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1. Printout from Extranet amp CD will not be Updated Automatically as WNReeasecone 8 References This manual has been prepared on the basis of and refers to a number of other NEG Micon documents and supplier documentation The named documents are to be regarded as background information for this manual NMCS Document 4002134 Tightening Torques NMCS Controller manual for NEG Micon PRVS turbines NMCS Controller manual NM80 amp NM92 AVN K09 Yaw hydraulics manual AVN B16 Brake hydraulics manual Svendborg Brakes Manual Winergy Manual Loher Operating Instructions Manual Generator LM 388P Installation and maintenance manual for 38 8 rotor blades LM 448P Installation and maintenance manual for 44 8 rotor blades QI 09 374 GB Bolt Assembly Instruction for Rotor Nacetle and Tower QI 19 011 GB Settings for TAC 84 Vibration Guard QI 19 022 GB Settings for TAC 85 Over speed Guard QR Standard I amp S Tools and Lifting Equipment QI 09 031 Paint repair Painting specification repair of paint work e e e e6 es 8 8 6 amp Appendix Appendix Installation amp service data Appendix Weights Dimensions amp Transport Guidelines NMCS Parameter List NMCS Stop and Reset Functions Appendix Parameter list Appendix Electrical diagrams Side 99 of 90
2. UNacatecow Do not remain in or near the tower and be prepared for blade parts falling to the ground due to lightning strike Once the storm has blown over wait at least one hour before approaching the tower again If there is still a crackling sound from the wet blades i e they are still electrically charged do not approach or touch the plant If the tower is struck by lightning and has suffered visible damage cut off the power supply to the plant and contact the Service Department for further inspection However a lightning strike will usually always cause the automatic cut out to trip with damage only to the MTA block 2 16 4 in case of unusual noise patterns It is always important for the turbine owner or operations manager to become familiar with the turbine s noise patterns Often an unusual noise pattern will reveal that an abnormal or faulty situation has arisen or is developing If inexplicable or unusual noises occur during ordinary operation contact the Service Department Halt the plant if it is felt that continued operation with an unrecognised noise could develop into something dangerous or cause further repair costs 2 16 5 Locking the yaw system The yaw system can be locked in place mechanically by interrupting the automatic cut out on the control panel and locking the cabinet The above procedure is necessary when servicing the yaw system or for other service work where yawing is not per
3. S TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 35 0190 Frimout from Extranet amp CD wil nof be Updated Automatically Sey Ne noor 4 1 5 Replacing brake lining 4 1 5 1 Replace pads 1 Remove the upper pad location stop the one on the same side as the bleeding screw from each half caliper by removing the M16 screw 2 Carefully push in the pistons by using a lever between the pad and the brake disk resting on the atter 3 Remove the lower pad location stop from each half caliper by unscrewing the M16 screw Remove the worn pads and their shims The shims are not reusable 5 Replace the lower pad location stop without shim and tighten the M16 screw Torque tightening acc Installation amp Service Data 6 Put the new pads in place 4 4 5 2 Determination of shim thickness Measuring the distance between the upper face of the body Measuring the recess in the pad location stop and the upper face of the pad 3 5 2 1 Body 2 Lining 3 Piston TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 36 of 98 Printout from Exiranst amp CD wil net he Updated Automatically rey CBG Move Final mounting 1 Pad locating stop 4 Piston 2 Shim E mm Thick 5 Lining 3 Body On each half caliper Referring to the
4. TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 1 27 01 2003 Editor PKR Approval KHG Side 82 of 90 Printout from Extranet amp CD wil not be Updated Automatically Oy MICO Placement of the adjustment screws Adjustment of the cam discs ea ee Of THOS 0828 Adjustment of the front cam disc untwist CW 1 Front cam disc untwist CW yaw clock wise The disc is gt Adjustment of the middle cam disc adjusted so the edge of the cam is 30 mm to the left of the centerline of the switch a Center bolt for cam discs Adjustment of the rear cam disc untwist CCW important 6 2 1 7 Tes gt Middle cam disc zero position The disc is adjusted so that it actuates the switch Rearcam disc untwist CCW yaw counter clock wise The disc is adjusted so the edge of the cam is 30 mm to the right of the centerline of the switch e All three cam discs seen from the front Remember to tighten the center bolt for the cam dises after adjustment ing the rewind box 6 2 17 1 1 Test of yawing clock wise CW 3 TI th A Y T 6 TI he nace e midd awing i e nace le is yawed counter clock wise CCW until the untwist CW switch is between the cam on le cam disc zero position and the cam on the front cam dise CW s manually stopped e untiwst switch is manually actuated A screwdriver can be useful for th
5. a Ngo acon Technician measuring and noting the horizontal movement on the adjustment tool 4 7 1 2 Alignment of generator without rotor The following figures show how to align the generator without the rotor mounted The process is as described above Alignment of generator without rotor side view TA Set TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 63 of 90 CN raare Alignment of generator without rotor top view easnsieinse 47 2 Lip seal e Check the lip seal on the shaft end and adjust so that the lip lies against the cover e If necessary lubricate the lip with bearing grease 4 7 3 Cleaning the generator e Ifthe cooling surfaces or ventilator on the generator are covered with dirt or other matter they must be cleaned 4 7 4 Lubricating generator bearings e Generator bearings are lubricated with grease through the lubrication nipple in accordance with Installation amp Service Data The generator must rotate during lubrication 47 5 Generator bolts 47 5 4 Screw bolt joint generator cross member e Retighten the bolts in accordance with service plan Torque tension in accordance with Installation amp Service Data o Replace defective or corroded bolts and nuts with new 4 7 5 2 Screw bolt joint cross memberfrubber damper e Retighten the bolts in accordance with service plan Torque
6. 6 The electrician carrying out this task must have adequate personal protection equipment PPE including but not limited to rubber gloves rubber mats and insulated footwear 7 Electricians must use insulated electrical tools 2 11 High temperatures High temperature work includes all processes involving welding burning or grinding in plant containing inflammable material SAFETY EQUIPMENT use safety footwear head protection eye protection long sleeved upper garments and long trousers as a minimum 1 Inform the supervisor that work involving risk of fire is being undertaken in order to allow co ordination with other work on site 2 Take all precautions against fire such as clearing up flammable materials as far as possible or setting up screens around ignitable material Fire blankets must be used during work involving risk of fire 3 It must be ensured that a fire extinguisher is available near the work area 2 12 Excavation Excavation may only be carried out by trained personnel 2 The supervisor must be informed ahead of any kind of excavation to allow co ordination with other nearby work 3 Drawings of the area must be studied to reveal the existence and location of cables piping etc in the earth 4 The local authorities must approve the excavation in cases where public authorities may have laid cables piping etc 5 A work permit must also be obtained if excavation is to be carried out near underg
7. Near Shore Windpark Wbr Wm vergunningaanvraag NSW Bijlage VI Onderhoudsplan Bijlage Ill Service amp Maintenance Manual NM80 amp NM92 Near Shore Windpark Wbr Wm vergunningaanvraag NSW Bijlage VI Onderhoudsplan Bijlage Ill Service amp Maintenance Manual NM80 amp NM92 Document opgemaakt ten behoeve van Wbr Wm vergunningaanvraag Near Shore Windpark Opgemaakt door Aangeboden aan NoordzeeWind consortium Ministerie van Verkeer en Waterstaat Directoraat Generaal Rijkswaterstaat Bestaande uit Directie Noordzee Koopmansstraat 1 Shell Wind Energy BV 2288 BC RIJSWIJK NV NUON Duurzame Energie Postbus 5807 2280 HV RIJSWIJK Rev Datum Status 0 18 03 03 Concept voor commentaar t 16 06 03 Definitief voor vergunningaanvraag Service amp Maintenance Manual NM80 2750 amp NM92 2750 TIC 725 002 GB 2003 NEG Micon A S Printout from Extranet amp CD will not be Updated Automatically Preface anc revision status This service manual has been prepared for use by trained NEG Micon service personnel or special external personnel accredited by NEG Micon The manual describes the procedures for service the wind turbine s components functions and safety systems It shows when and how maintenance adjustments and reporting of service work are to be carried out The manual has a detailed table of contents Chapters and 2 are an introduction including general safety
8. Side Date 27 01 2003 Editor PKR Approval KHG 68 of 99 Printout from Exirane amp CD wil not be Updated Automatically TT Nec acon 4 9 2 2 Screw bolt joint enclosure rubber dampers Retig speci 4 9 2 3 o Retig speci 4 9 2 4 Retig ten the bolts in accordance with service plan Tighten bolts in accordance with torque fications in Installation amp Service Data Screw bolt joint rubber damper base frame ten the bolts in accordance with service plan Tighten bolts in accordance with torque fications in Installation amp Service Data Met mast bolt joint Tripod for wind sensor ten bolts in accordance with the service plan amp check list One of two bolt joints for the met mast boom TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM Date 27 0 wae 1 2003 Editor PKR Approval KHG 69 of 90 Printout from Extranet amp OD will not be Updated Automatically EN ecancove 5 Service instructions Rotor REFERENCES Appendix Installation amp Service Data SAFETY EQUIPMENT Safety helmet safety shoes and fall protection TOOLS Binoculars camera 5 1 Blades 5 1 1 Fibre glass part The blades are inspected with binoculars from the ground If anything critical is observed the inspection is extended to a lift inspection of the blades Inspection from lift is only performed by critical e C
9. The chain in the right side of the generator viewed from behind has to be one link longer than the one in the left side The handle and cylinder is placed on top of the generator The special line up tool is installed Hydraulic lever cylinder and handle SSO NC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 te 27 01 2003 Editor PER Approval KHG Printout from Extranet amp CO will not be Updated Automatically Rec secon Working cylinder The bolts that hold the rubber dampers are loosened in each side of the generator Bolt loosened must be loosened in both sides Bolt loosened must be loosened in both sides Then the generator is lifted at the relevant end and the adjuster washer turned TIC 7257002 GB Service amp Maintenance Manual NM80 amp NM92 Date 27 01 2003 Editor PKR Approval KHG Printout rom Extranet amp CD will not be Undated Automatically ENG MICOR The generator is lifted The adjuster washer is turned One measurement pin is attached on the part of the coupling that is fixed to the generator The other part is mounted on the brake disc Do not attach to the shaft between the brake The generator is lowered again and two measurements is executed right underneath the high speed shaft and right above the shaft Measuring pin mounted on the brake disc Measure taken underneath TIC 725 002 GB Service a
