Beruflich Dokumente
Kultur Dokumente
Release K0801_14863_R00_EN
Revision 00
Wind Turbine Class – K08
14.08.2008
Type: N80/2500, N90/2300, N90/2500
Erection Instructions
Release
Document Number:
K0801_14863_R00_EN
Revision: Created:
00 S. Linck/ENS E. Graumann/ENS
Date:
14.08.2008
Classification:
NX - Nordex Internal
Status: Released:
FI – Final M. Franke/PDE P. Cordt/ENS
AST:
3763
Replaces:
Erection Instructions
Release K0801_14863_R00_EN
Revision 00
Wind Turbine Class – K08
14.08.2008
Type: N80/2500, N90/2300, N90/2500
Erection Instructions
K0801_014863_EN_R00_Erection_K08
Revision date: 14.08.2008
Copyright
Copyright 2008 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 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
Bornbarch 2
22848 Norderstedt
Germany
http://www.nordex-online.com
info@nordex-online.com
1. Conventions.......................................................................................................... 7
3. Tower erection.................................................................................................... 15
4. Tower completion............................................................................................... 55
6. Nacelle erection.................................................................................................. 79
7. Nacelle completion............................................................................................. 99
1. Conventions
DANGER
Warning of a life-threatening situation. Unless avoided a fatal injury will result.
WARNING
Warning of a potentially life-threatening situation. Unless avoided serious
injuries will result.
CAUTION
Warning of a potentially dangerous situation. Unless avoided minor injuries will
result.
NOTICE
Warning of potential material damage. Unless the instructions and notices are
observed, serious material damage may result.
NOTE
Provides additional information, notes and hints
OBSERVE DOCUMENT
Refers to information in other documents
NOTE
Document all necessary details and work steps in the Erection Report
(K202_601_IN).
Submit the Erection Report to Nordex immediately after erection has been
completed.
NOTE
Always document photos of damage and repairs together with a scale!
OBSERVE DOCUMENT
Observe the manufacturer and vendor documentation (see "References")
DANGER
FOR SPECIALIZED PERSONNEL ONLY
The tasks described in this document must only be carried out by industry-
typical appropriately qualified specialized personnel.
DANGER
NO ACCESS FOR UNAUTHORIZED INDIVIDUALS
Throughout the erection work no unauthorized individuals may be present on
the site.
Cordon off the construction site adequately and place warning signs.
Should unauthorized individuals be present within the construction site in spite
of barriers, stop the work and direct the individuals to leave the construction
site!
Tools
All necessary tools are in 2 containers.
These include:
● Diesel generator
● Cables and adapters for power supply
● Workbench
● Access ladder
● Lamps
● Special tools (ITH, Hytorc, wrenches)
● Lifting tackle
● Webbing slings and chain slings
● Guide pins and guide ropes
In countries with 110V grid supply 2 isolating transformers with corresponding
sockets are additionally supplied:
● 1 transformer as mounted version with protective tread (next to the top box)
● 1 transformer as portable version for the tower (siehe Abb.1)
● Preservatives
● Small parts
NOTE
All documents listed here must be available at the time of the respective
erection task.
The documents must have been read and understood by all individuals
involved in the erection.
The safety instructions in the individual documents must be observed in
particular
2.2.2 Standards
2.2.7 Drawings
2.2.10 Options
Abbreviation/term Definition
Control cabinet in the tower base, including
Bottom box
converter
CMS Condition Monitoring System
DIBt *) Deutsches Institut für Bautechnik
flZnncl Zinc flake coating (Delta-Stone-Seal)
FU Frequency converter
GL *) Germanischer Lloyd
HV High-strength
IBN Commissioning
IEC *) International Electrotechnical Commission
Flexible cable loop in the tower top to enable the
Loop
rotation of the nacelle
Luv Side facing the wind
LVB Load-spreading plate
PG Reinforced thread
EBR Equipotential bonding bar
PPE Personal protective equipment
A/F Wrench size
Top box Switch cabinet in the nacelle
tZn Hot galvanizing
Small outside diameter, individual wires do not
have a perfectly round profile, signs of rolling can
Compressed cable
be seen on the outside, rather the shape of a
massive round conductor
WT Wind turbine
*) Note: The abbreviations DIBt, GL and IEC are certificates determining in which wind
zones a tower may be erected. DIBt only applies in Germany; GL and IEC only apply
abroad.
3. Tower erection
To erect the tower the following steps must be carried out:
Preparatory work
● Attaching and unloading the tower segments
● Attaching and unloading the bottom box
● Preparing the foundation
● Installing the transformer in the tower
Tower erection
● Erecting the bottom tower segment
- Measure the bottom tower segment
- Ground the bottom tower segment
- Enter the turbine components
● Erecting the remaining tower segments
- Preparatory work on the erected tower segment
- Connect the tower segments
- Ground the tower flanges
- Fit the external screw connections
Final work
● Measuring the complete tower
● Tightening the tower screw connections
OBSERVE DOCUMENT
Component weights and dimensions:
http://sales.nordex-online.com/N80/N80-3-transport-de.pdf
NOTE
The time sequence of the work steps described here is project-specific.
Delivery condition
● Access ladder, platforms and lamps are already fitted to the tower segments.
Attaching and unloading the tower segments Turbine Class K08 Page 15 of 54
K0801_014863_EN_R00_Erection_K08 Erection Instructions
● Cables and service lift are already pre-installed in the tower segments
● 1 Every tower segment is covered by 1 tarpaulin on the front and the back.
Attachment points
● The small crane is attached to the top of the tower segment with 2 lifting tackles
(see Fig. 4)
● The small crane is attached to the bottom of the tower segment with 1 lifting
tackle (see Fig. 5)
WARNING
RISK OF TOPPLING AND ROLLING OFF
On a sloping ground the truck and tower segment can topple, slide or roll off.
Place the truck and tower segment onto a firm surface.
The firm surface must be on a firm level floor.
NOTICE
PAINT DAMAGE
Lowering can cause paint damage in the tower segment.
Before lowering the tower segment place a piece of clean textile (e.g. carpet)
onto the firm surface.
■ Lower the top end of the tower segment onto the prepared surface with the
hydraulic holding device
■ Detach the tower segment from the hydraulic holding device
Page 16 of 54 Turbine Class K08 Attaching and unloading the tower segments
Erection Instructions K0801_014863_EN_R00_Erection_K08
Fig. 2 Attach the top end of a tower segment (hydraulic holding device)
1. Lifting tackle
2. Firm surface
Fit lifting tackle to the top end of the tower segment (large crane)
■ Fit both lifting tackles for the large crane to the top end of the tower segment with
3 screws, 3 washers and 3 hexagon nuts each (see Fig. 4 ).
Attaching and unloading the tower segments Turbine Class K08 Page 17 of 54
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTE
The precise position of the lifting tackles (see Fig. 4) can be determined using a
spirit level held vertically against the hole circle.
The heads of the fastening screws of the lifting tackle must rest level on the
lifting tackle.
1 2
Fig. 4 Fit lifting tackle to the top end of the tower segment (large crane)
1. Attachment points
2. Lifting tackle fitted
Fit lifting tackle to the bottom end of the tower segment (small crane)
■ Fit the lifting tackle for the large crane to the topmost point of the hole circle with
3 hexagon socket screws, 3 washers and 3 hexagon nuts (see Fig. 5 ).
1 2
Fig. 5 Fit lifting tackle to the bottom end of the tower segment (small crane)
1. Attachment point
2. Lifting tackle fitted
Page 18 of 54 Turbine Class K08 Attaching and unloading the tower segments
Erection Instructions K0801_014863_EN_R00_Erection_K08
■ Attach the large crane with 2 webbing slings (load capacity 40t each) and 2
shackles (load capacity 35t each)
■ Attach the small crane with 1 webbing sling (load capacity 40t) 1 and a shackle
(load capacity 35t).
1 2
WARNING
RISK OF ROLLING OFF
Tower segments can roll off.
Place the tower segments on a firm surface.
The firm surface must be on a firm level floor.
Attaching and unloading the tower segments Turbine Class K08 Page 19 of 54
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTICE
PAINT DAMAGE
The tower segment must not come into contact with the soil.
Place a clean piece of textile under the tower segment on the firm surface.
NOTE
Where possible, install tower segments directly from the truck
NOTICE
DO NOT REMOVE THE TARPAULIN
Only remove the tarpaulin from the switch cabinet when the nacelle has been
fitted onto the tower.
Manufacturer IDS
■ Pull 2 webbing slings through the cabinet base (see Fig. 7; item 1)
Page 20 of 54 Turbine Class K08 Attaching and unloading the bottom box
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTICE
LOW LOAD CAPACITY
If the webbing slings or chains are too short on the crane hook, the load
capacity is not guaranteed.
The angle between the webbing slings or chains at the crane hook must be
< 60°
SENSITIVE COMPONENTS
The electronic components in the switch cabinet are very sensitive and must be
handled with utmost care.
● Lift the switch cabinet carefully
● Avoid jerky movements
1 2
Attaching and unloading the bottom box Turbine Class K08 Page 21 of 54
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTE
Condition for erecting the first tower segment:
Acceptance Report of the foundation (K202_032_EN) has been checked by the
project/site manager.
• The foundation has been released for erection by the project/site manager
• The casting of the foundation was at least 28 days ago
• The processing of the grouting mortar was at least 24 hours ago
3 4 5
1. Anchor bolts
2. Load-spreading plate
3. Hexagon nut
4. Spherical washer
5. Conical seat
■ Make hexagon nuts, spherical washers and conical seats ready in the assembly
position
Note: In all towers spherical washers are always used (conical seat/spherical
washer DIN 6319).
■ Lubricate the contact surfaces of all top washers with Molykote G-Rapid Plus
Caution: Do not lubricate the hexagon nuts!
NOTE
First place the transformer onto the tower segment, then erect the bottom tower
segment
■ Mark the position of the transformer on the foundation (starting from the door
position) (see Fig. 9)
10°
655
360
415
1190
2
1. Tower door
2. Transformer position
NOTICE
LEAKING FOUNDATION
The joints between the conduits and the concrete must be tightly sealed.
