
- Makra assembly cleaner R3000 (acetone-free)
- Or equivalent
Page 94 of 116
K0801_031656_EN
Screw assembly
Revision 04 / 2014-10-17
Lubricate the screw threads and contact surfaces of the screw head evenly
thin with Molykote G-Rapid plus
Lubricate the threads and contact surfaces of the nuts evenly thin with
Molykote G-Rapid plus
Note: Stainless steel screw connections can also be lubricated with
assembly paste OKS 250.
Tightening the screw connection
Tightening of a screw connection for which no particular specifications are
available in the respective documentation or special tightening schedules:
Place the washer under the screw head
The inner chamfer of the washer points towards the screw head
Place the washer under the nut
The inner chamfer of the washer points towards the nut
Secure all screw connections across the entire circle
Preload all screw connections to 60-70 % of the tightening torque
- Crosswise in groups of max. 3 screws
Tighten all screw connections twice crosswise or radially to 100 % of the
tightening torque
NOTE
Crosswise or radial tightening ensures even contact at the contact surfaces in
larger flange connections.
Fig. 66
Screw assembly
Radial tightening of a screw connection
K0801_031656_EN
Page 95 of 116
Revision 04 / 2014-10-17
15.2.2
Hydraulic tightening method

OBSERVE DOCUMENT
Manufacturer's operating instructions
Operating instructions I210_004 ITH bolt-tensioning cylinder
Data sheet K0822_044314_IN - Bolt tensioning cylinder technical data
NOTE
During hydraulic tightening, the entire screw connection is tightened 2 x with
the required preload force.
In the hydraulic tightening method, the screw preload force is applied via elastic
elongation of the stud bolt.
Tool
- Hydraulic tool with bolt-tensioning cylinder (e.g. ITH)
Fasteners
- Stud bolts and collar nuts
- Stud bolts and hexagon nuts
Lubricants
- Easier assembly
- Lubrication has no influence on reaching the preload force
Preparing the hydraulic tool
Check all cables, hoses and hydraulic pipes for potential damage
Connect the hydraulic pipes
Connect the 230 V power supply
Adjust the pressure via the manual control unit of the hydraulic pump
Preparing the screw connections
Lightly oil the thread of the stud bolts
- Drilling oil or cutting oil spray
Note: This makes the assembly easier and preserves the thread of the bolttensioning cylinders.
Screw in the stud bolts
The protrusion in accordance with the respective screw connection has
been reached, see fig.67
Page 96 of 116
K0801_031656_EN
Screw assembly
Revision 04 / 2014-10-17
Fig. 67
Example of rotor bearing protrusion a
Screw the nut onto the stud bolt

The screw protrusion beyond the nut is min. 1 x M (nominal diameter)
- E.g., M36: at least 36 mm
Tighten the nuts slightly immediately before attaching the bolt-tensioning
cylinder
The stud bolt cannot co-rotate when the bolt-tensioning cylinder is
attached
Tightening the screw connections
WARNING
RISK OF SERIOUS INJURY
If the stud bolt rotates along when the bolt-tensioning cylinder is attached, the
thread may get stripped during tightening and the cylinder may detach
suddenly with an explosive effect.
Observe the safety notes in the manufacturer's operating instructions
Do not face the direction of the tensile force of the bolt-tensioning cylinder
Screw in the stud bolts by hand
Do not use washers
Do not use screw lock
Immediately before placing the bolt-tensioning cylinder, tighten the nuts by
hand until the stud bolt does no longer co-rotate with the bolt-tensioning
cylinder
Tighten the screw connection using a hydraulic tool with bolt-tensioning
cylinder, see manufacturer's operating instructions
Screw assembly
K0801_031656_EN
Page 97 of 116
Revision 04 / 2014-10-17
15.2.3
Tightening torques up to K08 beta

Excerpt from VDI 2230 sheet 1 (edition 1986)
Head coefficient of friction K = 0.10
S70, S77: Head coefficient of friction tot = 0.08
Page 98 of 116
K0801_031656_EN
Screw assembly
15.2.4
Revision 04 / 2014-10-17
Tightening torques from K08 gamma