10. coolant temperautre PC Coolant may be diluted with a glycol water mixture in accordance with Installation amp Service Data 4 8 3 Water pump seals fittings e Check the water pump for leaks and direction of circulation If leaks are found the pump must be repaired or replaced e All fittings must be treated with anti corrosive apply if necessary Take particular care with external fittings 4 8 4 Coolant check Check anti freeze properties with a spectrometer see Installation amp Service Data for acceptance values e Check the anti corrosive properties of the coolant by measurement of pH value using litmus paper etc See Installation amp Service Data for acceptance value e Ifthe concentration or pH value is inadequate top up with anti freeze or demineralized water until the concentration is correct Change the coolant every three years IMPORTANT When changing the coolant old coolant must be disposed of in a responsible way Do not dispose of the old coolant on site and do not pour it down the drain TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 67 of 90 Printout from Extranet amp CD will not be Updated Automatically nn ran Necrose 2 48 5 Replacing components in cooling circuit 48 5 1 Replacing the water pump Close the shut off valves on both sides of the water pump and drain the contents o
11. 3 Bolt M18 x 2 5 x 50 3410000 2 D 10 Spring pack BSFH 340 X 210 EE 3597300 4 l 5 Gasketkit BSFH monospring 300 2787500 4 i 5 Nut M24 3597500 2 0 10 Mechanical bra ee Electr Motor 4AP7 1 4 B5 400 690 2920900 Pump for NEK 1500 hy unit K 0 25 D 48TR 17300 703 Oil Filter SFP 1 2 F A L00 2927600 20 5 t Press Transmitter MBS33060G1756 3167700 i 0 15 G502 1 1 0 1 NO solenoid Valve 13302 206 2 0 10 HJ4 0788 Reliefvalve 2913200 2 0 10 Check valve VUH14 OD440300090 t 2934700 2 0 10 asten Brake En 5 4 oe je a Set of pads US 2 5 3479300 6 l 3 Pad locating stop 3601800 8 2 10 Pad holding screw EIM16 3601900 16 4 10 Lock washer of screw 11 51 3602000 16 4 10 O ring 3602200 8 2 10 Anti extrusion ring 3602300 8 2 0 Cap seal 3602400 8 2 10 Electr Motor 4AP7 1 4 B5 400 690 2920900 2 0 10 Gear pump HLDP G 0505 D 3599100 2 0 10 EPE Filter 250F 0P10F NVOP 313400 10 2 2 Pressure Valve VM15 V3 889 04 A 2704 100 2 0 10 Check Valve OD 44 02 00 09 01 19300 176 2 0 10 Relief Valve VM 15 2705300 2 0 to Press Transmitter MBS33060G1756 3167700 2 0 10 Magnetic valve van CE 17301 700 2 0 10 a Ges ee Gasket ring 120x150x12 L NBR Tun 3630100 I Gasket ring 40x62x10 LN NBR input 3630200 1 Generator 7 as 5 5 He Ze Retubrication DE 3525600 5 Retubrication NDE 3525600 5 Brush 3525900 5 Earthing brush 3526000 5 1 TIC 725 002 GB Service amp Maintenance Manual NM80 amp Side Date 27 01 2003 Editor PKR Approval KHG 89 of 90
12. 5224 Blade Bearing Greasing System Remove empty and refit the grease collector bottles After a year all bottles should be at least full Grease collection bottle TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 73 of 90 Prinioul from Extranet amp CO wil net be Updated Automatically o B E NEGMIEON e Refill the grease pump using Molykote Long Term 2 Plus LT2 Plus grease The grease should be pumped into the grease nipple at the bottom of the grease pump reservoir The reservoir should be filled up until the plunger is level with the top of the Lincoln Label 300mm from screw on base of reservoir Using the TAC 2 manually operate the grease pump e Check that the grease pump operates by listening in the hub Check along the route of the grease lines for leaks Tighten fittings where necessary TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92_ Side Date 27 01 2003 Editor PKR Approval KHG 14 of 90 Neg secon 6 Service instructions Electrical parts REFERENCES Appendix Installation amp Service Data diagrams in Control system documentation SAFETY EQUIPMENT Helmet and protective footwear TOOLS Approved electrically protected hand tools appropriate for the task SAFETY PRECAUTIONS Render the wind turbine voltage free with the maximum cut
13. Expansion tank 8 Temperature sensor PT100 3 Test nipple 6 Manometer 9 Hand pump 10 Safety valve 4 8 1 Working with the system The system is always under pressure so care needs to be taken when removing hoses and fittings Relieve the pressure by draining the expansion tank approx 3 litres will flow out Check the fluid level by reading the pressure on the water pump manometer Coolant can be sampled from the drain cock on the water pump 4 8 2 Water pump seals Check the water cooler and hoses for leaks Repair or replace if leaks are found Checking the water level e Read the pressure on the water pump manometer The pressure must conform to the coolant level diagram e Ifthe pressure is too high lower the pressure by draining off coolant o Ifthe pressure is too low raise the pressure with pressure test kit TP 50 Power TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 66 of 90 Printout from Extranet amp CD will not be Updated Automatically Neg aircon NOTE if the pressure is too low test the cooling system for leaks If there are no leaks the expansion tank may be defective and must be inspected replaced Ghecking coolant levels Coolant pressure 2 8 EE en en Nen a2 F 2 g i i Bra peee a ee ee ee ae Ed a 18 44 bn 5 Bs 12 5 5 4 pe 30 20 40 0 10 20 30 40 50 89 70
14. braking mechanism by pulling on the line The unit must exert resistance e Visual check of bag and line 2 17 5 Check of first aid equipment Check that the contents are correct irst aid equipment in front ot nacelle 2 17 8 Check of fire extinguishers Check that the manometer on the fire extinguisher shows the correct pressure TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 25 of 90 En KN aircowe e Visual check of handle and split pin for damage Fire extinguisher in nacelle to the right of panel EWG TIC 725 002 GB rvice amp Maintenance Manual NM80 amp NM92 Date 27 01 2003 Editor PKR Approval KHG Side 26 of 99 Weneasgeowe 3 Service instructions Tower REFERENCES Appendix Installation amp Service Data Weight Dimension amp Transport Guide SAFETY EQUIPMENT Safety helmet safety shoes fall arrest harness 3 1 Foundation Check the concrete surface for cracks at the transition between the concrete and the embedded section If any cracks are present in the sealing they must be repaired with a flexible tar product ex Icopal Broisolation no 2 Sealing of the embedded section 1 Embedded section 2 Shelling 3 Sealing 3 2 Construction 3 2 1 Bolts IMPORTANT To avoid damage on t
15. for changing the oil from the oil supplier s 8 8 Stop valve for draining gearoil 444 5 Oil pump seals Check the oil pump for direction of circulation and leakage e Ifhoses or pump leak they must be repaired or replaced 4445 Heat exchanger e Check the heat exchanger and hoses for leakage e Inthe case of leaks retighten or replace Heat exchanger Side 30 of 90 2 ENE aoe 4 5 Disc brake system REFERENCES Appendix Installation amp Service Data SAFETY EQUIPMENT Safety helmet safety shoes and fall protection 4 5 1 Brake disc Check the thickness of the brake disk in accordance with Installation amp Service Data The contact surfaces must be smooth and free of cracks when visually inspected Check the brake disk for throw out with a gauge The maximum value is given in the Installation amp Service Data 4 5 2 Brake calliper and brake blocks e e Check the clearance between both brake linings and the brake disks Ifthe total gap between the blocks and the brake disks is more than 2 mm adjustment must be carried out Check the brake calipers for distortion wear and cracks 4521 Adjusting the gap between brake blocks and brake disc wear adjustent e Activate the hydraulic station so that the brake blocks are completely raised Remove the orange cover 40 and instead mount a M24 flange nut on the protruding centre bolt tightenin
16. rotational direction of pump 4 Press Enter again for Manual start stop shaft brake pump System shall go off gt Shaft brake valve 1 ON and pump stopping disregarding pressure 7 Replaceable wear parts This section comprises a list of replaceable wear parts and their expected lifetime Editor PKR Approval KHG 88 of 96 Service amp Maintenance Manual NM80 amp NM92 7 Side 3492100 Sealing ring front 35300 004 Lightning conductor with brush 1404000 Sliprise on ae Brushes for slipring Lubrication syste Filter FMPO6S LA TON 3222900 Fooling system a o Filter unit oif 2600 R 010 BNBHC V B4 KESO 3530100 Circulating pump water 3591900 Mechanical indicator 3510900 6 t 3 Sinter brake pad 15301 035 6 i 3 Positioning System Svendborg BrakesSystem F MS 300 1 set in bag 2610200 2 0 10 Pad retraction springs 3597200 6 1
17. the alignment is outside the tolerance of 1 mm with respect to the centering of the generator shaft alignment must be checked with alignment equipment e This must be done with the coupling removed Poor alignment may be due to a change of characteristics in the rubber dampers in the gear mounting coupling and generator mounting Generator rubber damper 4 7 1 4 Alignment of generator with rotor The following figures show how to align the the generator with the rotor mounted Alignment of generator with mounted rotor side view TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 PKR Approval KHG 57 of 90 Printout from Exranel amp CD wil not be Updated Automatically No micose Alignment of generator with mounted rotor top view Vertical alignment The procedure for vertical alignment of the generator is the same if it is adjusting the front end or the rear end of the generator It is impossible to predict the extent of what has to be adjusted This becomes obvious during the alignment process It is often only the front end that has to be adjusted vertically but it could become necessary to adjust both the front end and the rear end vertically and horizontally The alignment process starts with the mounting of the special hydraulic lever tool It is mounted on the crane and the hooks are attached to the front of the generator
18. the crane 3 Before lifting with crane forklift or other mechanical equipment ensure that the lifting equipment e g crane forklift straps lifting frames is certified The lifting equipment must be marked with its maximum lifting capacity The responsibility for certification and marking of lifting equipment rests with the supplier of the equipment 4 Machine operators must have a valid and approved licence for operating cranes and forklifts 5 Rigging may only be carried out by a qualified person It is this person s responsibility to determine he weight of the object and to select a suitable lift for it 6 Carry out a visual inspection of the lifting equipment prior to use Never use defective equipment Label defective equipment DO NOT USE 7 Plan the lift and make sure all involved personnel understand the plan 8 Arrange barriers to ensure that no one walk under a lifted object TIC 725 002 GB Service amp Maintenance Manual NMS Side Date 27 01 2003 Editor PKR 16 of 90 AMICON 9 Establish and maintain good communication between all involved Use standard crane signals 10 Persons outside hearing range must use standard crane signals to control the lift 11 Persons who cannot see each other e g a crane driver and a fitter in the nacelle must control the lift by radio or telephone 12 Lifting and control of main components tower sections nacelle and rotor may only be c
19. the front end of the nacelle 6 2 7 Cables wiring e Check cables and wiring for damage such as cracks and faulty insulation e Check that wiring is correctly mounted TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 78 of 99 Printout from Extranet amp CD will noi be Updated Automatically 6 2 8 RPM sensors Rotor e Check that the distance between the sensor and the scanning points is correct Sensor for rotor rpm Sensor for rotor rpm 6 2 9 RPM sensor Generator e Check that the distance between the sensor and the scanning points is correct e Check the fixings of sensor sensor fittings and scanning plate Sensor for generator rpm 6 2 10 Pressure switchiplug e For the pressure switches and transmitters heck the switch and plug for verdigris and rust In the case Side 79 of 90 TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 01 2003 Editor PKR Approval KHG Brintoul from Extranet amp CO will nol be Updated Automatically A iNegaecons of verdigris or rust clean or replace Pressure transmitter shaft disc brake Pressure transmitter yaw brake hydraulics 6 2 11 Slip rings e The slip rings are checked for dust by removing the cover Clean carefully for dust if necessary Beware the high voltage Ifthe blade hydrau