• Seal the joints with silicone
• Do not damage the oil-proof coating of the foundation during alignment
DANGER
DANGER OF FALLING
Only enter the access ladder with personal protective equipment (PPE)!
• Always secure yourself to the fall arrest system using the correct fall arrest
slider.
• If the fall arrest system is not yet operational, use the two lanyards of the
PPE alternately for protection.
• Only attach to the rungs of the access ladder.
NOTICE
FOUNDATION DAMAGE
The grouting mortar must have been processed at least 24 hours ago before
the bottom tower segment can be erected.
WARNING
FALLING ITEMS
Risk of injury due to loose falling objects.
Attach all loose items in the tower segment securely or remove them.
■ Carry out a visual inspection of the access ladder and (where applicable) the fall
arrest rail of the bottom tower segment.
► At the top end of the fall arrest rail a rail connection must have been fitted as
a stopper (see Fig. 10)
NOTE
Fall arrester must only be checked by specially trained experts.
If a fall arrest rail is present it can now already be released by the expert.
OBSERVE DOCUMENT
Assembly of the outer platform (external platform), I202_721_EN
Color key for screw connection, I401_689_EN
■ Fit the external platform to the top end of the tower segment in accordance with
instructions I202_721_EN
■ Mark all screw connections which have been tightened torque-controlled with
yellow paint (see I401_689_EN)
■ Attach the tower segment (see "Attach the tower segments" page 16)
■ Slightly lift the tower segment
■ Check the tower segment for paint damage
■ Expert repair of paint damage
WARNING
FALLING ITEMS
During the rotation of the tower segment loose items can fall out of the tower
segment. Nobody must be present underneath the tower segment during
erection.
SUSPENDED LOAD
Work below the tower segment must only be carried out after having consulted
the site manager, the crane operators and a safety person.
■ Apply 1 bead of silicone on the butt joints of the load-spreading plate, both on
top and on the sides (see Fig. 13)
■ All anchor bolts fitted with conical seat, spherical washer and nut
■ Preload all anchor bolts with an impact wrench
CAUTION
LOUD NOISE
Noise can cause hearing damage.
Always wear ear protection when working with an impact wrench.
NOTE
If the fall arrest system has not yet been released fit a sign to the access ladder:
"To ascend the tower the safety ropes of the personal protective equipment
must be used."
OBSERVE DOCUMENT
Theodolite operating instructions (in the theodolite case).
NOTE
Take the local conditions and lighting conditions into account:
• Carry out the measurement during daylight
• The tower door frame must not be inside the bearing range.
3
2 3
1
50–80 m
90°
50–80 m
1+5 4
2 4
1. Location 1
2. Location 2
3. Door entry (2 variants)
4. Measuring points 1-5
Measuring point 2
■ Starting from measuring point 1 change the height to measuring point 2
■ Note the vertical angle
■ Rotate horizontally up to measuring point 2
■ Note the degree value indicated on the theodolite as value 1 Measuring point 3
■ At the same height as measuring point 2 take a bearing of measuring point 3
■ Set the horizontal angle to 0
■ Lower the crosshair up to the vertical angle determined at measuring point 1
Measuring point 4
■ Do not change the height
■ Rotate up to measuring point 4
■ Note the degree value indicated on the theodolite as value 2 in the Erection
Report (K202_601_IN)
Measuring point 5
■ Check that point 1 and 5 match
Note: The deviation of the horizontal angle must not be greater than 0.001GON.
If the deviation is greater, repeat the measurement
■ Half the difference between reading 1 and 2 (smaller value from the larger value)
Note: The value calculated in this way is the vertical deviation of the tower axis
in [°]. This value must be converted to [mm].
2
3
1. Tower segment
2. Theodolite
3. Ruler/folding meter
Location 2
■ Move the theodolite to location 2
■ Carry out all measurements as for location 1
■ Calculate the linear vertical deviation B in [mm] (analog to deviation A)
2 2
C = A +B
■ Compare the total deviation C to the permitted deviation:
Note: Permitted deviation: 5mm/m
DANGER
DANGER OF FALLING
The floor plates have already been removed.
When working on platforms with partially removed floor plates secure yourself
with the lanyard to one of the safety lugs.
CAUTION
DANGER OF FALLING
The floor plates have already been removed.
When working on platforms with partially removed floor plates secure yourself
with the lanyard to one of the safety lugs.
NOTICE
DO NOT REMOVE THE TARPAULIN
Only remove the tarpaulin from the switch cabinet when the nacelle has been
fitted onto the tower.
■ Attach the bottom box to the large crane (see "Attach the bottom box" page 20)
■ Carefully lift the bottom box into the bottom tower segment
■ Lower the bottom box onto the bottom platform and align
■ Screw the bottom box to the platform
■ Where provided, remove the transport cross bars from the bottom box
■ Arrange for the transport cross bars to be returned to the manufacturer
■ Ground the bottom box over the equipotential bonding bar preassembled
■ Move the removed floor plates by crane into the tower
■ Install the floor plates in the tower
DANGER
DANGER OF FALLING
The floor plates have already been removed.
When working on platforms with partially removed floor plates secure yourself
with the lanyard to one of the safety lugs.
NOTICE
DO NOT REMOVE THE TARPAULIN
Only remove the tarpaulin from the switch cabinet when the nacelle has been
fitted onto the tower.
■ Ensure that the protective cage of the transformer and floor plates from the
upper platforms have been removed
■ Attach the medium voltage switchgear to the large crane
■ Lower the medium voltage switchgear onto the bottom platform and align
■ Screw the medium voltage switchgear to the floor plate
■ Refit the protective cage of the transformer
■ Fit the floor plates of the platform above the transformer
■ Move the bottom box by crane into the tower
■ Place the bottom box onto the bottom platform and align
■ Screw the bottom box to the platform
■ Where provided, remove the transport cross bars from the bottom box
■ Arrange for the transport cross bars to be returned to the manufacturer
Completion
■ Move the remaining floor plates by crane into the tower
■ Install the remaining floor plates in the tower
■ Fit the air scoop to the central tower ventilation (see Fig. 18)
WARNING
UNSTABLE TOWER
Dangerous tower oscillations may arise if the top conical tower segment and
the nacelle are not fitted on the same day.
Only fit the top tower segment together with the nacelle.
DANGER
DANGER OF FALLING
Only enter the access ladder with personal protective equipment (PPE)!
• Always secure yourself to the fall arrest system using the correct fall arrest
slider
• If the fall arrest system is not yet operational, use the two lanyards of the
PPE alternately for protection
• Only attach to the rungs of the access ladder
■ If the tower segment is still attached to the crane remove the lifting tackle from
the tower flange
Note: The lifting tackle remains on the crane.
■ Distribute the tower screws, washers and nuts ready for use on the platform
■ Undo the links of the access ladder
■ Press the links into the ends of the access ladder
■ If a short access ladder link is provided, place this with a 2nd pair of links onto
the installed access ladder
WARNING
FALLING ITEMS
Danger of injury when erecting the tower segment due to falling loose items.
OBSERVE DOCUMENT
Assembly of the outer platform, I202_721_EN
- Painting
WARNING
FALLING ITEMS
Risk of injury due to loose falling objects.
Attach all loose items in the tower segment securely or remove them.
WARNING
SUSPENDED LOAD
The freely suspended tower segment can slew to the side!
The following applies to the installers on the top platform of the already erected
tower segment:
Remain in a cowered position under the tower flange until the tower segment to
be fitted has come to rest just above the flange!
■ Rotate the tower segment such that the access ladder can be connected
■ Insert 2 guide pins from above through the flange holes and adjust the tower
segment (see Fig. 23)
NOTICE
SAFETY-RELEVANT SCREWS
Tower screws are important for safety
Do not relubricate the tower screw sets. They have been pretreated by the
manufacturer.
Observe the Technical Instructions for the mounting and documenting srv-bolts,
F010_001
The chamfer of the HV washer must point towards the screw head or the nut.
CAUTION
NOISE
Noise can cause hearing damage.
Wear ear protection when working with the impact wrench.
■ If a fall arrest rail is present, connect both ends of the fall arrest rails with the rail
connector
Caution: The clearance between the fall arrest rails must be max. 2mm.
NOTE
Rework on the ends of the fall arrest rails must only be carried out with a
certificate from HACA.
If a fall arrest rope is intended instead of a fall arrest rail, only fit the fall arrest
rope after all tower segments have been erected.
WARNING
FALLING ITEMS
When working on an external platform no persons may be present within a
radius of 15m around the tower.
DANGER
DANGER OF FALLING
There is a risk of falling if the snap hook is moved without being secured.
Before moving the snap hook always secure with the 2nd lanyard!
1. Safety rail
2. External platform
■ Fit the external and inner screw connections
■ Preload the external and inner screw connections with the impact wrench
CAUTION
NOISE
Noise can cause hearing damage.
Wear ear protection when working with the impact wrench.
NOTICE
SAFETY-RELEVANT SCREWS
Enter the following information in the erection report to enable the screw
connection to be identified uniquely:
• Nominal diameter
• Length
• Manufacturer
• Grade/Coating
• Serial number/Year
■ Mark all screws which have been tightened torque-controlled with yellow paint
(see Color key for screw connections, I401_689_EN)
■ Preserve the screw heads, washers and nuts of the external screw connections
with protective wax
DANGER
DANGER OF FALLING
Only enter the access ladder with personal protective equipment (PPE)!
• Always secure yourself to the fall arrester using the correct fall arrest slider
• If the fall arrester is not yet operational, use the two lanyards of the PPE
alternately for protection
• Only attach to the rungs of the access ladder
DANGER
DANGER OF FALLING
Only enter the access ladder with personal protective equipment (PPE)!
• Always secure yourself to the fall arrest system using the correct fall arrest
slider
• If the fall arrester is not yet operational, use the two lanyards of the PPE
alternately for protection
• Only attach to the rungs of the access ladder
NOTICE
SCREW CONNECTIONS CAN COME LOOSE
Because flange distortions are possible, already tightened screw connections
will undo again.