Excerpt from VDI 2230 sheet 1 (edition 2003)
Head coefficient of friction K = 0.10
Screw assembly
K0801_031656_EN
Page 99 of 116
Revision 04 / 2014-10-17
15.2.5
Tightening torques for hand-tightening

The tightening torques for hand-tight tightening of screw connections are guide
values.
Tighten the screw connection
- Use screws of grades 8.8, 10.9 and 12.9
In accordance with DIN 18800-7: 2008-11
- Use no more force than that achieved manually using a wrench
- Tighten the parts until an even contact is achieved in the clamping area
- Do not overload the screws
Nominal diameter
M12
M16
M20
M22
M24
M27
M30
M36
Tightening torque
[Nm]
10
50
50
100
100
200
200
200
15.3
Marking the screw connection

WARNING
RISK OF INJURY
There is a risk of injury from faulty preload force of the screw connections.
The existing color marking of all screw connections must be visible throughout
the entire service life of the WT. The existing color marking must not be
covered:
Do not paint a new color marking over the existing color marking
Renew color markings that have been painted over
Remove invalid color markings
Mark the screw connection with a finish pencil visibly and permanently with
color
Note: Do not use sealing varnish for the color marking.
Add a new color marking to the existing color marking
15.3.1
Screws with screw lock

Mark all screws glued in with screw lock with red paint
- Red dot on the head of the hexagon screw
- Red dot on the front surface of the stud bolt
Only check all screws that were glued in with screw lock manually
Note: Glued-in screws with the tightening torque applied are given only one red
color marking.
Page 100 of 116
K0801_031656_EN
15.3.2
Revision 04 / 2014-10-17
Hydraulically tightened stud bolts

During hydraulic tightening, the entire screw connection is tightened 2 x with the
required preload force.
Preload force applied for the 1st time
Mark all hydraulically tightened stud bolts with yellow paint
- Yellow paint line on the front surface of the stud bolt
Preload force applied for the 2nd time
Mark all hydraulically tightened stud bolts with red paint
- 1st red paint line on the front surface of the stud bolt
15.3.3
Screws tightened with the torque-controlled method

For torque-controlled tightening, the entire screw connection is tightened 1 x
with the required tightening torque after preloading.
Tightening torque applied for the 1st time
Mark all screws tightened to the tightening torque with yellow paint
- Yellow slanted line / on the front surface of the stud bolt or on the head of
the hexagon screw
15.3.4
Maintenance type 1
Hydraulically tightened stud bolts
During maintenance type 1, the entire screw connection is tightened 1 x to the
required preload force.
Mark all hydraulically tightened stud bolts additionally with red paint
- After the screw connection has settled
- 2nd red paint line on the front surface of the stud bolt
Screw is marked red/yellow/red
Screws tightened with the torque-controlled method
During maintenance type 1, the entire screw connection is tightened 1 x to the
required tightening torque.
Mark all screws tightened to the tightening torque additionally with yellow
paint
- After the screw connection has settled
- Yellow slanted line \ on the front surface of the stud bolt or on the head of
the hexagon screw
The screw is marked with a yellow cross
K0801_031656_EN
Page 101 of 116
Revision 04 / 2014-10-17
15.3.5
Maintenance type 3
Mark all screws maintained in accordance with type 3 with green paint
- Green line on one side of the nut or on the head of a hexagon screw
15.3.6
Maintenance type 4
Mark all screws maintained in accordance with type 4 additionally with green
paint
- Green line on one side of the nut or on the head of a hexagon screw
15.3.7
Test marking of the screw connection

Quality Management test marking
Mark all screws checked by Quality Management with white paint
- White dot on the front surface of the stud bolt or on the head of the
hexagon screw
Shift supervisor test marking
Mark all screws checked by the shift supervisor with orange paint
- Orange dot on the front surface of the stud bolt or on the head of the
hexagon screw
Color key
Photo
Page 102 of 116
Marking
Property of the connection
Red dot
Screw with screw lock
Yellow line
1st red line
Hydraulically tightened stud bolt

Preload force applied for the 2nd time
K0801_031656_EN
Photo
Revision 04 / 2014-10-17
Marking
2nd red line
Hydraulically tightened stud bolt