20. turbine is to be completed for each service visit TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 10 of 90 PN Kreator 2 Safety and safety equipment 2 1 General A wind turbine is a plant containing rotating mechanical parts with a potential for causing dangerous situations Certain basic safety rules must therefore be followed when visiting a wind turbine and in general the plant must be treated with respect Never inspect the plant or ascend the ladder unaccompanied For safety reasons there must always be two persons present during any kind of work in the plant All persons present must be aware of the location of the others Before moving to another area of the plant remember to inform the others of your intentions and make sure they all understand and confirm your message before you move into place NOTE This chapter contains general safety guidelines for working on the turbine The necessary detail with regard to safety methods instructions is given in the relevant chapters 2 2 Site access and general site rules Personnel may not work on the site unless they have taken the necessary safety training courses 2 There must always be two persons on site apart from visits to the control room or in special cases where a single person is responsible for supervising a wind farm provided that this person informs the supervisor or ot
21. 0 4 Let the stream flow until it is clear and free of air 5 Re tighten the bleeding screw and remove the the hose 6 If necessary refill with oil 44 7 Brake flange ring Check that grease from the yaw system is not escaping to the brake flange If it is clean the flange Brake flange 41 8 Automatic lubrication of the yaw bearing The WTG is be equipped with an automatic lubrication system for greasing the the yaw bearing The unit is re filled according to Service Plan amp Checklist and Installation amp Service Data Automatic lubrication system mounted next to the Grease manifold and grease feed line to lubrication hydraulic station for the yaw brakes point on the machine base frame over the yaw bearing Yj For service and maintenance instructions for the automatic lubrication system please refer to section Automatic lubrication of Main Bearing TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR 38 of 90 Printout from Extranet amp CD will not be Updated Automatically R amp S Nee more 44 9 Lubrication of yaw ring internal gearing The toothed rim and the yaw gear pinions are lubricated manually with grease according to Service Plan amp Checklist and Installation amp Service Data 4 1 10 Lubrication and oil level in yaw gear a Normally it is unnec
22. 003 _ 004 ld TIC 725002 GB Date 27 01 2003 Side 2 of D EN Grano Table of contents Preface and revision status aad Table of contents 3 General Information m T 1 The wind turbine and associated manuals 7 2 Liability and guarantee es scssecuseceesnenseessssaseneesecsnesscssceseesncssscsuessecsesseessaesneesesenseveesevaneses 7 3 Service scope and performance 13 L General nennen 1 3 2 The service life plan A Replacement of parts cecscccecssesscssesstessecscececsssessssessecenessesavecvessessuessecsussuecseceeessessseeseesseaneaneeneess 0 5 Project specitic data drawings parts lists Cf0 0 sesessesessessesseseesessesssesecsesecsveseesesssssssceneeseescaneesens 10 6 _ Service reports 1d 2 Safety and safety equipment 14 2 1 General nnen eeens eernenseeneenrnenservenenneneneeneneneansven aa 2 2 Site access and general site rules 22 1 Access to wind turbine area 2 2 2 Vehicles 2 2 3 Special vehicles 2 2 4 Visitors public access and safety 2 3 _ Safety equipment and personal protection nva onneenerenennvenvenn enn enscenven ennen ran eanaansensendsensenenn 3 24 _ Prevention of fires vene ennenneenvennennaaneeneensenennsansensennsensensennsersensennenndsakenssenvardeeveen 25 _ Working at heights 2 5 1 Hook up points 25 2 Working in the tower 2 53 Working in the nacelle 2 6 Manual handling and lifting of objects eesee
23. 5 4 1 Hydraulic oil e Check the oil level When the station is pressure free brake on the tank must be at least half full Check the tank lid dipstick Oil must appear on the dipstick 4 54 2 Sealing of hydraulic system All gaskets and screwed joints should be checked visually for leakage Leaking joints must be retightened and gaskets replaced 4543 General when checking hydraulic system All measured pressures before and after any adjustment must be noted in the report e Before starting service the rotor must be secured with the rotor lock e When draining or filling oil and when replacing the components everything must be kept as clean as possible 45 44 Overflow valve e Start the pump and increase the pressure until the overflow valve opens manometer shows constant pressure Read off the pressure The pump will stop when the time limit is reached e Check that the pressure does not fall when the pump stops A fall will occur immediately after the pump has stopped but pressure must stabilise quickly 4545 Accumulator Once the station is pressure free start the pump The pressure will then quickly rise to the pre load pressure of the accumulator after which it will rise more slowly Read off the pressure at which the change occurs Ifthe pressure is outside of the tolerance range the accumulator must be replaced 4546 Replacing the filter suction strainer e Operating problems with the statio
24. Approval KHG 8 of 90 Pontout from Extranet amp CD will not be Updated Automatically Nec arco 1 3 2 The service life plan As a helping tool the service plan amp check list includes a graphic service life plan see example below Year Code addon DEES TEC 725 002 GB Date 27 01 2003 Editor PKR S CNecatcons 1 4 Replacement of parts The service life of all main components is at least 20 years Main components are defined as tower blades hub main shaft gear and generator However this does not mean that defects and errors may not arise as durability is dependent on preventive maintenance and inspection 1 5 Project specific data drawings parts lists etc This manual is valid for the specific turbine type All illustrations in the manual are location or principle sketches Al components are designated by their usual name If detailed information is required about serial number item code parts lists with associated drawings for a particular project or turbine number should be consulted 1 6 Service reports e Service is performed in accordance with the service plan checklist e Major deviations are to be reported on a non conformity report e A Service Report must be drawn up showing materials consumed and spare parts employed for each service visit The Service Report forms the basis of the customer invoice e The logbook located in the
25. GM s Service Department The wind turbine should be kept clean and tidy on safety grounds This will also make it easier to detect any leakage During the period that the turbine is covered by NEGM s guarantee or service contract service and other work on the plant may only be undertaken by NEGM s service engineers or carried out by persons working under NEGM s instructions and liability If the turbine owner carries out work on the plant himself without express consent or instruction from NEGM s Service Department or has the work done by non authorised persons for whom NEGM can have no responsibility NEGM s guarantee and liability for service work shall be immediately void In this context the word work includes all dismounting mounting of components set up changes in the turbine computer and lubrication and bolt tensioning to main components rotor yaw system and tower Ordinary operation in accordance with the operating manual visual inspection cleaning etc does not fall within this definition of work Date 27 01 2003 Editor PKR Approval KHG 7 0f90 TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side 1 3 Service scope and performance 1 3 1 General The service procedures consist of a careful check of components and the testing of the wind turbine s operation and safety systems Service is carried out in accordance with this Service Manual and the as
26. ST 6 2 Incase of runaway operation 63 Thunders In case of unusual noise patterns 6 5 Locking the yaw system 6 6 Locking the rotor 6 7 Instructions for use of safety equipment NNNNNND x EN Service instructions Safety Equipment 24 2 17 1 Check of fall protection equipment 24 2 17 2 Check of signs and instructions 24 2 17 3 Check of other safety components 24 2 17 4 Check of lowering equipment 25 2 47 5 Check of first aid equipment 25 2 17 6 Check of fire extinguishers Service instructions Tower Foundation nneneenenenenreneneevers ververs venversenenevenneneeenveneneennevencanvuaveenenvvansevenvensverdenevenseveneenvnene 27 Construction 32 1 Bolts 3 2 2 Welds and flanges 32 3 Surface treatment and lubrication Fitting out equipment 3 3 1 Platforms 3 3 2 Ladders 3 3 3 Electrical cabinets cables lighting Tower dampers Service instructions Nacelle Yaw bearing 4 1 2 Yaw gear 4 13 Yaw brake 35 414 Brake lining 35 4 1 5 Replacing brake lining 36 4 1 6 Bleeding the caliper 37 4 1 7 Brake flange ring 38 4 1 8 Automatic lubrication of the yaw bearing 38 4 1 9 Lubrication of yaw ring internal gearing 39 4 1 10 Lubrication and oil level in yaw gear 4 1 11 Bolts in the yaw system Yaw brake hydraulics nennen eeevere vene vennenenenveneveneneveneenenenserenenendensnvenenenvervensenrenve
27. The container at the base of the right hand column from the ladder has a label to the right of its four holes giving the following information e The date the containers were filled The type of liquid in the containers e The volume of liquid in liters The level of liquid measured from the base of the container during standstill The containers are numbered from the bottom of the right hand column up followed by the bottom of the left hand column up During service e Check the containers for any sign of leakage Especially from the holes at the side of the containers facing the crane Measure the liquid level from the base of the containers upwards when the wind turbine is at a standstill The measured liquid level should agree with the data on the label on the lower right hand container Tolerance 5 mm The liquid level can be seen through the white polyethylene wall A torch may be helpful If one or more containers are leaking Mop as well as possible Check if the leak can be stopped by turning the plug If not empty the leaking containers by removing the screw plug and drilling out the polyethylene in the bottom hole at the side facing the ladder Ensure a facility for capturing the liquid is by hand To allow air to enter the container the screw plug above the liquid level may be removed and the polyethylene in the 4 hole bored out When no more liquid can be removed screw the plugs in again It is impossi
28. al handling and lifting of objects Manual handling must only be used when there is no alternative If manual handling is necessary the following guidelines must be adhered to L 3 4 6 7 If the weight is too heavy cumbersome or difficult to hold or too unstable for one person to manage use two persons to lift and carry it possible push or pull the object rather than lifting it It must be ensured that the object can be pushed or pulled in controlled manner Wear safety footwear If possible wear gloves to protect the hands from sharp edges splinters etc t is important to ensure good access to the object to enable it to be lifted correctly Also make sure that there are no obstacles in the route over which the object is to be transported If possible the object must be lifted and carried at between shoulder and hip height If the object is to be lifted from a position under hip height bend the knees rather than the back when ifting Place the feet a shoulder s width apart with the toes forward Keep your back straight and ook up while lifting The object must be carried as close to the body as possible Avoid twisting the body when lifting and carrying the object 2 7 Rules for mechanical hoists and crane work 1 If possible always use mechanical aids for lifting 2 Use the service crane for lifting tools and equipment into the nacelle The rotor must be braked before using
29. arried out by competent trained personnel 13 No persons other than those involved in the lift may enter the lifting area TIC 725 002 GB Date 27 01 2003 Editor PKR Side 17 of 90 Printout from Extranet amp CD will nol be Updated Auiomatically NEG atrcawe 2 7 1 Crane signals International recognised crane signals 1 HOIST Lift one hand and move it in circles horizontally 4 QUICK EMERGENCY STOP Lift both hands and face the palm of the hands to the crane operator The sign can be showed by anyone facing the crane operator 2 LOWER Lift one hand and move it up and downwards 5 STOP Lift one hand and face the palm towards the crane operator Keep the hand still 3 DIRECTION Show the hand stretched out and move it back and forth in the wanted direction Also use the sign for jib position and reach 2 8 Rules for two man teams There must normally be at least two persons for each task In special circumstances independent work can be permitted see safety procedures for independent work 1 Make sure than all tasks are planned for at least two persons and that the two persons are not isolated from each other during the work e g out of sight or hearing range Tf for any reasons one of the team needs a break the work must be interrupted 3 Under no circumstances may a person halt the work or leave the area without informing the other The other person must take on an i