Check and retighten already tightened screw connections until all screw
connections have reached the specified tightening torque.
NOTICE
SAFETY-RELEVANT SCREWS
Enter the following information in the erection report to enable the screw
connection to be identified uniquely:
• Nominal diameter
• Length
• Manufacturer
• Grade/Coating
• Serial number/Year
■ Mark all screws which have been tightened torque-controlled with yellow paint
(see Color key for screw connections, I401_689_EN)
DANGER
DANGER OF FALLING
Only enter the access ladder with personal protective equipment (PPE)!
• Always secure yourself to the fall arrest system using the correct fall arrest
slider
• If the fall arrest system is not yet operational, use the two lanyards of the
PPE alternately for protection
• Only attach to the rungs of the access ladder
NOTICE
Only install the fall arrest rope after placing the last tower segment!
Only trained specialized personnel is authorized to carry out these tasks.
Observe the corresponding instructions of the manufacturer of the rope
protection system
After fitting the fall arrest rope have it accepted and released by an expert
■ Lead the fall arrest rope along the access ladder all the way to the tower base.
■ Attach the fall arrest rope to the bottom bracket of the access ladder using:
- 1 tightening screw
- 1 thimble
- 1 shackle
- 1 rope clamp
OBSERVE DOCUMENT
For tightening torques see Screw connections K0801_011163
NOTE
All screw connections not listed here must be tightened in accordance with
table "VDI 2230 sheet 1" in the annex of General Assembly Notes, I201_773.
A/F
Tower Designation Quantity
[mm]
Hexagon nut M36– 8.8 – tZn 160 55
Spherical
DIN 6319 – C 37 160
washer
R60 MT
Conical seat DIN 6319 – D 42 160
Protective TSW 55 – 3 – G 174 long version
80
cap with cap
Hexagon nut M42 – 8.8 – tZn 160 65
Spherical
R70 MT DIN 6319 – C xx 160
washer
R75 MT
R80 MT Conical seat DIN 6319 – D xx 160
Protective TSW 65 – 3 – G 174 long version
80
cap with cap
Hexagon nut M42 – 10.9 – tZn 160 65
Spherical
DIN 6319 – C xx 160
washer
R100 MT
Conical seat DIN 6319 – D xx 160
Protective TSW 65 – 3 – G 174 long version
80
cap with cap
Tower A/F
Designation Quantity
segment [mm]
Hexagon
HV – M36 x 250 – 10.9 – tZn 152 60
Segment screw
1 (bottom)
Hexagon nut HV – M36 – 10 – tZn 152 60
and 2
Disk HV – 37 – C45 – tZn 304
Tower A/F
Designation Quantity
segment [mm]
Hexagon
HV – M36 x 220 – 10.9 – tZn 138 60
screw
Segment
2 and 3 Hexagon nut HV – M36 – 10 – tZn 138 60
Disk HV – 37 – C45 – tZn 276
Segment 3 Hexagon M36 x 165 – 10.9 – tZn 60 55
and screw
nacelle Disk HV – 37 – C45 – tZn 60
Tower A/F
Designation Quantity
segment [mm]
Hexagon
HV – M36 x 220 – 10.9 – tZn 138 60
Segment screw
1 (bottom)
Hexagon nut HV – M36 – 10 – tZn 138 60
and 2
Disk HV – 37 – C45 – tZn 276
Hexagon
HV – M36 x 220 – 10.9 – tZn 138 60
screw
Segment
2 and 3 Hexagon nut HV – M36 – 10 – tZn 138 60
Disk HV – 37 – C45 – tZn 276
Segment 3 Hexagon M36 x 165 – 10.9 – tZn 60 55
and screw
nacelle Disk HV – 37 – C45 – tZn 60
Tower A/F
Designation Quantity
segment [mm]
Hexagon
HV – M42 x 320 – 10.9 – tZn 132 70
Segment screw
1 (bottom)
Hexagon nut HV – M42 – 10 – tZn 132 70
and 2
Disk HV – 43 – C45 – tZn 264
Tower A/F
Designation Quantity
segment [mm]
Hexagon
HV – M36 x 250 – 10.9 – tZn 152 60
screw
Segment
2 and 3 Hexagon nut HV – M36 – 10 – tZn 152 60
Disk HV – 37 – C45 – tZn 304
Hexagon
HV – M36 x 220 – 10.9 – tZn 138 60
screw
Segment
3 and 4 Hexagon nut HV – M36 – 10 – tZn 138 60
Disk HV – 37 – C45 – tZn 276
Segment 4 Hexagon M36 x 165 – 10.9 – tZn 60 55
and screw
nacelle Disk HV – 37 – C45 – tZn 60
Tower A/F
Designation Quantity
segment [mm]
Hexagon
HV – M42 x 310 – 10.9 – tZn 132 70
Segment screw
1 (bottom)
Hexagon nut HV – M42 – 10 – tZn 132 70
and 2
Disk HV – 43 – C45 – tZn 264
Hexagon
HV – M36 x 250 – 10.9 – tZn 152 60
screw
Segment
2 and 3 Hexagon nut HV – M36 – 10 – tZn 152 60
Disk HV – 37 – C45 – tZn 304
Hexagon
HV – M36 x 220 – 10.9 – tZn 138 60
Segment screw
3 and 4 Hexagon nut HV – M36 – 10 – tZn 138 60
Disk HV – 37 – C45 – tZn 276
Segment 4 Hexagon M36 x 165 – 10.9 – tZn 60 55
and screw
nacelle Disk HV – 37 – C45 – tZn 60
Tower A/F
Designation Quantity
segment [mm]
Hexagon
HV – M42 x 190 – 10.9 – tZn 200 70
Segment screw
1 (bottom)
Hexagon nut HV – M42 – 10 – tZn 200 70
and 2
Disk HV – 43 – C45 – tZn 400
Hexagon
HV – M42 x 310 – 10.9 – tZn 132 70
screw
Segment
2 and 3 Hexagon nut HV – M42 – 10 – tZn 132 70
Disk HV – 43 – C45 – tZn 264
Hexagon
HV – M36 x 250 – 10.9 – tZn 152 60
screw
Segment
3 and 4 Hexagon nut HV – M36 – 10 – tZn 152 60
Disk HV – 37 – C45 – tZn 304
Hexagon
HV – M36 x 220 – 10.9 – tZn 138 60
screw
Segment
4 and 5 Hexagon nut HV – M36 – 10 – tZn 138 60
Disk HV – 37 – C45 – tZn 276
Segment 5 Hexagon M36 x 165 – 10.9 – tZn 60 55
and screw
nacelle Disk HV – 37 – C45 – tZn 60
Tower A/F
Designation Quantity
segment [mm]
Hexagon
HV – M42 x 190 – 10.9 – tZn 200 70
Segment screw
1 (bottom)
Hexagon nut HV – M42 – 10 – tZn 200 70
and 2
Disk HV – 43 – C45 – tZn 400
Hexagon
HV – M42 x 190 – 10.9 – tZn 200 70
screw
Segment
2 and 3 Hexagon nut HV – M42 – 10 – tZn 200 70
Disk HV – 43 – C45 – tZn 400
Hexagon
HV – M42 x 310 – 10.9 – tZn 132 70
screw
Segment
3 and 4 Hexagon nut HV – M42 – 10 – tZn 132 70
Disk HV – 43 – C45 – tZn 264
Hexagon
HV – M36 x 250 – 10.9 – tZn 152 60
screw
Segment
4 and 5 Hexagon nut HV – M36 – 10 – tZn 152 60
Disk HV – 37 – C45 – tZn 304
Hexagon
HV – M36 x 220 – 10.9 – tZn 138 60
screw
Segment
5 and 6 Hexagon nut HV – M36 – 10 – tZn 138 60
Disk HV – 37 – C45 – tZn 276
Segment 6 Hexagon M36 x 165 – 10.9 – tZn 60 55
and screw
nacelle Disk HV – 37 – C45 – tZn 60
4. Tower completion
To complete the tower the following tasks need to be carried out:
● Preserving the foundation screw connection
● Assembling the service lift
● Fitting the insulation for the bottom box
● Fitting the cooling systems of the bottom box
● Sealing the tower
● Fitting the fire extinguishers
● Attaching the warning signs
● Storing the rescue and abseiling equipment
NOTICE
TIGHTEN THE ANCHOR BOLTS
Tighten all anchor bolts before preservation
OBSERVE DOCUMENT
For tightening torques for the foundation screw connections see Screw
connections for erection (K0801_011163_EN)
■ Spray the anchor bolts, washers and nuts with a protective wax against
corrosion.
■ Tighten the foundation screw connection to the tightening torque (see
K0801_011163_EN)
■ Press 1 black protective cap onto each external screw connection (see fig. 31,
item 1)
NOTICE
Do not apply a bitumen insulating coat to the tower, screw connections and
load-spreading plate
WARNING
• The service lift must only be assembled by specially trained personnel.
• The service lift must only be commissioned for test purposes. The test must
be indicated by a sign.
• After completed assembly the service lift must be certified by an official
expert.
CAUTION
DO NOT ENTER AREA BENEATH SERVICE LIFT
The area beneath the service lift must be marked on the bottom platform.
• Nothing must be deposited on this area.
• Nobody must be present in this area.
OBSERVE DOCUMENT
Service lift Assembly Instructions
It is found in a compartment in the wall of the service lift.
NOTE
This chapter is only relevant when:
• An IDS converter is being used.
• The transformer is erected inside the tower.
NOTICE
No plastic components may fall onto the transformer.
Delivery condition
The insulation consists of approx. 4cm thick stable foam sheets.
The foam sheets are numbered and already have the holes for the coolant hoses
and control cables.
Fitting the insulation for the bottom box Turbine Class K08 Page 57 of 64
K0801_014863_EN_R00_Erection_K08 Erection Instructions
1 2
■ Note the positions of the hose fittings and control cables in relation to the cut-
outs and adjust the cut-outs if necessary
■ Slide the foam sheets together in the opposite direction to the arrows
■ Clamp foam sheet V vertically between foam sheet IV and the converter
Caution: The foam sheet must be tight. If necessary, cut the corners to fit
■ Fit the sheet panels on the frame (see fig. 32, item 2)
OBSERVE DOCUMENT
Structure of the cooling unit at the bottom of K08, I202_723_EN
NOTE
The white compensating hose is only installed in the switch cabinet if an IDS
converter is used.