Maintenance type 1
Yellow slanted
line
Screws tightened with the torque-controlled

method
Tightening torque applied for the 1st time
Yellow cross
Screws tightened with the torque-controlled

method
Maintenance type 1
Green line
Maintenance type 3
2 green lines
Maintenance type 4
K0801_031656_EN
Page 103 of 116
Revision 04 / 2014-10-17
Photo
15.4
Marking
White dot
Quality Management test marking
Orange dot
Shift supervisor test marking
Srv fasteners
OBSERVE DOCUMENT
Technical Specification F302_076 Safety-relevant screws
Technical Specification F302_132 Safety-relevant nuts
WARNING
RISK OF INJURY
At temperatures below -20 C, proper functioning of the srv fasteners and the
screw lubricant Molykote G-Rapid plus cannot be guaranteed. A safetyrelevant assembly is not possible.
In frosty conditions, tools must be thawed and dried in a heated container
Only perform assembly work at temperatures above -20 C.
15.4.1
Lubricating srv fasteners

Prelubricated srv fasteners
All prelubricated srv fasteners must be assembled in the delivery condition
Notice: Additional lubrication must not be added to prelubricated srv
fasteners. The threads of the screws and nuts must be completely free from
grease and oil.
Page 104 of 116
K0801_031656_EN
Srv fasteners
Revision 04 / 2014-10-17
Prelubricated srv fasteners

HV fasteners
Tower flange
Srv fasteners with nuts that have been pretreated with

Molykote
Rotor blade
Srv fasteners with integrated lubricant in the coating

Not prelubricated srv fasteners
Remove grease and oil from the screw threads near the screwing area of the
nut
Remove grease and oil from the thread of the nut
Lubricate the screw threads and contact surfaces of the screw head evenly
thin with Molykote G-Rapid plus
Lubricate the threads and contact surfaces of the nuts evenly thin with
Molykote G-Rapid plus
15.4.2
Assembling srv fasteners

NOTE
The identifying mark of the srv stud bolts must be visible at the top.
Tightening of an srv screw connection for which no particular specifications are

available in the respective documentation or special tightening schedules:
The inner chamfer of the washer must point towards the contact surface of
the screw or towards the nut
Use HV screw connections in sets
- Set: Screws, washers and nuts are from the same manufacturer
Tighten the HV screw connections from the nut
- Hold the screw in place using a second tool, if necessary
Preload all screw connections to 60-70 % of the tightening torque
15.4.3
Re-using srv fasteners

In the torque-controlled tightening screws and nuts may be re-used after
disassembly and thorough cleaning subject to the following conditions:
No wear, damage and corrosion of the threads has been detected
No plastic deformation of the screw has been detected
Srv fasteners
K0801_031656_EN
Page 105 of 116
Revision 04 / 2014-10-17
No plastic deformation of the screw has been detected when applying the
tightening torque
- Plastic deformation (contraction, elongation): Tightening torque is not
reached
The nuts are not HV nuts or other nuts that have been pretreated with
Molykote
Notice: HV nuts and other nuts pretreated with Molykote must not be reused.
Tightening controlled by yield point and by angle of rotation
Notice: After tightening controlled by yield point and angle of rotation the screw
connection must be approved by Engineering before being re-used.
15.4.4
Documenting the use of the srv fasteners

SAFETY-RELEVANT SCREWS
For the unique identification of the screw connection the identifying mark of
the screw connection must be visible and must be documented:
Screw length up to bottom edge of the screw head
Nominal diameter
Grade
Coating
Manufacturer
Serial number / year
Prelubricated / manually lubricated
Page 106 of 116
K0801_031656_EN
Srv fasteners
Revision 04 / 2014-10-17
3
Fig. 68
3
Identification mark of srv screw connection
1
2
3
4
Srv fasteners
Manufacturer
Serial number
Grade
Coating
K0801_031656_EN
Page 107 of 116
Revision 04 / 2014-10-17
16.
Quality notes on the preservation

OBSERVE DOCUMENT
Technical report K0801_042665 Rework and repair of damage and surface
defects in hot-dip galvanized components
16.1
Preserving the nacelle