30. b report any abrasion or damage e Ensure all cabling is properly secured replace any tye wraps or P clips that have broken or are missing 6 3 2 2 Visual Inspection of Connectors e Visually inspect the condition of the following connectors and make sure that they are secure a All connectors on the hub control box b All connectors on the Axis boxes on each blade c Connectors on the motor of each blade Report any defective components and repair 6 3 2 3 Visual Inspection of Hub Panels e Inspect the hub axis and control panels check for loose components moisture ingress loose internal cabling or any other damage Push all socket mounted componets to ensure the are firmly in their sockets e Report any defective components and repair TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 85 of 90 BG MOOR 6 3 2 4 Pitch motor brushes Check the pitch motor brushes every 3 years and replace 6 3 2 5 Battery Checks The battery sys below 80 of t follows Turn off battery charger by opening fuse 1F4 in the hub control box L 2 Turn on the 3 Check the v The voltage should nominal Record results for each blade 6 3 2 6 Lighting Checks battery isolator for the blade to be tested 2Q1 oltage between terminals on contactor 3K 1 1 and 3K 1 5 using a DVM em is a self checking system and w
31. ble to remove all the liquid Information including date wind turbine number and amount of containers from which liquid has been removed must be reported TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 31 of 90 SNecaticon 4 Service instructions Nacelle 4 1 Yaw system REFERENCES Appendix Installation amp Service Data SAFETY EQUIPMENT Safety helmet and safety shoes Yaw system 7 T 7 uN 4 internal gearing yaw ring 5 Seal 8 Bolt for tower top flange yaw system 2 Brake block 6 Yaw bearing 9 Tower 3 Brake caliper 7 Top flange with yaw 4 Bolt for yaw ring nacelle fing 4 4 1 Yaw bearing 4141 Seals e Visually check seals for cracks and wear If seals are damaged they must be replaced e Clean seals and seal surfaces 41 1 2 Yaw ring e Check the teeth visually for wear and cracks Mark and report damaged teeth and assess whether the turbine can continue operations with more frequent inspection intervals Service amp Maintenance Manual NM80 amp NM92 Side Editor PKR Approval KHG 32 of 90 WNEoMicone Yaw ring teeth 4 1 2 Yaw gear 41 2 1 Seals a Check the gear visually for leaks e fjoints are leaking retighten the bolts e Check the gasket at the exit shaft e ifthe gasket is leaking report this and decide if it
32. ces described in this manual are special equipment andard NEGM consignment NOTE Some of the following safety equipment is extra equipment individually designed for the requirements of customers and local authorities and therefore not included in the standard NEG consignment NOTE There may be special official requirements for safety equipment which require specially trained fitters inspectors 2 17 1 Gheck of fall protection equipment Visual check of fall protection rail wire on ladder for damage e Check that slides lock onto the rail or wire and are lubricated with oil If the slide does not lock it must be replaced e Check of runners snap hook and shock absorbers for rust cracks deformation and function Check of a fall protection harnesses for wear and function 2 17 2 Check of signs and instructions e Visual check of signs and instructions Damaged or lacking signs must be replaced ae 2 17 3 Check of other safety components e Check fixing points eye bolts handrails and screens for rust cracks fixing and of TEC 725 002 GB her visible damage Service amp Maintenance Manual NMB80 amp NM92 Side Date 27 01 2003 Editor PKR 24 of 96 Printout from Extranet amp CD will not he Updated Automatically DOOR 2 17 4 Check of lowering equipment e Check lowering unit for rust dirt and damage e Test of the unit s
33. clothing on or near heaters Do not allow accumulations of flammable material or waste Use fire blankets when carrying out work with a risk of fire and follow the appropriate safety precautions Be familiar with the location and use of fire extinguishers on the site Learn the emergency procedures in the case of fire TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side T Approval KHG 13 of 90 Date 27 01 2003 Editor PKR Printout from Extranet amp CD will nef be Updated Automatically SG MICON 2 5 Working at heights 2 5 1 Hook up points Yellow eye brackets on top of cooler enclosure Yellow eye bracket on nacelle roof Service amp Maintenance Manual NM80 amp NM92 Side Editor PKR Approval KHG 14 of 90 Printout from Branst amp CD wil sot be Updated Automatically GARCON Yellow eye bracket close to roof hatch Four yellow eye brackets on tower wail in the top of each Yellow eye brackets inside hub tower section 2 5 2 Working in the tower 1 When in the tower you must wear safety footwear and a safety helmet 2 The safety harness must be fixed to the safety rail or cable when ascending or descending 3 Before ascending check that the safety rail and harness are complete If any form of fault is discovered ascent must be postponed until the dama
34. de We draw your attention to the fact that the instructions on the labels are followed e Ifthere are scratches etc these have to be repaired e Ifitis necessary to repair damages on the surface of the blades please follow the instructions given in the enclosed Guidance to Repair of Fibreglass reinforced Polyester Since a wind turbine blade is a heavy dynamic loaded construction it is important to inspect the blades regularly in order to repair any damage before it reaches a critical stage TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 71 of 90 Pentout from Burana amp CD wil nal be Updaied Automatically amp SNEG MOON 5 1 5 Repair Instructions for glass fibre reinforced polyester Sanding of damaged area e The damaged area is sanded sandpaper with grain size 80 120 until the surface is completely clean The area is then washed with acetone in order to remove the slip and to ensure complete dryness Building up of damaged area Ifthe damaged area has a depth exceeding approx 1 mm it is necessary to build up the area with fibre glass reinforced polyester until the built up area is approx 0 5 0 8 mm lower than the surrounding surface If a fibreglass mat with a weight of 450 g m2 is used each fibre glass laminate will have a thickness of approx mm When the fibre glass laminate has hardened gelcoat is u
35. ease thoroughly ors is ing e Apply two droplets of adhesive to receptor thread Loctite 243 Install the receptor in the thread and tighten it by means of a special tool Use the two small holes in the surface of the receptor e Fill the groove between the receptor and the blade as well as the two small holes in the surface with a sealer Groove and holes are filled from bottom to top to avoid air holes under the surface Remove excess sealer if any 51 4 General Maintenance After some time of use it is inevitable that a border will be shaped on the front edge of the consisting of insects and dirt This border might have a negative influence on the effect of the blades and if it is requested that it i removed the following instruction can be recommended blade S The blades are cleaned with Yacht Cleanser which is a highly content rated cleansing agent without grinding mediums based on water that can be thinned with water e Hereafter Yacht Polish which is a wax fluid with grinding mediums is used This polish cleans and polishes in 1 one working operation For extreme difficult spots and rooted dirt Yacht Rubbing can be used To obtain the best possible result of this treatment it is recommended to finish off with Yacht Wax which is a wax fluid without grinding mediums This wax protects and preserves the blade You may be contempt with only giving Yacht Wax on the front edge of the bla
36. ed in emergency repairs must be disposed of responsibly off site 8 A speed limit of 25 km h applies to all types of vehicle on site 2 2 3 Special vehicles Drivers of special vehicles such as extra wide or high vehicles may only drive onto the site with the prior agreement of the supervisor who will advise as to the preferred route and possible site risks The supervisor will also arrange for auxiliary vehicles if necessary 2 2 4 Visitors public access and safety All persons present at a wind turbine or on the work site without a work task to perform are defined as visitors This includes persons employed to work at a different locality making a temporary visit to the site in question A person present for the purpose of carrying out work to the wind turbine or associated equipment is defined as an employee however short the duration of the work This person will be registered as a site employee will receive introductory training and work under the normal rules for employees All visitors to the site and all suppliers must report to the supervisor on arrival Visits may be made only with the supervisor s permission A competent person must always accompany the visitor Visitors must wear strong enclosed shoes suitable for muddy and stony areas and must be suitably dressed They will be assigned personal protection equipment which they must wear TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Da
37. ension in accordance with Installation amp Service Data Replace defective or corroded bolts with new 4 5 3 3 Brake hub clamping element e Retighten the bolts in accordance with service plan Torque tension in accordance with Installation amp Service Data 45 34 Brakelbracket e Retighten the bolts in accordance with service plan Torque tension in accordance with Installation amp Service Data Replace defective or corroded bolts with new TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 _ Editor PKR T Approval KHG 52 of 90 Printout om Extrans amp LO wil nol be Updated Automatically MG MECON 45 4 Brake hydraulics Brake hydraulics TiCG0126 014 7 Acummulators 5 Oil tank 9 Pressure transmitter 2 Motor 6 Test connector 10 Test connector 3 Air filter 7 Valve 11 Solenoid valves 4 Pump 8 Pressure reduction valve Diagram of brake hydraulics 8 m Precharge 12 bar 7 197bar accumulator 4 Gear pump 7 Tank 10 Throttle 2 Cheek valve 5 Electrical motor 8 Pressure transmitter 3 Relief valve 6 Suction strainer 9 Solenoid valve TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 ditor PKR Approval KHG 53 of 99 Printout trom Extranet amp CD will nat be Updated Automatically e Eige muco 4
38. ent PPE as a minimum wear safety helmet and safety footwear when accessing the wind turbine 1 In cold weather there is a risk of ice falling from the wind turbine blades This is especially so when starting up after a period of low temperatures and low wind speeds Do not approach a wind turbine if there is any risk of ice on the blades 2 Fix the open tower door to the hinge to avoid being caught behind a slamming door 3 Do not approach or remain in a wind turbine during an electric storm or if such storm is imminent 4 Do not approach a wind turbine for the first hour after an electric storm has passed over due to the risk of static electricity on the blades 2 2 2 Vehicles 1 All motor vehicles must contain a suitable fire extinguisher 2 Up to date first aid equipment must be available in works vehicles and on work sites Specially appointed personnel must have taken a suitable first aid course with regular refresher courses 3 Vehicles must only use approved access roads to the site Vehicles must not drive outside the site boundary 5 Machine operators must not fill machines from a diesel drum instead they must use a diesel tanker and drip tray 6 All types of spillage of fuel oit on the site must be immediately reported to the supervisor to allow prompt remedial action to be taken 7 Maintenance except in emergency situations and oil changes to plant and vehicles are not permitted on site All worn parts or oil us