Page 58 of 64 Turbine Class K08 Fitting the cooling systems of the bottom box
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTICE
At locations with high outside temperatures, it may also be necessary to
connect the High speed stage. In this case, install a jumper in terminal box 1
Fitting the cooling systems of the bottom box Turbine Class K08 Page 59 of 64
K0801_014863_EN_R00_Erection_K08 Erection Instructions
Page 60 of 64 Turbine Class K08 Fitting the cooling systems of the bottom box
Erection Instructions K0801_014863_EN_R00_Erection_K08
Coolant drainage
There is a drainage hose for coolant at the bottom of the converter
■ Lay the drainage hose along the cables up to a free conduit in the foundation
Caution: Observe the Assembly Instructions Converter drainage hose,
I403_077_EN
■ If the transformer has been erected in the tower:
- Extend the drainage hose
- Lay the drainage hose along the lattice
■ Seal the existing gaps and holes between the fan air scoop and the tower
entrance
- Adjust the material provided to fit
- Seal the existing gaps and holes with silicone
NOTE
A special bracket is provided for every fire extinguisher
In lattice towers there is one fire extinguisher in the transformer station
OBSERVE DOCUMENT
WT signs, I501_050_A01
■ Mark protruding threaded rods of the cable brackets with signal paint
■ Position the cable clamps in such a way that the cables go through the center of
the hole in the platform
Storing the rescue and abseiling equipment Turbine Class K08 Page 63 of 64
K0801_014863_EN_R00_Erection_K08 Erection Instructions
■ Drill an M10 hole to the right and the left of the box
Caution: Drill the hole approx. 15cm from the box
■ Screw on the attachment rope
■ Seal the drill holes with silicone
■ Pass the strap through both handles and tie the box down on the platform
Page 64 of 64 Turbine Class K08 Storing the rescue and abseiling equipment
Erection Instructions K0801_014863_EN_R00_Erection_K08
OBSERVE DOCUMENT
Record all executed work in the Erection Report I_K202_601.
OBSERVE DOCUMENT
Tightening torque and reference dimension of the srv studs
Assembly Drawing 801 _06_00005.
NOTICE
COMPONENT FRACTURE
Lifting the drive train at an angle or allowing the rotor bearing to slew during
assembly when installing the drive train can result in a fracture of the labyrinth
in the bearing cover and sealing ring.
Only attach the drive train to the lifting lug on the rotor bearing when the drive
train is secured to the transport frame.
LEAKING GEARBOX OIL
To ensure that no gearbox oil can leak out of the seals, the gearbox must be
level during transport and storage.
Page 66 of 78 Turbine Class K08 Attaching and lifting the drive train
Erection Instructions K0801_014863_EN_R00_Erection_K08
■ Adjust the adjustable chain in such a way that all 4 bearing surfaces of the drive
train lift simultaneously and horizontally
Caution: Different pulling forces on the 4 bearing surfaces can damage the
seals.
■ Lift the drive train
■ Clean all bearing surfaces of the drive train
► The bearing surfaces must be clean, free from grease and, either bare metal or
coated with zincdust paint
■ Repair all paint damage to the bearing surfaces of the gearbox whilst it is on the
transport frame
- grinding
- cleaning
- priming
- painting
WARNING
SUSPENDED LOAD
Risk of injury from lifted drive train.
Coordinate the work between the crane operator, site manager and safety
person.
Attaching and lifting the drive train Turbine Class K08 Page 67 of 78
K0801_014863_EN_R00_Erection_K08 Erection Instructions
WARNING
SUSPENDED LOAD
Risk of injury from lifted drive train.
At least 4 persons must be inside the nacelle.
1 person in the nacelle must be in constant radio contact with the crane
operator.
1 2 3 4
Page 68 of 78 Turbine Class K08 Placing the drive train onto the machine frame
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTICE
COMPONENT FRACTURE
The labyrinth in the bearing cover and sealing ring can fracture if lifted at an
angle.
The drive train must touch down simultaneously at the front and the back.
■ Test the rotor lock bolt once the drive train is in place
■ Remove the guide pin and move the rotor bearing housing laterally if the rotor
lock bolt does not fit into the rotor lock disc
■ Secure the rotor bearing housing on the front gearbox supports of the machine
frame
OBSERVE DOCUMENT
Assembly drawing 801_06_00003
Placing the drive train onto the machine frame Turbine Class K08 Page 69 of 78
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTICE
SAFETY-RELEVANT SCREWS
Enter the following information in the erection report to enable the screw
connection to be identified uniquely:
• Nominal diameter
• Length
• Manufacturer
• Grade/Coating
• Serial number/Year
Page 70 of 78 Turbine Class K08 Placing the drive train onto the machine frame
Erection Instructions K0801_014863_EN_R00_Erection_K08
OBSERVE DOCUMENT
Assembly Drawing 801_06_00005
NOTICE
SAFETY-RELEVANT SCREWS
Enter the following information in the erection report to enable the screw
connection to be identified uniquely:
• Nominal diameter
• Length
• Manufacturer
• Grade/Coating
• Serial number/Year
■ Screw 16 nuts M48 and washers onto the 16 srv studs M48
► Clearance 3mm
113 +2
(363)
613 +2
702
69
Placing the drive train onto the machine frame Turbine Class K08 Page 71 of 78
K0801_014863_EN_R00_Erection_K08 Erection Instructions
1. Shorter hydraulic plunger rod if there is a set of steps over the shaft
2. Longer hydraulic plunger rod positioned directly against the rotor bearing
3. Adjustment screw
■ Push both bearings apart with an oil pressure of 450bar
Note: The oil pressure is generated by a pump in both cylinders.
Caution: The rotor brake must be released.
■ Using the rotor brake disc, rotate the rotor shaft at least one full turn
■ Measure the distance traveled with 1 gage on each side of the gearbox
■ Record both readings in the Erection Report
■ Maintain a pressure of 450bar on the hydraulic cylinders of the hydraulic plunger
rods
■ Lower the crane until the drive train is resting fully on the machine frame
■ Detach the shackles from the rotor shaft
■ Slew with the crane vertically across to the lifting lugs on the gearbox
■ Attach the shackles to the lifting lugs on the gearbox
■ Lift the gearbox with the crane with a load capacity of 18t to relieve the shearing
strain on the elastomer bearing bushes of the gearbox supports
■ Lower the crane until the gearbox is resting fully on the machine frame
■ Fully detach the crane
► The hydraulic plunger rods remain fitted
■ Attach the guide ropes of the drive train to the shackles
Danger: Attach the guide ropes; do not let them fall.
WARNING
RISK OF INJURY
Flying objects following thread fracture.
During the tightening method nobody must be present in front of the tightening
cylinders in the direction of the tensile force.
■ Tighten all nuts M48 in accordance with the Tightening plan for gearbox clamps
1 2 5 6
2 1 6 5
3 4 7 8
4 3 8 7
Screwing the drive train to the machine frame Turbine Class K08 Page 73 of 78
K0801_014863_EN_R00_Erection_K08 Erection Instructions
1 3 5 6 4 2
2 4 6 5 3 1
Fig. 49 Tightening plan for the rotor bearing housing
■ Mark the heads of all tightened srv studs (gearbox and rotor bearing) with a line
of yellow paint
■ Retighten the tightened srv studs after approx. 18 hours
- M48: 1250kN (1300bar)
- M36: 670kN (1350bar)
■ Mark all srv studs for the gearbox and rotor bearing that have been tightened
twice with a line of red paint
■ Prime and preserve the bare metal surfaces at the top of the gearbox clamps
with varnish paint
■ Preserve the srv studs and nuts with protective wax
■ Place plastic caps onto the nuts of the gearbox clamps
■ Tighten loose hexagon socket screws M27 for the gearbox clamps hand-tight
Page 74 of 78 Turbine Class K08 Screwing the drive train to the machine frame
Erection Instructions K0801_014863_EN_R00_Erection_K08
■ Remove the hydraulic plunger rods between the rotor bearing housing and the
gearbox
■ Attach 2 locking plates with 4 hexagon socket screws M30 to the journals
■ Tighten 4 M30 hexagon socket screws to a tightening torque of 1000Nm
OBSERVE DOCUMENT
Attachment device assembly: Drawing 03210-1009443
OBSERVE DOCUMENT
Assembly Instructions: I403_083, chapter 6.2
OBSERVE DOCUMENT
Energy absorber:
■ Check all executed tasks and record them in the Assembly Report
OBSERVE DOCUMENT
Assembly Report: K403_083
DANGER
DANGER OF FALLING
Persons are unprotected at the open side of the nacelle.
Only remove the safety rail once the safety rope has been installed.
The safety rope is certified for a maximum of 4 persons.
All persons must secure themselves to the safety rope by using the PPE.
■ Remove the safety rail and the attachment device from the open side of the
nacelle
■ Lower the safety rail to the ground with the on-board crane
Note: Safety rails are stored in the container.
■ Fit the roof attachment with the bottom screw of the quick-release fasteners
■ Attach the roof pole
■ Remove the webbing slings on the right and left of the machine frame
Note: Webbing slings must be returned to Nordex.
6. Nacelle erection
To erect the nacelle the following tasks need to be carried out:
● Preparing the nacelle
- Opening the nacelle roof
- Fitting the lightning arrester
- Fitting the air scoop
- Fitting and connecting the obstacle lights (optional)
- Fitting and connecting the wind sensors
- Fitting the safety rail
- Connecting the brake motor control box
● Installing the nacelle on the tower
- Installing the nacelle
- Preparing the nacelle with the drive train
1 2 3
1. Hand pump
2. Valve 610, lever engages in 3 positions
3. Valve
640, roof, lever is spring-centered
NOTICE
LIGHTNING STRIKE
Impairment of the functionality of the lightning arrester through electromagnetic
interference.
Do not lay the ground cable alongside signal cables.