NOTE
The following parts have adequate corrosion protection and are, therefore, not
preserved further:
Hot-dip galvanized parts
Stainless-steel parts
The following colors must be used for painting
- RAL 7035 (light gray)
- RAL 5009 (azure blue)
- RAL 2002 (vermilion)
- RAL 9005 (jet black)
- RAL 1003 (signal yellow)
16.1.1
Preserving parts outside of the nacelle

All parts that are not hot-dip galvanized or from stainless steel must be
painted completely and without gaps in the appropriate part color
- Degrease
- Apply primer
- Apply paint
Spray all hot galvanized parts with a damaged zinc coating completely and
without gaps with zinc paint or zinc spray
- Degrease
- Apply primer
- Apply zinc coating
All pipe systems that are not galvanized or have untreated surfaces must be
painted completely and without gaps in the appropriate part color
- Degrease
- Apply primer
- Apply paint
Spray all other pipe systems completely and without gaps with IWETEC
special wax or equivalent
Page 108 of 116
K0801_031656_EN
Preserving the nacelle
16.1.2
Revision 04 / 2014-10-17
Preserving parts inside the nacelle

WARNING
RISK OF INJURY
Risk of injury from limited brake operation.
Do not preserve the following surfaces:
Contact surfaces of the brake pads at the rotor brake disk
Yaw brake disk
Paint all bare surfaces completely and without gaps in the appropriate part
color
- Degrease
- Apply primer
- Apply paint
All surfaces pretreated with zinc-rich paint must be treated completely and
without gaps with zinc paint or zinc spray
- Degrease
- Apply primer
- Apply zinc coating
Seaside location or sea transport
Spray all other pipe systems or galvanized parts completely and without gaps
with IWETEC special wax or equivalent
- e.g., elastomer bearings
16.2
Preserving the fasteners

NOTE
Hot-dip galvanized fasteners have adequate corrosion protection and are,
therefore, not preserved further.
Overview for treating fasteners with light signs of corrosion
Tightening
method
Torquecontrolled
Hydraulic
Lubrication Before assembly

Mechanically
prelubricated
Manually
prelubricated
After
assembly
Replace fastener
Clean
Re-use after
disassembly
No
Clean
Preserve
Yes
None
K0801_031656_EN
Page 109 of 116
Revision 04 / 2014-10-17
16.2.1
Cleaning fasteners before assembly

WARNING
RISK OF INJURY
Risk of injury from corrosion at the fasteners due to insufficient coat thickness.
Replace all fasteners if the coat thickness is significantly reduced after
cleaning.
Treating fasteners not pretreated with Molykote with light signs of
corrosion
Clean fasteners
Brush light signs of corrosion off the fasteners using a hard nylon brush
All screws, washers and nuts are free from residue and signs of corrosion
Note: Light signs of corrosion are present if it can be fully removed with a hard
nylon brush.
Replace fasteners pretreated with Molykote having signs of corrosion
NOTE
Cleaning the threads or friction surfaces pretreated with Molykote would
destroy the existing lubrication film and thus change the coefficient of friction
of the screw connection.
Replace fasteners pretreated with Molykote having signs of corrosion
Note: HV fasteners are always pretreated with Molykote.
Always replace complete fastener sets
- Screw
- Washer
- Nut
16.2.2
Preserving fasteners after assembly

OBSERVE DOCUMENT
Assembly instructions V-1.1-GE.KS.01-A Wax preservation S70/S77
Page 110 of 116
K0801_031656_EN
Revision 04 / 2014-10-17
WARNING
RISK OF INJURY
Risk of injury from modified friction coefficient of the screw connections due to
preservative on the friction surfaces.
When preserving the screw connection no preservative must enter the threads
or contact surfaces between the nut and the washer.
Preserve wind turbine class K07 in accordance with the specifications in the
assembly instructions V-1.1-GE.KS.01-A Wax preservation S70/S77
Preserving uncoated anchor bolts
WARNING
RISK OF INJURY
There is a risk of injury from corrosion at the anchor bolts.
Anchor bolts cannot be replaced. Perform the preservation of the anchor bolts
with extra care:
Immediately remove signs of corrosion on the anchor bolts
Preserve anchor bolts immediately after tightening, during erection
Do not mix the preservative Molykote G-Rapid Plus with other substances
Brush off stubborn signs of corrosion from the threads of the anchor bolts with
a wire brush, if necessary
Lubricate the foundation screw connection after tightening completely and
without gaps with Molykote G-Rapid Plus
- Thread of the anchor bolts
- HV washers
- Hexagon nuts
Place black protective cap on the external screw connection
Preserving uncoated fasteners in the outside area
Paint all uncoated fasteners completely and without gaps in the appropriate
part color
- Degrease
- Apply primer
- Apply paint
Note: Do not paint the foundation screw connection, see chapter "Preserving
uncoated anchor bolts"
K0801_031656_EN
Page 111 of 116
Revision 04 / 2014-10-17
Preserving uncoated fasteners in the inside area