39. ent cover on gearbox 4443 Pinion Remove the gearbox inspection hatch to allow visual inspection of gearwheels Gearbox inspection hatch z TIC 725 002GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 46 of 9D Printout from Extranet amp CD will nol be Updated Automatically Ry Nac ancowe Check that the contact surfaces are free of pitting and that the teeth engage over their whole width Any signs of incipient wear must be reported indicating wind turbine no gearbox no operating hours and a description of the non conformity and its extent A colour photo of the damage may be included NEG Micon s Service Department will then in co operation with the gear manufacturer assess the extent of the damage and initiate any necessary action o Make sure the lid is fitted correctly so that the vent cap is above the low speed step Faulty fitting will lead to oil being forced out of the cap Make sure the gearbox and lid fit closely 4 4 2 Gear mounting e The rubber element of the gear mounting should be checked visually for cracks and signs of perishing and replaced if necessary The coupling and generator must then be realigned Rubber element of gear mounting _ yy I i 44 3 Gearbox bolts 44 3 1 Bolts in the taper bushing Retighten the bolts in the taper bushing between the main shaft and gearbox i
40. ependent worker must agree to contact each other at set intervals If the individual worker does not contact the base person at the agreed time the tast named must set in motion the agreed emergency procedure and then start to search for the person 2 19 Rules for electrical work 2 10 1 General It is only permitted for fitters employed by NEG Micon or NEG Micon s electrical supplier to carry out inspection testing and repair of electrical installations and equipment There must always be two persons present when working on live equipment 120V and above 2 10 2 High voltage In this manual high voltage is defined as 1000 V and above in accordance with international standards 1 There must always be two persons present when working on high voltage equipment Before work begins the electrical equipment must be by a qualified person 3 The circuit being worked on must be declared dead by the use of authorised equipment before work begins The testing equipment must be tested before and after the circuit has been declared dead If it is necessary to test a circuit in live state the testing equipment must be contact voltage proof 5 The contact voltage proof testing equipment must be earthed The switch controlling the testing equipment must be locked if possible and the key kept by the person leading the work 7 There must be a warning notice on the insulation 8 All instructions regarding the high voltage system
41. essary to lubricate the yaw gear of whatever type as the pinion step worm gear and planet step are lifetime lubricated Drainage hole in yaw motor Oil filler neck and air relief on yaw motor The cogwheel step in the yaw gear has been lubricated with grease compound in accordance with the lubricant list and need only be checked if the gear has lost grease Ifthe gear has lost lubricant or grease due to leakage or repair it must be refilled lubricated in accordance with the lubricant list 4 1 11 Bolts in the yaw system 4 41 41 41 Bolt joint yaw bearing ring base frame Retighten the bolts in accordance with the service plan Torque tension in accordance with Appendix Installation amp Service Data e Loose bolts must be reported Loose or defective bolts must be replaced 4 1 11 2 Bolt joint yaw gear base frame e Retighten the bolts in accordance with the service plan Torque tension in accordance with nstallation amp Service Data e Replace defective or corroded bolts TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 39 of 90 2 Qe Bicot 4 4 41 3 Bolt joint brake calliper base frame e Retighten screw bolt joint brake caliper base frame in accordance with the service plan e Torque tension in accordance with Installation amp Service Data 4 1 11 4 Bolt joint hydraulic u
42. et angle nacelle sensor to 0 8 2 21 Wind sensors Check that the wind sensors are clean and without damages 6 2 22 Test of control panels e Check all manual functions on the operating panels in the tower and nacelle e Check that the filters are clean e Check that no parts are loose Check the cable insulation for cracks or signs of high temperature Chrono 2 6 3 Electrical parts and sensors in Hub 8 3 1 Limit Switches 8 3 1 1 Visual Check of Condition Visually check the condition of the limit switches fastners and brackets Record any defects and repair 6 3 1 2 Functional test 1 Using the TAC test facility drive the pitch to the FINE limit switch 2 The TAC will record the pitch angle at which the switch is operated 3 The batteries will then return the pitch to the FEATHER pitch position and operate the first feather limit switch 4 Record the Pitch angle for each blade at which the FINE limit switch operates 5 Record the Pitch angle for each blade at which the FEATHER limit switch operates NOTE FEATHER limits are staggered at pitch angles of 95 90 and 85 degrees on blades 1 2 and 3 respectively 6 3 2 Electrical Systems Warning The supply to the hub panels must be isolated including the battery supply using the isolator on each axis box and the hub supply isolator in the nacelle 6 3 2 1 Visual Inspection of Cabling e Inspect the condition of all cables in the hu
43. f the expansion ank approx 3 litres will flow out e The pump can now be replaced NOTE New gaskets must always be mounted along with the new pump 48 52 Check replacement of expansion tank e Check the expansion tank by draining the expansion tank of coolant approx 3 litres will flow out ext check the gas pressure with a manometer connected to the valve at the top of the tank The gas pressure must be approx 1 5 bar 9 Ifthe pressure is lower top up until the pressure is 1 5 bar o Wait two minutes and then check the pressure Ifthe pressure has dropped the tank is useless and must be replaced Finally adjust the pressure of the coolant in accordance with the diagram on fig Checking coolant levels using pressure test kit TP 50 Power 4 9 Base frame and enclosure 4 9 1 Welds and corrosion protection Welds do not require regular inspection but defects should be reported and repaired in accordance with the specification for the welding seam in question e Visual inspection of corrosion protection Remove rust with a brush or grind and paint in accordance with painting specification 4 9 2 Bolts 43 2 1 Screw bolt joint cast welded part e Retighten the bolts in accordance with service plan Tighten bolts in accordance with torque specifications in Installation amp Service Data Bolt joint cast welded part TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92
44. g it by hand Release hydraulic pressure from the brake Using a hook spanner adjust the large coupling until the clearance between disk and blocks is a total of 1 0 mm Measure with a feeler blade at the centre of the blocks Apply hydraulic pressure to the brake Remove the M24 flange nut and mount the orange cover G40 Deactivate the hydraulic station lowering the brake Service amp Maintenance Manual NM80 amp NM92 Side Editor PKR Approval KHG 51 of 90 a Neg Mico 4 5 2 2 Check of brake lining e fthere is less than 4 mm of lining on each brake block these must be replaced For replacement use blocks of type MIBA MD 550 Temperature sensors in the brake linings are of type 180 C 4 5 2 3 Replacing brake blocks Adjust the large coupling right back as described above e Remove the wiring to the temperature sensor e Mount the new blocks remember to turn the curved edge towards the calliper e Mount the temperature sensor wires Adjust the brake until the total gap is 1 0 mm See above 45 3 Disk brake bolts 45 31 Brake hub brake disk e Retighten the bolts in accordance with service plan Torque tension in accordance with Installation amp Service Data Replace defective or corroded bolts with new e After tightening apply corrosion protection to bolt heads and fit caps 453 2 Brake bracket gearbox e Retighten the bolts in accordance with service plan Torque t
45. ge has been remedied 4 When ascending and descending small tools and other small loose parts must be kept in a bag or box fastened to your body e g to the safety harness Loose parts must not be carried in pockets Heavy parts must be transported with the nacelle crane and not taken up manually 5 Once the hatch between the nacelle and the tower has been closed and secured it is permitted to disconnect the safety line if there is sufficient screening before the enclosure is mounted TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 15 of 90 Negaticons 2 5 3 Working in the nacelle 1 2 The sky lights must not be opened at wind speeds over 20 m s If there is a risk of a person falling from the nacelle the long strap on the safety line must be fixed to yellow hook up points in the nacelle If necessary several belts can be joined to secure access to a work position far from the fixing point When working outside on top of the nacelle or on the hub all tools must be securely fixed to either the safety belt or to one of the yellow hook up points The mechanical brake is engaged when it is necessary to stop the rotor rotating A sign in the nacelle indicates the escape route in the case of fire in the tower In the case of fire in the tower the escape route is by hoist through the bottom hatch in the bracket section 2 6 Manu
46. han 10 minutes after the wind turbine has come to a complete standstill If the wind turbine is stationary on arrival this must be noted on the label of the sample bottle Oil sump temperature must be higher than 40 C at the time of sampling Verify the temperature with the control system The temperature must be noted on the label on the sample bottle The relevant procedure will depend on the individual lubrication system The following procedures have been defined and the procedure used must be noted on the label of the sample bottle It is very important that residues which have accumulated at the sampling site are removed before the actual sample is taken Clean the drain cock externally with a clean cloth Start the pump Empty at least 0 5 L from the drain cock into a suitable container Now fill the sample bottle Pour the oif from the sample bottle into the waste bucket in order to flush the sample bottle Refill the sample bottle and screw on the cap tightly Attach the label to the sampling bottle Check the oil level in the gearbox and top up if required Send the waste oil already collected for destruction ANNE The label pasted on the bottle must contain the following information Information label Tetbine type Opeasiion time H a NEGMICON Sample ny NE Dountry 4 tacks Projest turbine name SA Produced snaar Tebal SEG SSG Mic
47. he paint work the tightening tool must be kept free of contact with the tower wall when tightening the bolts in the flange joints of the tower sections Date 27 01 2003 Editor PKR Approval KHG 27 of 90 Frimout from Extranet amp 2D wil nel be Updated Antomaticaly TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 ie ER Eramo The tightening tool must be kept free of contact with the tower wail e Retighten the tower bolts between sections in accordance with service plan Torque tightness in accordance with Installation amp Service Data Retighten the tower bolts between the top section and the nacelle yaw system in accordance with service plan Torque tightness in accordance with Installation amp Service Data o Ifthe bottom section is bolted to the embedded section retighten bolts Torque tightness in accordance with Installation amp Service Data Damaged bolts and nuts must be replaced in accordance with specification Tower section bolt flange joint Nacelle tower bolt joint Date 27 01 2003 Editor PKR Approval KHG 28 of 90 Printout from Extranet amp CD will not be Updated Automatically Te KIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side CE AAECONS 3 2 2 Welds and flanges e Visual 0 year inspection of doorframe and welds between doorframe and tower shell Visual inspect