WARNING
FALLING LOAD
Falling air scoop if the attachment points do not have sufficient load capacity.
Use the red attachment points to lift the air scoop.
1 1
2 2
WARNING
SUSPENDED LOAD
Risk of injury from freely suspended air scoop.
Only enter the rear part of the nacelle if the air scoop has been positioned to
within a few centimeters of the top of the nacelle.
■ Hold the air scoop with 1 guide rope in the required position
■ Adjust the connecting brackets using 1 guide pin
► The drill holes fit exactly above each other
■ Screw the air scoop to the nacelle
Caution: Do not bend the brackets. Place washers as spacers between the
connecting brackets.
1 3 2 3
DANGER
HAZARDOUS VOLTAGE
Electric shock resulting from incorrect handling of electrical equipment.
The electrical installation must be carried out by electrical professionals only.
OBSERVE DOCUMENT
The documentation for the obstacle lights is stored with the devices.
NOTICE
SENSITIVE MEASURING INSTRUMENTS
Wind sensors are very sensitive and must be handled with extreme care.
Improper handling can damage the wind sensors.
• Do not rotate from the wind sensor housings
• Do not bend the sensor brackets of the wind sensors
• Store wind sensors in dry conditions
• Only transport wind sensors upright.
Additional dimension 3
1. North marking
2. Lightning protection cage
NOTICE
SENSITIVE MEASURING INSTRUMENTS
Destruction of or damage to the wind sensors from improper handling.
Wind sensors are very sensitive and must be handled with extreme care.
Do not rotate from the wind sensor housings
1. North marking
2. Counter-bracket
3. 2 screws
1 2
102cm 83 cm
DANGER
HAZARDOUS VOLTAGE
Electric shock resulting from incorrect handling of electrical equipment.
The electrical installation must be carried out by electrical professionals only.
NOTICE
LIGHTNING STRIKE
Impairment of the functionality of the lightning arrester through electromagnetic
interference.
Lay lightning protection cables at least 0.5 apart from all other signal cables
No cable loops must be present.
DANGER
DANGER OF FALLING
Persons are unprotected at the open side of the nacelle.
Fit the safety rail for fall protection to the open side of the nacelle.
1 3
2
DANGER
HAZARDOUS VOLTAGE
Electric shock resulting from incorrect handling of electrical equipment.
The electrical installation must be carried out by electrical professionals only.
■ Connect the cable in the top box in accordance with the circuit diagram
■ Connect the 5-pin CEE power outlet to the geared motor
■ Connect the grounded power outlet to the brake of the geared motor
Note: If the rotor is installed with the rotor blades already attached (star
arrangement), the connections for the geared motor are not required.
■ Connect the 5-pin CEE connector to the power supply in the tower
DANGER
DANGER OF FALLING
Persons are unprotected at the open side of the nacelle.
The safety rail for fall protection must have been fitted to the open side of the
nacelle.
■ Remove the wax preservation from the contact surfaces of the nacelle, rotor
bearing housing, and gearbox clamps
► The contact surfaces must be either bare metal and free from grease or coated
with zinc silicate
■ Prepare the adjustable chain and round sling
- 1 adjustable chain, 3 m effective working length, 31.5 t capacity
- 1 round sling, 2 m (4 m) effective working length, 40 t capacity
Note: The length of the adjustable chain can be changed
■ Attach the adjustable chain and round sling to the shackle
- 1 shackle 35 t capacity
■ Attach adjustable chain with shackle to the front of the machine frame
- 1 shackle 25 t capacity
■ Attach 2 round slings or 2 chains with 2 shackles to the welded lifting lugs on the
generator frame
- 2 shackles, 25 t capacity each
- 2 round slings or 2 chains, 4 m (6 m) effective working length
69°
2
1. Crane hook
2. Center of gravity
3
4
1. Yaw bearing
2. Yaw brake disk
3. Rubber seal before installation
4. Rubber seal after installation
5. Nacelle coaming edge
► The rubber seal at the coaming edge sits on the side of the yaw brake disk
NOTICE
The rubber seal must not be squeezed between the yaw brake disk and tower
flange when the nacelle is lowered onto the tower.
The crane must continue to hold the load of the nacelle, otherwise the nacelle
could tilt.
■ Lubricate the thread and under the head of all screws with Molykote G-Rapid
Plus
■ Lift the nacelle and place it onto the tower
■ Insert all screws
■ Preload all screw connections with an impact wrench
DANGER
DANGER OF FALLING
Persons are unprotected at the open side of the nacelle.
All persons must secure themselves with the safety rope to a webbing sling
immediately after entering the nacelle.
■ Attach the safety rope to one of the webbing slings on the nacelle frame
■ Slide the rubber seal under the yaw brake disk using a suitable tool
► The rubber seal engages under the collar of the yaw brake disk
► Any dripping grease is diverted inside the nacelle
NOTICE
SAFETY-RELEVANT SCREWS
Enter the following information in the erection report to enable the screw
connection to be identified uniquely:
• Nominal diameter
• Length
• Manufacturer
• Grade/Coating
• Serial number/Year
DANGER
FALLING LOAD
The nacelle can fall due to insufficient load capacity of the screw connections if
the specified preloading torque is not reached.
Only lift the nacelle if the specified preload force of 1000Nm has been applied
to the following screw connections:
• Rotor bearing M36 hexagon socket screws
• Gearbox clamp M48 hexagon nuts
1 2
1. Elbow α
2. Crane hook
3. Center of gravity
DANGER
WARNING
FALLING LOAD
Increased load due to installed drive train.
Only use round slings with a capacity of 40 t (60 t if rotor hub is installed) and
shackles with a capacity of 55 t.
SEALED LIFTING LUGS
The lifting lugs of the generator frame must now not be used.
The lifting lugs have been sealed. The seals must not be removed.
■ Attach the nacelle using the shackle and the lifting lug on the rotor bearing
housing
- Adjustable chain with round sling
- 1 shackle, 55 t capacity
■ Attach nacelle to 2 lifting lugs on the machine frame
- 2 round slings, 2 m (4 m) effectiving working length, 40 t capacity each
- 2 shackles, 55 t capacity each
■ Attach the following to the lifting tackle nacelle with rotor hub
- 1 round sling, 2 m (4 m) effective working length, 40 t capacity
Note: Double up the round sling if necessary
- Adjustable chain, 45 t capacity
- Shackle with collar, 75 t capacity
7. Nacelle completion
To complete the nacelle the following tasks need to be carried out:
● Completing the hydraulic system
● Inspecting the rotor brake at the rotor brake disk
● Assembling the individual components
- Assemble the yaw drive cam limit switch
- Assemble the automatic rotor bearing lubrication system
- Seal the lifting lugs
- Fit the oil overflow
- Fit the fire extinguisher
● Assembling the coupling
- Link coupling
- Multi-disk coupling
● Aligning the generator
● Checking the generator alignment
- Fixturlaser alignment system
- Set dial gage
● Adjusting and screwing on the generator elastomer bearings
● Completing the gearbox cooling circuit
● Assembling the guard for the coupling
● Commissioning and testing the rotor brake
● Completing the generator cooling circuit
● Securing the on-board crane
1 2
WARNING
ROTATING COMPONENTS
Risk of injury from rotating components.
Only lock the rotor using the rotor brake under the following conditions:
• Wind velocity is below 12m/s
• Rotor has been stopped prior to being locked
• Rotor brake has been applied with holding pressure
• It is not permitted to leave the WT while the rotor is locked at the rotor brake
disk.
• Do not carry out any work on the following components:
- Rotor hub
- Rotor brake
- Torque-transmitting components and their bearing seats
• Rotor blades are in the feathering position
• Do not pitch the rotor blades
Page 100 of 126 Turbine Class K08 Inspecting the rotor brake at the rotor brake disk
Erection Instructions K0801_014863_EN_R00_Erection_K08
1. Adjustment screw
2. Locknut
■ Undo the locknut
■ Adjust the adjustment screw
► The clearance is the same on both sides
■ Tighten the locknut
► The rotor brake disk runs freely and centered between the brake pads
■ Apply the rotor brake several times
■ Vent the rotor brake at the highest point above the miniature test port
Note: Vent using the manual lever at the hydraulic unit.
■ Remove preservation from the rotor brake disk
Caution: The brake pads must not be contaminated with protective wax.
Assembling the individual components Turbine Class K08 Page 101 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
Caution: The yaw drive cam limit switch is locked and delivered in the 0 position; it
must not be turned.
2
1
Page 102 of 126 Turbine Class K08 Assembling the individual components
Erection Instructions K0801_014863_EN_R00_Erection_K08
1. Angled nipple
■ Connect the plug connections on the right and left to the angled nipple
1 2 3
1. 2-part cover
2. Insert into the lifting eyes
3. Connect both parts of the cover
Assembling the individual components Turbine Class K08 Page 103 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
■ Attach the fire extinguisher to the red bracket on the top box frame
1 2
1. Link coupling
2. Link
■ Apply lubricant to the threads of the 12 hexagon socket screws or check
lubrication
- New screws: The hexagon socket screws are supplied prelubricated by the
manufacturer.
- Used screws: Apply lubricant to the threads of the 12 hexagon socket
screws.
■ Prepare 12 hexagon socket screws with one special washer each
■ Attach the link to the rotor brake disk and generator flange
■ Tighten 12 hexagon socket screws to a tightening torque of 1070Nm
Caution: After generator alignment, the distance between the rotor brake disk and
the generator flange must be 550mm.
siehe "Aligning the generator" Seite 108
1. Fitting Screw
2. Clamping nut
3. Pressure screws
4. Slip clutch
■ Fit the transition piece to the disk packs
■ Remove 2 x 4 clamping nuts
■ Rotate the generator flange such that the drill holes of the fitting screws align
with those of the rotor brake disk
NOTICE
THREAD DAMAGE
Threads can be destroyed by incorrect lubrication or too high tightening torque.