Spray uncoated fasteners completely and without gaps with IWETEC special
wax or equivalent
- Tower
- Nacelle
- Rotor hub
Paint uncoated fasteners exposed to moisture or weather completely and
without gaps in the appropriate part color
- Degrease
- Apply primer
- Apply paint
16.3
Repairing paint damage at low temperatures

OBSERVE DOCUMENT
Manufacturer's instructions for the paint used
If the paint cannot be applied due to low temperatures, the damaged locations
must be temporarily preserved properly.
Grind down and clean damaged spots
Properly preserve paint damage
- Short-term preservation: e.g. wax
- Long-term preservation: e.g. grease, oil
Note: Observe the temperature ranges when applying the preservation.
Document the preservation in the erection report
Properly preserve paint damage at higher temperatures
- Grind
- Clean
- Apply primer
- Apply paint
Note: Observe the temperature ranges for the application of the paint.
Page 112 of 116
K0801_031656_EN
Repairing paint damage at low temperatures
17.
Revision 04 / 2014-10-17
Revision index
Rev.
Date
04
2014-10-17
Reason for revision
AST
Updates from NeMo 14-2 included

9220
Different changes from several classes added
Author
S. Gastler
Attachment of the tower section to the crane

Chapter "Inserting the flange bushings": Flange bushing 100 mm (reducing
bushing 100 mm from M56 to M36, SAP no. 1067562) added
AST 8556 Chapter "Hooking in the J hook" prepared
AST 8556 Chapter "Attaching the tower section to the crane" adapted to the
use of the J hook
Preparation of the tower section

Chapter "Preparing the tower section": Checks in top section added
Chapter "Securing the service lift" changed
Erection of the base section
Chapter "Preparing the electrical installation":
- check of the protective devices added
Chapter "Preparing the electrical installation" und "Connecting the power
supply in the tower" updated
Information added to the chapter "Preparing the electrical installation"
Checking the grounding of the emergency power generator and the PE
continuity
Information added to the chapter "Connecting the power supply in the tower":
Establishing a connection from the PE terminal of the emergency power
generator to the tower grounding system
Chapter "Assembling the base section on the foundation":
- Reference to document I402_010 added
Chapter "Grounding tower interiors"
- Do not use any copper paste
- Zinc spray for corrosion protection added
K0801_031656_EN
Page 113 of 116
Revision 04 / 2014-10-17
The following chapters were moved to the chapter "Assembly of the tower
interiors"
- Chapter "Disassembling the platform parts of the standard plus platform"
- Chapter "Installing the main converter"
- Chapter "Assembling the platform parts of the standard plus platform"
AST 8556: Chapter "Assembling the base section on the foundation": Text
about J hook added
Assembly of the tower interiors

Chapter "Mounting the main converter": information on transport cross
beams updated
Chapter restructured
Completion of the erected tower section
Chapter "Preparing the top platform"
- Note on placing the wood planks added
- Information on the position of the screw box added
Chapter "Grounding the tower flange"
Erection of the tower