48. heck leading edge for cracks pinholes and scratches and repair e Check trailing edge for cracks and scratches and repair e Check surfaces for scratches and pinholes and scratches and repair NOTE If any additional parts such as vortex generators stall strips etc are mounted on the blades check for missing parts and proper mounting 1 2 Hub connection e Check corrosion on all metallized parts only at the root end of the blade and repair e Check corrosion marks on the sealing for the flange and embedded bearings If any marks repair sealing Sealing has to be water proof TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 70 of 90 ey E NBG MEON 5 1 3 Lightning conducting system When lightning receptors are struck by lightning they are exposed to very high temperatures which are capable of evaporating some of the material from the lightning receptor Lightning receptors are therefore shaped and mounted in a way that makes replacement possible Replacement of lightning recep performed as follows e Remove the old receptor from the tip by means of a special tool Use the two smali holes in the surface of the receptor if they are intact Alternatively the old receptor must be removed by dril e Remove the old sealer from the hole for the receptor and degrease thoroughly Grind the new receptor to a mat finish on the sides and degr
49. her responsible person at NEG Micon before and after carrying out the work 3 Suitable personal protection equipment PPE must always be employed as noted in Section 2 3 Special PPE for part tasks is specified in the procedures 4 Access to the site is prohibited in extreme weather conditions This includes but is not restricted to blizzards making access dangerous and storms with a higher risk of lightning strike 5 Smoking is strictly forbidden outside the dedicated area 6 Alcohol and other intoxicants may not be partaken of on site and persons under their influence shalt not be permitted access 7 All waste including waste created by engineers and site personnel must be placed in the rubbish bins or covered containers 8 All forms of incineration of material on site are strictly forbidden 9 The supervisor prior to starting must approve all welding and other use of flames and all necessary precautions must be taken 10 As far as possible personnel must use the toilet facilities and not the site area for calls of nature 11 Naked flames are not permitted on the site outside the marked areas 12 All personnel must inform a responsible person before leaving the site TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Editor PKR rintout from Extranet amp Cb wil nat be Updated A E ENEG micone 2 2 4 Access to wind turbine area Personal protection equipm
50. ill alarm if the DC system on any blade drops 1 nominal 216 volts DC However annually the voltage should be checked as be in the range 216 to 195 V DC Which is checking that the voltage is 90 of e Turn on the lights and check that they are all operational with no damage or defective elements e Repair as required TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Date 27 01 2003 Editor PKR Approval KHG Side 86 of 90 Printout from Extranet amp CD wil not be Updated Automatically EF WN meamor 6 4 Safety test 8 4 1 Check connections in the wire netting door in the front of the nacelle e Check connections of the switches in the door which gives access to the hub hatch in the front of the nacelle When the door is opened the emergency line has to be tripped and input on TOI 613 Hub hatch closed must go low Switch bod Switch at access door for the hub hatch 6 4 2 Check connections at hub hatch e Check connections of the hub hatch switches When hatch is opened the emergency line has to be tripped and input on TO12 608 Hub hatch closed must go low e Check the Hub hatch override switch TOI2 607 64 3 Check connections at shaft brake Test of connections is done by disconnecting 1 wire at the assembly box for each test e Check sensor for Shaft brake hot input 508 on TOI2 in control panel e Check sensor for Shaft brake wor
51. illustrations above 1 Measure the distance A between the upper face of the body and the upper face of the pad by using a depth gauge This measurement must take place at 2 different locations A and A 2 Measure the distance B on the pad locating stop by using a depth gauge This measurement must take place at 2 different locations B and B 3 The thickness E of the shim is calculated as follows B A B A E mm 2 0 04 The tolerance of E is 0 01 4 The shim of thickness E is made from the set of shims delivered with the new lining pads Measure the shim thickness E with a digital caliper 4153 Final mounting 1 Mount the upper pad locating stop with its shim of the calculated thickness Tighten the M16 screw Torque tightening according to Installation amp Service Data 2 The remaining gap J refer to illustration above is measured with a thickness gauge set A 0 03 mm tightening of the pad is allowed on one point only 4 4 8 Bleeding the caliper A flexible hose fitted at both ends with a M16x 2 union is needed for bleeding the caliper Connect one end of the flexible hose to the bleeding screw and the other end back into the reservoir of the hydraulic unit Power up the unit 3 Slowly loosen the bleeding screw and create an oil stream through the pipe _ TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 37 of 9
52. ions Check the surface of the hub for Paint quality Serious rusting Cracks NOTE Check that rotor lifting holes are greased TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 72 0f 90 Printout from Extranet amp CD wil not be Updated Automatically EN Nee MEON 52 2 Blade Bearings 5221 Visual inspection Check the inner amp outer seals all the way round each bearing There should be no sign of rusting wear of grease coming out and the seal should look uniform all the way round 5222 Grease Sampling from Blade Bearing A grease sample should be taken from each bearing as follows e Remove one grease collection container inc adapter Wipe away excess grease e Take sample min 10cc using clean syringe Put the sample in a clean airtight bottle label and send off in accordance with normal practices Grease is Molykote Long term 2 plus 2 2 3 Blade Bearing Greasing System TAC 2 Parameters During the commissioning of the turbine the greasing system is set to deliver a full reservoir of grease into the bearings in the first three months of running This was achieved by setting the pump interval parameter in the TAC 2 to turn the pump on once every 4 hours At the first service this setting must be changed to a 27 hour pump interval which will pump a reservoir of grease into the bearings over a period of one year
53. ions of structure around hole just below top flange e If cracks are found they must be reported and tested as further specified contact R amp D 3 2 3 Surface treatment and lubrication 9 Check the galvanization and paint work for damage e Remove any rust with brush or grind and paint in accordance with paint work specification e Lubricate door hinges and lock with oil 3 3 Fitting out equipment 3 3 1 Platforms Check platforms for damage e Check and if necessary retighten fixings for platform stays Platform in tower 3 3 2 Ladders e Check and if necessary retighten fixings for ladder fittings TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side l Date 27 01 2003 Editor PKR Approval KHG 29 of 90 Printout from Extranet amp CD will not he Undaied Automatically a gt Nee acon Ladder fixing 3 3 3 Electrical cabinets cables lighting See Chapter Electrical Parts 3 4 Tower dampers The tower dampers consist of a number of containers in the tower top arranged in two columns just below the top platform The containers are filled with a pre defined amount of liquid The volume of the iquid in each container and the number of containers in each tower varies from tower to tower Tower dampers on left side of the ladder Side 38 of 90 TIC 725 002 GB Date 27 01 2003 amp Neo sicone
54. is necessary to change the gasket or if the turbine can continue to operate with more frequent inspection intervals VIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 33 of 90 T Printout from Extranet amp CO will net ps Updated Automatically amp NEG Micon 4122 Yaw motor Function test Yaw motors 4123 Yaw pinions e The Teeth of the pinion that is hidden behind a cover must be checked visually for wear and cracks Yaw pinion behind cover TEC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Date 27 01 2003 Editor PKR Approval KHG Side 34 of 90 Printout trom Extranet amp CD will net be Updated Automatically NEG MICON 4 1 3 Yaw brake yaw brake calliper Yaw brake calipers finally mounted Ls 1 Lower pad location stop 5 Lining 2 Shim 6 Upper pad location stop 3 M16 screw 7 Shim 4 Pistons 8 M16 screw 9 Bleeding screw 4 1 4 Brake lining Thickness of the brake lining must be min 3 mm new 10 mm e Ifthe brake lining has come loose from the holder it must be replaced e REMEMBER to fit the yaw lock when repairing yaw brakes The mounting procedure is as follows 1 Remove motor 2 Fit lock into shaft hole i gear 3 Bolt the lock to the gear flange Yaw lock Mounted yaw lock
55. is purpose le now yaws clock wise until the zero position switch is actuated and the yawing stops 62 17 12 Test of yawing counter clock wise CCW 7 T he nacelle is yawed clock wise CW until the untwist CCW switch is between the cam on the middle cam disc zero position and the cam on the rear cam dise CCW Yawing is manually stopped 9 The untiwst switch is manually actuated A screwdriver can be useful for this purpose 10 The nacelle now yaws counter clock wise until the zero position switch is actuated and the yawing stops TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 ditor PKR Approval KHG 83 of 90 ABE Mrcows 6 2 18 Yaw sensor and nacelle position bracket Check that the distance between the inductive sensor and the scanning points is correct Check the fixings of sensor and sensor fittings Inductive sensor mounted on brake caliper and 0 Loom with wires from inductive sensor degrees bracket mounted on tower flange 1 The nacelle is yawed to align the sensor and the nacelle position bracket 2 The actual yaw angle compared to north is determined using a compass 3 The yaw angle is keyed in to Reset nacelle position in the Service menu under WTG set up 6 2 19 Yawing counter Check that the yawing counter counts the correct way when yawing is performed 6 2 20 Adjust the Res
56. ity sensors Check connections at hub hatch Check connections at shaft brake Control panel and other junction boxes Cables wiring RPM sensors Rotor RPM sensor Generator Pressure switch plug Slip rings Wind sensors Vibration sensor for TAC84 on gear box Ball vibration sensor Nacelle crane Adjustment of rewind box Testing the rewind box Yaw sensor and nacelle position bracket Yawing counter Adjust the Reset angle nacelle sensor to 0 Wind sensors Test of control panels Limit Switches Electrical Systems Check connections in the wire netting door in the front of the nacelle Check connections at hub hatch Check connections at shaft brake Test of safety and emergency line Test of shaft brake system 88 TIC 725 002 GB Service amp Maintenance Manual NM30 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 6 of 90 Printout from Extranet amp CD will not be Updated Automatically GNacarrecow 1 General Information 1 1 The wind turbine and associated manuals An NEGM wind turbine is a mechanical plant functioning as a power station and supplying electricity to the electricity grid It is vital for safety that the plant is handled correctly and in accordance with this manual Compliance with the manual s rules and instructions will ensure the plant a long service life and the minimum operating and mainte
57. l NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 44 of 99 Printout from Branst amp CD wil not be Undated Automatically 2 NEG Moon 4342 Bolt joint bearing housing base frame Retighten the bolts in accordance with service plan Torque tension in accordance with Installation amp Service Data Replace defective or corroded bolts with new 4 4 Gear box REFERENCES Appendix Installation amp Service Data SAFETY EQUIPMENT Safety helmet and safety shoes Gear box main shaft amp main bearing TIC00121 02 SZ 1 Main shaft 5 Gear stay bolt 9 Brake caliper 2 Hole through shaft 6 Vent cover 10 Gear box 3 Main bearing 7 Brake disc 11 Taper bushing 4 Bearing housing bolts 8 Slip ring TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PER Approval KEG 45 0 90 KN 2 44 1 Gearbox housing and pinion 4411 Seals 9 Check shaft seals for leakage e Report any significant oil loss and assess whether it is necessary to replace gaskets or allow the turbine to continue with increased frequency of oil level checks 4412 Venting e The vent cover in the gearbox lid must be checked and cleaned if necessary Blockage may lead to overpressure in the gearbox resulting in oil spillage V