During assembly note the following points:
• Do not lubricate pressure screws with grease
• Only use low viscosity oil for relubricating pressure screws
• Do not lubricate fitting screws with copper grease to facilitate subsequent
removal
• Do not retighten pressure screws marked in red; these were tightened by
the coupling manufacturer
approx. 1mm
1 2 3 4
1. Clearance
2. Tighten 4 pressure screws crosswise
3. Tighten all pressure screws to the tightening torque
4. Head contact surface
■ Tighten 4 opposite pressure screws crosswise
- First hand-tight
- Then to 50Nm
- Then to 90Nm
■ Tighten all pressure screws successively and in several cycles to the tightening
torque of 90Nm
Caution: Pressure screws must not make contact with the head contact surface.
NOTE
After the generator has been aligned, the clearance between the rotor brake
disk and the RADEX N flange must be 570mm.
OBSERVE DOCUMENT
Operating instructions: Fixturlaser alignment system
WARNING
EYE DAMAGE
The laser beam can cause damage to the retina.
Never look directly into the laser beam.
Observe the safety instructions in the operating instructions of the Fixturlaser
alignment systems.
Due to the inclined gearing of the gearbox helical gear stage, the high-speed shaft
of the gearbox moves slightly towards the generator:
■ Only rotate the coupling in one direction during alignment, preferably the working
direction
■ Measure the distance between the rotor brake disk and the generator flange
550 mm
1 2
3
5
4 6
Checking the generator alignment Turbine Class K08 Page 109 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
Page 110 of 126 Turbine Class K08 Checking the generator alignment
Erection Instructions K0801_014863_EN_R00_Erection_K08
Enter data
■ Check the system settings:
- Measuring unit mm
- Automatic switch-off: e.g. after 15 minutes
- Enter the current time and current date
■ Measure the required dimensions A to D
► The distance C between the generator elastomer bearings is 1400mm
■ Set resolution to 0.01
Note: The resolution of 0.01 has been preset
■ Set measuring duration to 3 seconds
Note: The measuring duration of 3 seconds has been preset
NOTE
In gusty/windy conditions the measuring duration must be 10 seconds.
Measurement
■ Carry out the measurement at 3 points (Tripoint)
■ Rotate the generator shaft by at least 30° for each subsequent measurement
■ Save one measurement before and after adjustment
NOTE
The rotor brake must be applied during each measurement.
CAUTION
ROTATING ROTOR
Uncontrolled rotor rotation due to the rotor brake not being applied.
Personnel must be able to brake the drive train in an emergency.
Checking the generator alignment Turbine Class K08 Page 111 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
OBSERVE DOCUMENT
Operating instructions: Fixturlaser alignment system
■ Tighten the screw connection between the generator elastomer bearings and
the generator frame to a tightening torque of 170N
■ Carry out a test measurement
■ Record the values within the tolerance in the Erection Report
Example: 8010.ibn.after.12
■ Readjust the generator elastomer bearings if the tolerance is not met.
siehe "Adjusting and screwing on the generator elastomer bearings" Seite 115
Page 112 of 126 Turbine Class K08 Checking the generator alignment
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTE
The angular alignment can be checked in a single operation using 2 dial gages.
Checking the generator alignment Turbine Class K08 Page 113 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
Page 114 of 126 Turbine Class K08 Checking the generator alignment
Erection Instructions K0801_014863_EN_R00_Erection_K08
Adjusting and screwing on the generator elastomer bearingsTurbine Class K08 Page 115 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
■ Screw the adjustment screws under the generator elastomer bearing plate to the
generator frame
Note: This prevents slipping
■ Undo 4 hexagon socket screws M16 per generator elastomer bearing
■ Align the generator elastomer bearing plate by using the adjusting screws
■ Check the offset again
● Values are within the tolerance:
- Tighten 4 hexagon socket screws M16 between the generator elastomer
bearing and the generator frame to a tightening torque of 170N
- Record the values in the Erection Report
● Values are outside the tolerance:
- Readjust the generator elastomer bearings
■ Repeat the procedure until all values are within the tolerance
Height adjustment
Caution: Take the load off the generator bearing during height adjustment
otherwise the fine thread can be destroyed.
■ Check the offset
● Values are within the tolerance:
- Record the values in the Erection Report
● Values are outside the tolerance:
- Readjust the generator elastomer bearings
3
10
Page 116 of 126 Turbine Class K08 Adjusting and screwing on the generator elastomer bea-
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTE
The distance between the generator elastomer bearing housing and the
adjustment nut must not exceed 10mm.
Use 2mm or 5mm shims.
Adjusting and screwing on the generator elastomer bearingsTurbine Class K08 Page 117 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
Connect the cooling hoses for the flow and return to the oil filter
■ Remove the blanking plug
■ Attach the lower cooling hose to the T fitting
■ Attach the upper cooling hose with pipe elbow to the top outlet of the oil filter
Page 118 of 126 Turbine Class K08 Completing the gearbox cooling circuit
Erection Instructions K0801_014863_EN_R00_Erection_K08
1. Oil filter
2. Upper cooling hose lower cooling hose at the T fitting
■ Tighten the hexagon nut with a wrench hand-tight
► The screw connections are tightly sealed
NOTICE
OIL ESCAPE
Gear oil can emerge from the bearing seals if the gear oil supplied is used to
refill the cooling circuit too early.
Only refill the cooling circuit with the additional gear oil supplied during first
commissioning after the pumps have been operated once and the pipes have
been filled.
Assembling the guard for the coupling Turbine Class K08 Page 119 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
Eickhoff gearbox
Attach the guard on the gearbox side to the following 3 points:
● At the top to the elbow above the bearing cover of the high-speed shaft of the
gearbox
● On the right to a U profile section
● On the left to a U profile section
■ Tighten the guard on the gearbox side with 2 hexagon socket screws M8 and
washer and self-locking nut each
Page 120 of 126 Turbine Class K08 Assembling the guard for the coupling
Erection Instructions K0801_014863_EN_R00_Erection_K08
■ Tighten the 2 parts of the guard on the gearbox side one under the other with 5
hexagon socket screws M8 and washer and self-locking nut each
■ Screw the 2 parts of the guard on the generator side successively to the
mounting surfaces on the generator
■ Tighten the guard on the generator side with 10 hexagon socket screws M8 and
washer each
■ Tighten hexagon socket screws M8 to a tightening torque of 18Nm
■ Tighten the 2 parts of the guard on the gearbox side one under the other with 6
hexagon socket screws M8 and washer and self-locking nut each
Commissioning and testing the rotor brake Turbine Class K08 Page 121 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
1 2 3 4 5
1. Hand pump
2. Valve 810.2 (behind the round component)
3. Valve
640, roof, lever spring-centered
4. Valve 610, lever engages in 3 positions
5. Valve
600, rotor lock, lever is spring-centered
Page 122 of 126 Turbine Class K08 Commissioning and testing the rotor brake
Erection Instructions K0801_014863_EN_R00_Erection_K08
Abb. 97 Marking
Commissioning and testing the rotor brake Turbine Class K08 Page 123 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTICE
VIBRATION
The lock disk can become dislodged due to vibration if it is not secured
correctly.
Use the safety pin to secure the rotor lock disk when it is extended and
retracted.
CAUTION
AGGRESSIVE FLUID
Coolant and antifreeze can cause injury to the eyes and skin.
Wear protective gloves and eye protection.
NOTE
The ready-mixed Varidos FSK-45 is used as a coolant and antifreeze.
The system pressure is 2.5bar.
Page 124 of 126 Turbine Class K08 Completing the generator cooling circuit
Erection Instructions K0801_014863_EN_R00_Erection_K08
1. 1.062 g/cm3
NOTE
Density at 20°C approx. 1.062g/cm3, approx. 45Vol.-%
If the density is outside the tolerance limits of 1.056 to 1.067g/cm3
(40–50Vol.-%), the complete coolant must be replaced.
Completing the generator cooling circuit Turbine Class K08 Page 125 of 126
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTE
Target pH 7.5 to 9.0
Page 126 of 126 Turbine Class K08 Securing the on-board crane
Erection Instructions K0801_014863_EN_R00_Erection_K08
8. Rotor erection
To erect the rotor the following work must be carried out:
Preparatory work
● Unloading and preassembling the rotor hub
- Position the rotor hub
- Prepare the pitch bearing
- Assemble the hub cage
Completion
● Final work
- Lock the rotor
- Move the rotor blades into the feathering position
- Turn the nacelle into wind
- Remove the geared motor and lift it out of the nacelle
Unloading and preassembling the rotor hub Turbine Class K08 Page 127 of 152
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTICE
RISK OF TILTING
On uneven floors the rotor hub can sag or tilt.
Place the rotor hub on a firm level floor.
PROTECT ELECTRICS AGAINST HUMIDITY
Only remove the protective tarpaulin of the rotor blade flange when the
respective rotor blade is being installed.
Immediately refit the protective tarpaulin in wet weather if there is a delay in the
installation of the rotor blades.
Page 128 of 152 Turbine Class K08 Unloading and preassembling the rotor hub
Erection Instructions K0801_014863_EN_R00_Erection_K08
Unloading and preassembling the rotor hub Turbine Class K08 Page 129 of 152
K0801_014863_EN_R00_Erection_K08 Erection Instructions
OBSERVE DOCUMENT
On the hydraulic tightening method of ITH:
General remarks on assembly, I201_773
OBSERVE DOCUMENT
Final work (preservation), K0801_011162
Page 130 of 152 Turbine Class K08 Unloading and preassembling the rotor hub
Erection Instructions K0801_014863_EN_R00_Erection_K08
■ Glue in the screws with a medium-strength screw lock and apply a red color
mark to the head
■ Place the hub cage onto the rotor hub
Note: Both removable struts of the hub cage are opposite the hatch hinge.
If the hatch is opened downwards, the two upper struts can be removed.
■ Seal the screws and metal covers at all rotor blades completely with silicone
NOTE
The rotor blades can be lifted from the truck directly in the transport position.
The should be fitted directly to the rotor hub without intermediate storage.
Rain deflector, vortex generator and erosion protection film have already been
attached.
NOTICE
Do not damage the rain deflector, vortex generator and erosion protection film
■ Place 1 edge protection for the respective rotor blade type and 1 webbing sling
near the arrow mark around the rotor blade tip see Fig.108
■ Place 1 webbing sling around the rotor blade root
NOTE
The required screws, washers and nuts differ depending on the rotor blade and
rotor hub types.