AST 8556: Chapter "Lifting the tower section onto the tower" Text about J
hook added
Chapter "Mounting the tower section onto the tower":
- Reference to document I402_010 added
Chapter "Screw connections for a 4-part tower":
- Screw length for tower N117 R91 MT changed: Tower sections 2 and 3
Completion of the tower
Chapter "Operating the service lift":
- New operating instructions for Hailo TOPLift K0802_058498 and
K0802_058530 replace operating instructions NALL15_011823
- Strain relief for Hailo and Zarges merged
Page 114 of 116
K0801_031656_EN
Revision 04 / 2014-10-17
Chapter "Removing the aluminum hollow section on the loop":

- "Rectangular pipe" replaced with "aluminum hollow section"
- Information updated and added
- Figure changed
- Returning assembly tools for loop to tower manufacturer
Chapter "Completing the water cooling system for the main converter"
updated
Chapter "Laying grounding cables":

Quality notes for the installation of electrical connections

Chapter "Insulating cables with roll-on sleeves":
- Secure the top end of the roll-on sleeve with cable ties
Chapter "Pre-assembling the cables using mechanical connections":
- Table cable type and mechanical connector revised
K0801_031656_EN
Page 115 of 116
Nordex Energy GmbH

Langenhorner Chaussee 600
22419 Hamburg
Germany
http://www.nordex-online.com
info@nordex-online.com

Erection Instructions Tubular Steel Tower Up To 100 M

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Erection Instructions Tubular Steel Tower Up To 100 M

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Erection instructions

Tubular steel tower up to 100 m

- Translation of the original instructions Document is published in electronic form.

Safety information .............................................................................................. 8

Symbols and notes ............................................................................................... 9

Notes on text format............................................................................................ 10

General notes on erection................................................................................ 11

Completion of the foundation .......................................................................... 13

Checking the acceptance of the foundation........................................................ 13

Preparing the foundation.....................................................................................

Marking the position of the tower door................................................................ 17

Attachment of the tower section to the crane ................................................ 18

Assembling the LLA weldment............................................................................ 18

Hook in the J hook .............................................................................................. 21

Attaching the tower section to the crane............................................................. 22

Preparation of the tower section ..................................................................... 23

Unloading the tower section................................................................................

Checking the vertical ladder................................................................................ 28

Assembling the air vent....................................................................................... 29

Securing the service lift....................................................................................... 29

Erection of the base section ............................................................................ 30

Preparing the electrical installation ..................................................................... 30

Establishing the power supply in the tower ......................................................... 31

Marking the tower door ....................................................................................... 32

Lifting the base section onto the foundation ....................................................... 32

Assembling the base section on the foundation ................................................. 33

Seite 3 von 116

Grounding the base section ................................................................................ 36

Assembly of the tower interiors ...................................................................... 37

Mounting the tower stairs.................................................................................... 37

Disassembling the platform parts of the standard plus platform ......................... 39

Installing the main converter ............................................................................... 40

Assembling the platform parts of the standard plus platform .............................. 42

Installing the converter cooling ...........................................................................

Mounting the tower exteriors............................................................................... 45

Completion of the erected tower section ....................................................... 46

Measuring the vertical alignment of the erected tower section ........................... 46

Sealing the tower flange ..................................................................................... 47

Grounding the tower flange................................................................................. 47

Providing the fall protection system ....................................................................

Erection of the tower ........................................................................................ 51

Interruptions during tower erection ..................................................................... 51

Lifting the tower section onto the tower .............................................................. 52

Establishing the power supply ............................................................................ 53

Assembling the tower section onto the tower ..................................................... 54

Seite 4 von 116

Completion of the tower ................................................................................... 64

Operating the service lift ..................................................................................... 64

Removing the aluminum hollow section on the loop ........................................... 65

Sealing the tower ................................................................................................ 68

Assembling the fire extinguisher ......................................................................... 69

Attaching the signs.............................................................................................. 69

Installation of the main converter ................................................................... 71

Connecting the main converter to the transformer substation ............................ 72

Grounding the components.................................................................................

Completing work ................................................................................................. 74

Quality notes on the installation of the electrical connections .................... 75

Laying the cables ................................................................................................ 75

Stripping cables .................................................................................................. 76

Pre-assembling the cables using mechanical connections.................................

Pre-assembling copper cables using a crimp connection ................................... 83

Insulating cable connections with roll-on sleeves ............................................... 85

Connecting cables to the connection system in the main converter ...................