58. lics does not work properly there may be a problem with the slip rings replace the unit and send the old part to the workshop Enclosed stip ring unit side view TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 E Editor PKR E Approval KHG 80 of 99 Printout from Extranet amp CD wil net be Undated Automatically BG MicoN 6 2 12 Wind sensors Check that the wind sensors are clean so that air can pass unhindered Check that the sensor is properly attached Wind sensor Wind sensor mounted on meteorology boom 6 2 13 Vibration sensor for TAC84 on gear box Check that the bolt joints are tight Accelerometer for TAC84 placed on gear stay TIC 725700 B Service amp Maintenance Manual NM80 amp NM92 Side Editor PKR Approval KHG 81 of 90 BG Morse 6 2 14 Ball vibration sensor Check the mechanical function of the ball vibration sensor by lowering the ball The switch should be easily moved Ball vibration sensor neven 6 2 15 Nacelle crane Activate the crane in the nacelle 6 2 16 Adjustment of rewind box Rewind box after rernoval of cover model with decoder 1 The center bolt is loosened to allow adjustment of the cam discs 2 The cam discs are adjusted with the three adjustment screws refer to the following illustrations
59. ll sockets in cabinets 6 1 6 Cables and cable mountings G Retighten bolts in cable clamps and supports for race ways in nacelle e Check cables are not damaged e g cracks or faulty insulation 8 1 7 Crane in top of tower Lower the hook and check the links closest to the crane for wear 6 Check the hook for wear and cracks 6 1 8 Lighting Check that all light fixtures are intact and working Eire 725002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 76 of 90 Racancow 6 2 Electrical parts and sensors in nacelle 6 2 1 Test of temperatures The following Pt100 sensors have to be tested It s done by applying a short circuit at the individual temperature sensors Check in Temperature menu that the value goes low The port name TOI2 xxx refer to the TOI located in tl Sensors located in the nacel e e o 66 6 68 6 06 eo ee s e s 86 oo 6 2 2 G 2 ee amp 6 2 3 TOI2 300 Genera TOI2 303 General 012 313 Genera TOI2 316 Genera TO12 400 Gear be 012 403 Gear be O12 406 Gear in TOI2 4 TOI2 740 Gear be TOI2 742 Gear be TOI2 745 Gear in e nacelle e or W1 temperature or W2 temperature TOI2 306 Generator W3 temperature OI2 310 Generator bearing front or bearing rear or slip ring box aring front 1 aring rear 1 ermediate front 6 Gear intermediate rear aring fro
60. mitted If mechanical locking is needed for major work one of the yaw motors should be dismounted and a cover plate for gear locking mounted Service equipment 2 16 6 Locking the rotor 2 16 6 1 Using the locking bolt in the brake disk lt 15m s SAFETY PRECAUTION Locking bolts in the brake disk may NOT be used at wind speeds over 15 m s At least one blade must be in breaking position See Installation amp Service Data The brake disk has two diametrically opposite holes to take a 24 mm cotter bolt for manual locking of the high speed gear shaft Insert the bolt in one of the holes and fix it with the cotter When working on the rotor rotor shaft and gearbox or when changing the brake lining the gearbox shafts must be locked with a locking bolt on the brake disk Service amp Maintenance Manual NM80 amp NM92 Side Editor PKR Approval KHG 22 of 99 Printout from Extranet amp CD will not be Updated Automatically Nera atcoe Lock bolt stored under generat 2 16 6 2 Using the rotor lock at the main bearings lt 25 m s The rotor lock is mounted in the nacelle and is ready for use The tip of the lock is conical and makes its way into one of the holes in the rotor lock disc The lock is pressed into place by means of a wrench tor Rotor lock disc MPORTANT Always check the weather forecast for the period for which the rotor is to be locked If severe wea
61. mp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 60 of 99 Printout from Extranet amp CD will nat be Updated Automatically Measure taken right above the shaft x After that the bolts are re torqued The above procedure is repeated until the measure is within the tolerance see drawing Horizontal alignment If a horizontal alignment has to be done the procedure is as folows Loosen the bolt that is holding the generator horizontally Mount the special alignment tool on the generator and on the frame on which the generator rests Bolt and holes for the special alignment too Mounting the special alignment tool TIC 725002 GB f Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 61 of 90 Brimtout from Extranet amp OD wil nol he Updated Automatically Bs AEON The bolt that holds the generator vertically is loosened A measurement is taken with the pins on each side of the generator to see how much movement is needed The adjuster screw is turned with an Allen key until the difference is within the tolerance see drawing Loosening the bolt Adjustment screw on the side of the generator A technician measures and notes the distance that the generator has been moved horizontally Service amp Maintenance Manual NM80 amp NM92 Side itor PKR Approval KHG
62. must be in writing if possible If communication is verbal the instructions must be written down and read back to the originator to make sure that they have been correctly received Signals or an agreed time interval MAY NOT BE USED for switching equipment on or off 9 The electrician carrying out this task must have adequate personal protection equipment PPE including but not limited to rubber gloves rubber mats and insulated footwear 10 Electricians must use insulated electrical tools TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PK Approval KHG 19 of 90 7 Hi not is Updated Automatically Printout from Extranet amp Neo recone 2 40 3 Low voltage In this manual low voltage is defined as less than 100V in accordance with international standards If possible equipment must be isolated before starting work If it is necessary to test a circuit in live state testing equipment must be contact voltage proof 3 Ifthe equipment is controlled by a switch this must be interrupted wherever possible and the key kept by the person leading the work 4 Ifthe equipment is controlled by fuses these must be removed and kept by the person leading the work 5 Using authorised equipment it must be established before work begins that the circuit to be worked on is dead The testing equipment must be tested before and after the circuit is declared dead
63. n input 509 on FOIZ in control panel 6 4 4 Test of safety and emergency line The emergency line is the line with all operator emergency stop buttons Breaking this will also apply the shaft brake The Safety line will cause pitch to shutdown by batteries and converter disconnected For testing of the 2 systems switch the Service key on Activate all operator emergency stops in turn Check that each stop causes an emergency stop alarm 602 Emergency stop reset line after each test They are placed at Operation panel in tower base Control panel in nacelle Switch at hatch to hub Activate all safety chain units in turn Check that each stop causes alarm 603 Safety stop reset line after each test The units are TAC 85 take module out TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Date 27 01 2003 PKR 87 of 90 iy En E Nga arco 6 4 5 Test of shaft brake system Note the output on TOI Shaft brake valve 1 is passing an inverter relay before applied to the shaft brake valve on the hydraulic unit meaning the signals are opposite by looking on the TOI output and the valve Set Service key on 2 Under Service gt Manual test press Enter at Manual start stop shaft brake pump 3 Output Shaft brake Valve 1 shall go off release and Shaft brake pump running under pressure control for start stop pump Test
64. n accordance with the bolt tension list in the Appendix Installation amp Service Data 443 2 Screw bolt joint gear stay base frame Retighten the bolts in accordance with the service plan Torque tension in accordance with Installation amp Service Data Replace defective or corroded bolts with new in accordance with specifications After tightening apply corrosion protection to bolt heads and fit caps TIC 725 002 GB Service amp Maintenance Manua Date 27 01 2003 Editor PKR Side 47 of 90 a Ng moar 44 4 Gear oil and oil cooling system REFERENCE Appendix Installation amp Service Data 4441 Oil level e Check the oil level through the sight glass when the turbine is at a standstill Ifoil level is too low refill with oil of the same grade and manufacturer as indicated in the Installation amp Service Data 44 4 2 Replacing the oil filter Oil filter Change the filter in accordance with Installation amp Service Data service plan e Change the filter if the filter alarm is given e Check that the filter type is correct NOTE Clean up any oil spills TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 48 of 90 Print fom Extranet amp GO will not be Updated Automatically Te Ne agcow 4443 Oil samples The samples must be taken no later t
65. n bearings REFERENCES Installation amp Service Data Main shaft 1 Bearing housing 5 Lubrication channel 2 Lubrication channel 6 Lightning conductor 3 Lip seal 7 Scanner bolt 4 Main shaft 8 Main bearing TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editos PKR Approval KHG 42 of 90 Printout from Extranet amp CD will not he Updated Automaticaliy VCE MICON 4 3 1 Main shaft Main shaft with gear box joint cover is removed Main shaft with main bearing housing or 4 3 1 1 Inspection of main shaft Inspect the main shaft for corrosion protection and repair any damage 43 2 Main bearing 43 2 1 Main bearing housing and lip seal e Check the bearing covers and retighten if necessary e Check the bearing housing for corrosion protection Repair damage e Check lip seal for cracks The lip seal must be adjusted so that the lip is just against the bearing cover after lubrication The distance from the bearing cover to the outer edge of the lip seal must be 20 mm TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 43 of 90 Prinioul kom Garant amp CD wil nol be Updated Automatically A CNsgangon 4 3 3 Oil lubrication system The WTG is equipped with an automatic oil lubrication system for
66. n may be due to blocked filters The problem may present as excessive pumping time suction strainer The filter should be replaced one year after erection of the turbine Further inspection replacement should be carried out only in the case of irregular operation 454 7 Suction strainer e Replace the whole station and take it back for repair at the workshop 4548 Gables and hoses e Electrical cables and hydraulic hoses should be checked for softness and mechanical damage Service amp Maintenance Manual NM80 amp NM92 Side Editor PKR Approval KHG 54 of 90 ER Qromcow 4 6 Coupling 46 1 Centaflex elements Check the rubber elements visually for cracks Report small cracks and assess whether it is necessary to replace the coupling element or whether the turbine can continue operation with more frequent inspection intervals In the case of large cracks replace the coupling element Check paintwork for damage 4 6 2 Spacing 8 The spacing between the brake disk and the generator hub must correspond to coupling length 4 mm This can only be checked when the coupling has been removed 4 6 3 Coupling bolts 4831 Screw bolt joint brake disc coupling e 4 8 3 2 Screw bolt joint coupling brake disk g e TIC 725 002 GB Retighten the bolts in accordance with service lan Torque tension in accordance with Installation amp Service Data Replace defec