Delivery condition
The manufacturer delivers the blades to the construction site with the studs
preassembled. The studs are glued in with low-strength screw lock.
NOTICE
The coating was changed for LM. Screws, washers and nuts must have the
same coating! Never mix flZnncl and tZn.
NOTICE
DAMAGED THREADS
The screw threads must be clean, dry, and free from grease and oil.
Clean studs with a degreasing agent if grease or oil are present on the threads.
NOTICE
SAFETY-RELEVANT SCREWS
Enter the following information in the erection report to enable the screw
connection to be identified uniquely:
• Nominal diameter
• Length
• Manufacturer
• Grade/Coating
• Serial number/Year
Screw connection per rotor blade to rotor hub (rotor blade types NR 45, LM
38.8 and LM 43.8)
NOTICE
Studs and nuts feature a coating with integrated lubricant (flZnncL).
Do not lubricate the studs and nuts.
Screw connection per rotor blade to rotor hub (LM 48.8 with standard rotor
hub)
NOTICE
Studs and nuts feature a coating with integrated lubricant (tZn).
Do not lubricate the studs and nuts.
Screw connection per rotor blade to rotor hub (types LM 38.8 and LM 43.8,
without integrated lubrication)
NOTICE
Studs and nuts are pretreated (tZn).
Do not lubricate the studs and nuts.
NOTE
Position of the 0° screw:
Left to the 0° marking of the rotor blade (when looking at the rotor blade root
towards the blade tip), see Fig.109.
The 0° screw is marked to be easier to detect during assembly and
maintenance.
2 2
1. 0° screw
2. 0° marking
NOTICE
The pitch auxiliary box requires three-phase current 400V/50Hz (min. 32A). A
soft start limits the current requirement when the pitch motors start up.
The pitch bearings must only move a max. of 30sec with the pitch auxiliary box
at 400V/50Hz mains supply. After that they must observe a pause of 2 minutes.
■ Check the plug connector contacts and tighten them firmly prior to operation
NOTICE
The plug connection is implemented through indirect contacts.
The contacts are destroyed if the plug connectors are removed under load.
■ Rotate the pitch bearing into the assembly position using the pitch auxiliary box:
- Align the 0° marking of the rotor hub (marked hole) with the 0° screw of the
rotor blade
■ Rotate the pitch bearing accordingly using the pitch auxiliary box
- Every rotor blade must be screwed to the pitch bearing in the rotor hub
- Screw the 0° screw into the marked hole of the pitch bearing
■ Carefully move the rotor blade along with the crane and / or rotate the pitch
bearing slightly to and fro if problems are encountered when inserting the rotor
blade screws
■ Screw 1 ISO washer and 1 hexagonal nut manually onto each stud up to the
pitch bearing
■ Tighten the screw connections crosswise in groups of 4 nuts at a time using an
impact wrench
CAUTION
NOISE
Noise can cause hearing damage.
Always wear ear protection when working with an impact wrench.
NOTE
Not all nuts are accessible by the impact wrench.
Use a wrench in addition
NOTICE
DO NOT MOVE THE PITCH BEARING BEYOND 360°
The gear cam limit switch system loses its preset state if the pitch bearing is
moved beyond 360°.
Move the pitch bearing max. 340°. Then move back to the original position.
8.2.4 Move the rotor blade into the 90° position (feathering position)
■ Connect the pitch auxiliary box to the next pitch drive
■ Place the rotor blade onto the rotor blade bearing block see Fig.110
Note: The position of the bearing block is marked on the rotor blade by a small
black arrow.
■ Detach the crane
NOTICE
The rotor hub with the rotor blade must also stand firmly in strong gusts of wind.
Brace the rotor blade with ground anchors and ratchet straps
Preparatory work
■ Check the prerequisites
► The drive train is completely bolted to the nacelle
■ Turn the rotor shaft so that is in the Y position
► The rotor shaft is in the Y position
NOTE
The rotor shaft must be in the following position:
The torque support for the slip ring points towards the converter cabinet (FU1)
of the rotor blade flange 1, see Fig.112.
NOTE
The torque support is also used as a cable duct to the converter cabinet 1.
Rotate the torque support by 120° at a time if it points into a different direction.
The required M16 tap holes are provided in the rotor shaft.
To the star with the guide ropes sufficient personnel or machines (construction
vehicles, tractors) must be available.
Fit the lifting tackle for the rotor hub and the rotor blades
NOTE
The screws 2–6 have normally been removed to allow the two lifting tackles for
the star to be fitted to the rotor bearing.
The removed screws are in the rotor hub. They are attached to the pitch box
frame.
■ Attach one guide rope each (length = 1.5 x tower height) to the loop
NOTE
• Observe the rotor movements
• Control via radio:
- the work of the crane operator
- the work of the support team on the guide ropes
• Coordinate the installers in the nacelle
• Define unique communication signals between the site manager, crane
operator and safety person
OBSERVE DOCUMENT
Final work (preservation), K0801_011162
NOTICE
Keep the sling as vertical to the rotor blade and tight as possible. The loop can
slip away if the rotor reaches the vertical position.
■ Whilst the rotor hub is being lifted, lubricate the threads and head seats of the
screws used to connect the rotor shaft to the rotor hub with Molykote G-Rapid
Plus
■ Slowly slew the star towards the rotor shaft
NOTE
The rotor shaft must be positioned as follows (see Fig. 112):
• The torque support must point towards FU1
• The centering pin must fit into 1 of the 3 holes in the rotor shaft, see Fig.119
2
1
1. Rotor hub
2. Rotor shaft
3. Centering pin
DANGER
FALL HAZARD
If the rotor hub is not mounted correctly, it is not possible to climb over the rotor
hub safely, mount the individual rotor blades as specified, or perform
maintenance work on any of the rotor blades.
The positioning of the rotor shaft and the rotor hub in relation to each other
must be exact.
NOTICE
SAFETY-RELEVANT SCREWS
Enter the following information in the erection report to enable the screw
connection to be identified uniquely:
• Nominal diameter
• Length
• Manufacturer
• Grade/Coating
• Serial number/Year
OBSERVE DOCUMENT
General remarks on assembly, I201_773
■ Mark the end planes of the tightened stud bolts with a yellow paint line
■ Insert the rotor lock at the rotor shaft
■ Mark the end planes of the studs after the 2nd preloading additionally with a red
mark
■ Preserve the studs and nuts with protective wax
■ Turn the rotor blades to feathered position (by 180°)
NOTE
Completely screw on the drive train.
Preferably carry out the rotor hub assembly on the ground.
Position the rotor shaft such that the torque support points towards cabinet FU1
and the rotor lock could be inserted.
In wet weather leave the protective tarpaulin on the rotor blade flanges during
assembly.
Only remove the tarpaulins immediately before the rotor blade assembly.
■ Attach 2 special lifting tackles at the top to the pitch bearings of the rotor hub
■ Prepare 2 round slings with a load capacity of 20t each
■ Prepare 2 shackles with a load capacity of at least 25t each
■ Attach the rotor hub
► The crane picks up the load and lifts the rotor hub against the rotor shaft
NOTE
The rotor shaft must be positioned as follows, see Fig. 112:
• The torque support must point towards FU1
• The centering pin must fit into 1 of the 3 holes in the rotor shaft, see Fig.119
■ Place the HV washers onto the screws in such a way that the chamfer points
towards the screw head
■ Slide the screws from the nacelle through the lock disk and the rotor shaft
■ Preload the screw connections with an impact wrench
■ Tighten the screw connections to the specified tightening torque of 3000Nm
■ Detach the rotor hub
■ Remove the lifting tackles
■ Check the O-ring profile (Ø 3.5mm:)
► The O-ring profile is properly inside the groove at the rim of the inner rings of
the pitch bearing
► The O-ring profile has been glued in properly
■ Lift the geared motor with the crane against the brake disk
■ Attach the geared motor with screws and washers
Caution: The torque support must rest on the generator frame on the right
■ Fit and secure the bottom bolt of the torque support
■ Connect the geared motor to the auxiliary power supply
NOTE
This section contains additional and variant descriptions for screwing the rotor
blades individually to the rotor hub.
WARNING
Lift the rotor blades with 2 cranes each
The drive train must be secured to the rotor shaft with the locking bolt when
working in the rotor hub
NOTE
When the rotor blade approaches the nacelle the person responsible in the
nacelle continues to instruct the crane operator.
Continue to monitor and, if necessary, correct the angle between the rotor
blade and the rotor hub from the ground.
LM: M36x490/250-10.9
NR: M36x452/250-10.9
52 ±2
220 ±2
NOTE
Crane operator: Move along carefully
■ Continue rotating the rotor hub until the next pitch bearing is in the assembly
position (vertical)
■ Install the rotor blade 2 and 3 as rotor blade 1
Prerequisite:
● All 3 rotor blades have been fitted
9. Electrical installation
For the electrical installation the following tasks must be carried out:
● Connecting the cables in the rotor hub
● Installing power and ground cables
● Ground cables
● Line-side cable connection in the bottom box
● Installing the control cables
● Final cable work
DANGER
ELECTRICITY
Electric shock due to incorrect handling of electrics.
The electrical installation must be carried out by electrical professionals only.
9.1 Notes
Circuit diagrams
The circuit diagrams of the WT are stored in the top box or bottom box.
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. 50cm before the
gland or the cable inlet.
The labeling material is in the bottom box, panel 1
Compressed cables
If compressed cables are used (e.g. NYY >50mm2), special sleeves must be used.
These sleeves are moved over the compressed cable and then crimped together in
the cable lug or compression joint.
This sleeve ensures an adequate filling volume in the cable lug.
Small parts
Optic fibre cables, cable lugs and other small parts for the electrical installation are
delivered to the site on separate pallets.
NOTE
The lighting in the rotor hub is only activated during commissioning.
Take along additional lighting into the rotor hub!
The battery disconnector switches are only switched on during commissioning.
NOTICE
To secure the connectors always use the screws fitted to them.
All seals must be provided in the screws.
Page 154 of 170 Turbine Class K08 Connecting the cables in the rotor hub
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTE
Lattice towers
The erection of the lattice towers is carried out exclusively by SeeBA
Energiesysteme GmbH. This company is also responsible for routing all the
cables in the tower and preparing the loop.
The technician for the WT erection only pick up the cables from the top platform
of the lattice tower or the cableway to the transformer station and then carry out
all subsequent work.
NOTICE
USE ORIGINAL SCREWS
The PG glands for the bottom box are too large for the cables used in the lattice
tower.
Replace the existing rubber seal with the supplied thicker rubber seals to close
the clearance.
L2
L3 L1
Abb. 129 Cable bundle
NOTE
Fit cable bundles at a distance of approx. 50cm from each other.
Use the whole width of the cableway
Installing power and ground cables Turbine Class K08 Page 155 of 170
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTICE
DO NOT DAMAGE CABLES
Avoid pressure and abrasion marks in the cable insulation
.
Observe minimum bending radius in accordance with DIN VDE 0298, part 3:
Permanent cable routing:
• r = 4d
• minimum radius = 120mm
Free movement or cable entries:
• r = 5d
• minimum radius = 150mm
Delivery condition
The cables to be connected to the nacelle are on the top platform in the tower top.
These cables are fitted with cable grips and attached to the round ladder.
At the top end of the bottom tower segments the cables are cut flush with the flange
and protrude by approx. 0.5m at the bottom end. The two top cable clips in every
tower segment are permanently attached.
The bottom clips are only loosely attached.
■ If the bottom clips are not loosely attached, undo the clips
Page 156 of 170 Turbine Class K08 Installing power and ground cables
Erection Instructions K0801_014863_EN_R00_Erection_K08
1. Nut (80Nm)
2. Cableway for control cables and auxiliary power system
3. Stator cable cross section 240mm2
4. Rotor cable cross section 185mm2
■ In the rotor cables (only the two front cable bundles) swap the position of the
cables L1, L2, L3 at each tower flange.
1 2
■ Always swap the cables in clockwise direction (as viewed from the top)
■ Connect the white cable (from the top) to the white cable (from the bottom) with
compression joints
■ Change the positions L1, L2 and L3 in the brackets
Installing power and ground cables Turbine Class K08 Page 157 of 170
K0801_014863_EN_R00_Erection_K08 Erection Instructions
1 2 3
120°
L1 L1 L1 L2 L2
L2 L3 L2 L3 L3 L1 L3 L1
L2 L3
1. Compression sleeve
2. Compression joint
3. Cable connected
Page 158 of 170 Turbine Class K08 Installing power and ground cables
Erection Instructions K0801_014863_EN_R00_Erection_K08
■ Route the cables from the tower wall in the existing bundles of 3 in the cableways
above the bottom box
- Attach with additional cable ties
- Use the whole width of the cableway
- Install at a distance (unlike in the photograph)
1
2
Installing power and ground cables Turbine Class K08 Page 159 of 170
K0801_014863_EN_R00_Erection_K08 Erection Instructions
NOTE
The cables must be connected in different ways depending on the converter
manufacturer, see circuit diagram.
IDS
● Stator rotating field, swap the 5 cables (L1-L2) once
● Rotor rotating field, swap the 2 cables (L1-L2) once
SEG
● Stator rotating field, swap the 5 cables (L1-L2) once
● Rotor rotating field, swap the 2 cables (L1-L2) once
Converteam
● Stator rotating field, swap the 5 cables (L1-L2) once
■ Route the stator cable from the top through the glands into the bottom box
■ Attach the stator cable to the cableways above the bottom box
■ Route the rotor cable up to the center of the bottom box: 2 x L1, L2, L3
■ Route the rotor cable from the top through the glands into the bottom box
■ Attach the rotor cable to the cableways above the bottom box
Page 160 of 170 Turbine Class K08 Installing power and ground cables
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTE
Stator cable: W01
Rotor cable: W02
L3 L3
1
L2 L2 2
L1 L1
NOTICE
LABEL THE CABLES
To be able to correctly route the cables in bundles of 3 they must first be
labelled. If the cables in the tower are only connected later, the cables in the top
tower segment can already be checked for conductivity and labelled by hand.
However, this does not replace the check for conductivity prior to connection in
the control cabinet
■ Undo the shackles of the cable grips from the round ladder
■ Attach the shackles approx. 0.5m higher at the machine frame
Installing power and ground cables Turbine Class K08 Page 161 of 170
K0801_014863_EN_R00_Erection_K08 Erection Instructions
■ Route the labelled cables in bundles of 3 through the nacelle to the generator
■ Attach the cables in bundles of 3 using cable ties
Abb. 140 2 bundles of 3 to the rotor terminal box with M50 glands
■ Route the cables from below through the metric glands into the terminal box
■ To relieve tension tighten the glands (M50, metal) to 20Nm
Page 162 of 170 Turbine Class K08 Installing power and ground cables
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTE
The cables can only be connected in the terminal box after the cables have
been connected in the tower, clearly checked for conductivity and labelled and
connected in the bottom box.
Installing power and ground cables Turbine Class K08 Page 163 of 170
K0801_014863_EN_R00_Erection_K08 Erection Instructions
1 2 3
1. Rotor (Winergy)
2. Rotor (VEM)
3. Stator
1 2
1. Stator
2. Rotor
■ Connect cables
■ Apply required torque
Page 164 of 170 Turbine Class K08 Installing power and ground cables
Erection Instructions K0801_014863_EN_R00_Erection_K08
NOTE
The torques are specified on labellabels in the terminal boxes of the
generators. The screws have been pre-installed hand-tight in the terminal
boxes.
9.4.1 Nacelle
■ Fit cable lugs M12 to the 3 ground cables of the loop
■ Connect the ground cables from the loop to the equipotential bonding bar (EBR)
in the nacelle (M12, 71Nm)
■ Apply copper grease to the contact surface
Note: The generator should already be connected to the EBR.
■ Place the 3 ground cables individually between the bundles of 3 of the power
cables in the cableways
■ Route the cables through the holes in the machine frame and the platform under
the nacelle
Caution: The 3 ground cables must be routed downwards through the front hole
in the platform.
9.4.2 Loop
■ Fit M12 cable lugs to the 3 ground cables of the loop
Caution: Next to the loop roll there are 3 threaded bushings. The surface must
be bare metal
■ Remove paint and contamination from the surface of the threaded bushings
9.4.3 Tower
■ Check that at each tower flange the transitions are bridged with 4 short ground
cables.
9.4.4 Foundation
The bottom platform in the tower base contains an EBR at the tower wall. The
following ground cables must already be attached to it:
● 3 ground cables from the bottom box
● Ground cable from the tower wall
● Foundation ground electrode to the tower wall
Mechanical design
The busbar system for the mains connection is a triple T bars.
The cable inlet in the bottom box consists of a 4-part plate system. The clearances
of different widths are sealed by profile terminals. Cable inlet plates and profile
terminals are pre-installed.
Page 166 of 170 Turbine Class K08 Line-side cable connection in the bottom box
Erection Instructions K0801_014863_EN_R00_Erection_K08
The power cables at the busbar systems are connected using brace terminals for
ring conductor terminal (Cu/AL, up to 300mm²).
11
6
10
1 2 3 4 9
Line-side cable connection in the bottom box Turbine Class K08 Page 167 of 170
K0801_014863_EN_R00_Erection_K08 Erection Instructions
1. Cable clip
2. Cable inlet plates
3. Profile terminal
Assembly
■ Prior to starting work ensure that the power cable and bus system are
disconnected
■ Remove the 3 front cable inlet plates
Note: Start with the rearmost bus system
■ Pull cable from below into the cabinet
Note: All cable connection systems are uniquely marked by labeling the triple T
bars; e.g. L1, L2, L3, PE
■ Tighten the connection terminals:
- Tightening torque 30Nm: ProfiClips (Wöhner)
- Tightening torque 45Nm: Flach-Direkta (Rittal)
Page 168 of 170 Turbine Class K08 Line-side cable connection in the bottom box
Erection Instructions K0801_014863_EN_R00_Erection_K08
■ Attach the power cables to the cable stop bars using the existing aluminum cable
clips
- Aluminum cable clips: Ø 30–34mm, M6, 0.8Nm
Caution: The use of cable ties is not permitted here.
■ Install the next cable inlet plate
NOTE
The plastic elements for sealing the cable inlet plates must be straight
Do not move the plastic elements during installation. No clearances must be
present.
Always use the specified connection terminals and cable clips.
■ Route the ground cable also between the cable inlet plates
■ Install the next cable systems in the same manner
NOTE
Use the existing cable brackets. Attach all cables using cable ties.
Delivery condition
The cables for control and auxiliary Power system are already pre-installed or rolled
up with the loop in the top tower segment.
The supply cable to the Diesel generator is connected to the bottom box during
commissioning.
The optic fibre cable is delivered separately to the site.
The control cables in the tower base for the converter cooling, temperature
measurement, tower fan and signal exchange to the medium voltage switchgear
(only if transformer is in the tower) are provided by Nordex.
Installing the control cables Turbine Class K08 Page 169 of 170
K0801_014863_EN_R00_Erection_K08 Erection Instructions
10.2 Preservation
There are 3 preservation options:
● Preservation using paint
● Preservation using wax
● Preservation using metallic coating
NOTICE
INCORRECT PRESERVATION
Only use special preservatives:
• supplied varnish in the appropriate RAL colors
• special spray wax
• alkali zinc silicate coating
• zinc spray
NOTE
Only use zinc spray if the diameter of the damaged spot in the coating is
<15mm.
Derust and degrease the spots to be sprayed prior to preservation.
Apply several layers of zinc spray.
NOTE
The pitch bearing is only lubricated during commissioning.
■ Hand the first 4 pages of the completed Erection Report to the project manager
immediately after erection
■ Hand the completed Erection Report to the project manager after completed
erection
Prerequisites
● Rotor idles
● Rotor is not locked
Note: The rotor must only be locked in exceptional cases (e.g. if work is not yet
completed).