67. nance costs NEGM s operating and control manual must be read carefully before operating the control system mounting the tower or maintaining the plant The safety regulations must also be read and followed scrupulously 1 2 Liability and guarantee The turbine owner has general responsibility for the operation and safety of the plant and must prevent all risks of the grid being threatened by its operation Normally the owner will co operate with NEGM s Service Department over this on the basis of a Service Contract If major renovation work or the replacement of large parts is to be carried out after the expiry of the guarantee or service period the owner must contact NEGM s Service Department It must be borne in mind that detailed knowledge of and experience with lifting equipment weights and the weight distribution of the different components is necessary to avoid accidental damage or injury to parts or persons during renovation work NEGM accepts no liability for direct damage or injury or consequential claims arising where the turbine owner himself carries out work to the plant or has it done by persons not approved by NEGM The turbine owner should inspect the plant at regular intervals to familiarise himself with normal operation and noise patterns In this way non conforming operating forms or noises will be immediately reveal problems with the wind turbine allowing the turbine owner to intervene and report the matter to NE
68. nd year If necessary change the oil See list of lubricants in appendix Installation amp Service Data 42 2 Filter e Inspect and replace if necessary indicator or otherwise according to the service plan 4 2 3 Set pressures for valves e Check the set pressures with a manometer Any deviation should be reported and repaired Side Approval KHG 4i of 90 Printout from Extranet amp CD will not ps Updated Automatically Te TIC 725 002 GB Date 27 01 2003 A WNecascone 4 2 4 Check of pressure transmitter e Check that the control display agrees with the manometer 4 2 5 Pre pressure in accumulator Check the pressure by monitoring the pressure build up With 0 bar in the accumulator start the pump The pressure can be discharged by means of the needle valve on port L1 The pressure build up will happen very rapidly until the pre charge pressure is reached Hereafter the pressure build up will happen slowly 42 6 Seals of hydraulic system e Check all gaskets and screwed joints visually for leakage Retighten leaking screw joints e Check that the hose between the brake pump and brake calipers has been mounted so as to avoids wear IMPORTANT Never repair or service the brakes without having read and understood the manual Never dismantle pressure switches accumulators or couplings as there is hydraulic pressure in each of these NOTE Remember to mount the yaw lock 4 3 Main shaft mai
69. nenennenen enen en ennen enenenenn 48 1 Working with the system 482 Water pump seals 4 8 3 Water pump seals fittings 4 8 4 Coolant check 4 8 5 Replacing components in cooling circuit Base frame and enclosure 49 1 Welds and corrosion protection 49 2 Bolts nennen 5 5 1 Fibre glass part lt 5 1 2 Hub connection 70 5 1 3 Lightning conducting system 5 1 4 General Maintenance 5 1 5 Repair Instructions for glass fibre reinforced polyester 5 2 Hub structure 5 2 1 Visual Inspections 52 2 Blade Bearings 6 Service instructions Electrical parts 6 1 _ Electrical parts in tower 6 1 1 Temperature sensors in the tower base 6 1 2 Test of humidity sensor at towerbase 6 1 3 Test of lightning detector 6 14 Main panel and operation panel 6 1 5 Other cabinets 6 1 6 TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 3 of 90 Necancons 6 1 7 6 1 8 62 Electrical parts and sensors in nacelle 6 2 1 6 2 2 6 2 3 6 2 4 6 2 5 6 2 6 6 2 7 6 2 8 aa a Kb PERLE NN DO EO AD in PWN me 6 2 2 63 Electrical parts and sensors in Hub 63 6 3 2 6 4 _ Safety tes 6 4 6 4 2 6 4 3 6 4 4 6 4 5 7 Replaceable wear parts 8 References Appendix Crane in top of tower Lighting Test of temperatures Test of pressure humid
70. nit base frame e Retighten screw bolt joint hydraulic unit base frame in accordance with the service plan e Torque tension in accordance with Installation amp Service Data 4 2 Yaw brake hydraulics Yaw brake hydraulic station Yaw brake hydraulic station 8 3 1 Accumulator 5 Filter 9 Sight glass level indicator 2 Valve 6 Outlet caliper 10 Test connector M1 amp M2 3 Pressure transmitter 7 Oil tank 11 Relief valve 4 Level indicator 8 Motor 12 Test connector M3 ice 725002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 40 of 90 Printout from Extranet amp OD wil not be Updated Automatically a GNegaticox Flow diagram yaw brake system P VAW DAKE GYEH ee eee ee g F a LON Boasiarge Baseer nd WE va Gert ee mm a spe a 4 nen eae i es ik 5 LO bar a 7 Accumulator 7 Coupling cluctch housing 13 Relief valve 2 Valve 8 Motor 14 Pressure valve 3 Test connector 9 Level indicator 15 Gear pump 4 Check valve 10 Test connector 16 Filler caps breather 5 Test connector 11 Pressure transmitter 17 Oif tank 6 EPE filter 12 Brake caliper 1 of 4 4 2 4 Hydraulic oil e Check the oil level through the sight glass on the side of the unit If oil level is too low refill with oil of the same type Take an oil sample every seco
71. nne 40 4 2 1 Hydraulic oil 422 Filter 42 3 Set pressures for valves 4 2 4 Check of pressure transmitter 42 5 Pre pressure in accumulator 4 2 6 Seals of hydraulic system Main shaft main bearings cccscssesesssseesesessecsresecsssscenssssnssesisensennssessessvesesacavesseasssessoseesassoeecsee 42 43 1 Main shaft 4 3 2 Main bearing 43 3 Oil lubrication system TIC 725002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 4 of 90 Printout from Extranet amp CD will net be Updated Automatically EN meae 44 45 4 7 4 8 4 9 4 3 4 Main shaft and main bearing bolts ensenennvorsoenenensenseneerenennensenseveensenennennsensvenssensenn 44 Gear DOK nonsense nnen vorvonreersensenreanennsansanenaneansensvensenvensvenvensensenennen eneen enneennenneeneeeneenneenennseneensenne 4 4 1 Gearbox housing and pinion 442 Gear mounting 44 3 Gearbox bolts 444 Gear oil and oil cooling system Disc brake system 4 5 1 Brake disc 4 5 2 Brake calliper and brake blocks 4 5 3 Disk brake boits 4 5 4 Brake hydraulics Coupling 4 6 1 Centaflex elements 462 Spacing 4 6 3 Coupling bolts 4 6 4 Cover Generator 41 1 Alignment of generator 4 7 2 Lip seal 47 3 Cleaning the generator 474 Lubricating generator bearings 4 7 5 Generator bolts Cooling SYStOI nnen enenerreneneene
72. nt 2 aring rear 2 ermediate front 2 TO12 747 Gear in TOI2 4 TOI2 7 POR2 7 TOI2 7 FOI2 7 5 TOI2 727 Nacelle TO12 730 Control nn Vn an Ven Ken Van Ven Pan an Van Van Van Pan Van Van ARTA A SS an ermediate rear 2 0 Main bearing temperature 0 Water temperature before cooler 2 Water temperature after cooler 5 Gear oil temperature 7 Gear oil temperature after exchanger OI2 720 Generator inlet temperature TOI2 725 Ambient temperature temperature panel temperature Test of pressure humidity sensors When checking pressure remove the cap on the transducer and check in main menu that the corresponding pressure goes low TOH 202 Humidity sensor tower base TOI2 702 Humidity sensor nacelle TOI2 102 Gear oil pressure TOL2 103 Gear oil filter pressure TO12 202 Shaft brake pressure TOI2 203 Yaw brake pressure Check connections at hub hatch Check connections of the hub hatch switches When hatch is opened the emergency line has to be tripped and input on TOI2 608 Hub hatch closed must go low Check the Hub hatch override switch TOI2 607 Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR o al KHG Printout from Extranet amp CD will not be Updated Automatically Neg Meow 6 2 4 Check connections at shaft brake Test of connections is done by disconnecting wire at the assembly box for each
73. nterventionist role For example he must regularly call to his olleague if the latter is out of sight o ta If the two persons are so far from each other as to be out of hearing range two way radios or mobile phones must be used Check that the batteries in the telephone or radio have sufficient charge at the start of work Service amp Maintenance Manual NM80 amp NM92 l Side Date 27 01 2003 Editor PKR Approval KHG 18 of 90 Prinjoul from Extranet amp CD will nal be Updated Automatically ae Wee aticone 2 9 Independent work In special cases not involving electrical work service personnel may be permitted to work independently Le without a partner If independent work is carried out the following rules must be followed Only competent personnel may work independently 2 The independent worker must always have a facility for contacting another person at the company or in the site office via mobile telephone or two way radio Check that the batteries in the telephone or radio have sufficient charge before work begins 3 The independent worker and the person at the company or site office must have agreed an emergency procedure before the worker departs for the site to carry out the task 4 The independent worker must inform the person at the company when he arrives at the site area and when work is complete and the site left 5 The person at the company site office and the ind
74. o components around the transformer is under tension we 5 Put the cover back on 6 Remove supply to Jomitek box and check that both signals TOI1 530 Lightning detector and TO11 531 Lightning detector fault goes OFF 7 Reconnect power and enter Service gt Manual test and press Enter at Manual reset lightning sensor check that output TOI1 837 Reset lightning sensor goes ON and that Jomitek box reset s by putting both outputs ON TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 75 of 90 Pramtout ron Exhanet amp CD will not be Updated Automatically TUUT TT SNaoancon 7 6 1 4 Main panel and operation panel e Open main panel door this shall trip the stator circuit breaker and the input Main panel door open shall be low TOL 506 s Retighten bolts in mounting e Retighten wire and cable connections Check warning notices are mounted e Check the cabinet for leaks and rust and dirt Repair any leaks Check plug and power cables at the inlet to the cabinet e Visual check of components for visible damage 6 1 5 Other cabinets This includes other electrical equipment such as input cabinets with main knife switch fuses and other equipment installed in the wind turbine e Retighten bolts in mounting e Check cabinets for leaks and rust and dirt Repair any leaks Repush a
75. on AIS aree Z1 lt DK 8900 Rondes s 33 rsg 87106 909 Mobilgaar 3C 1 International country code of turbine site e g DK for Denmark and D for Germany 2 Number for tracing sample in Concorde to be completed by NEG Micon Service Stock 3 Turbine or project name incl possible local no e g Syithom C1 Rerup 3 Use owner s name only if there is no project or turbine name 4 Oil sump temperature taken by the controller and comments e g 55 C sample taken at 55 C in oil sump no comments 25 C stopped sample taken at 25 C in oil sump turbine had stopped more than 10min before sample was taken TIC 725002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 49 of 99 Printout from Extranet amp CD wil not be Updated Auiomatically 4444 Changing the gear oil e Drain the oil through the base cock while still hot e Remove the top lid of the gearbox to check whether there is any sludge residue in the base Remove the magnetic plug from the bottom of the gearbox and clean Flush any sludge or impurities out of the gearbox and cooling system before filling with new oil Refill with new filtered oil through the hole in the top cover Check if there are any leaks from the gearbox where it has been opened If different oil from the recommended type is used approval must be obtained from the gearbox manufacturer together with a written procedure
76. out before work begins WARNING Note that there will still be voltage on the input terminals of the cables from the transformer and electricity grid 6 1 Electrical parts in tower 6 1 1 Temperature sensors in the tower base The following Pt100 sensors have to be tested It s done by applying a short circuit at the individual temperature sensors Check in Temperature menu that the value goes low The port name TO xxx refer to the TOT located in the tower base Sensors located at tower base e TOIL 300 Transformer W1 temperature TOI1 303 Transformer W2 temperature TOI1 306 Transformer W3 temperature TOI 310 Transformer room temperature e TOIL 313 Tower base temperature TOII 316 Main panel temperature TOI 400 Operation panel temperature 2 TOI 403 Converter ambient o TOL 406 Stator filter temperature e TOII 710 Converter grid side 1 e TOH 712 Converter grid side 2 e TOII 715 Converter generator side 1 TOH 717 Converter generator side 2 6 1 2 Test of humidity sensor at towerbase TOI1 202 Humidity sensor tower base 6 1 3 Test of lightning detector 1 Test of Jomitek lightning detector box 2 Take of the top cover of the Jomitek box and fix it preliminary with 2 screws in one end of the cover By careful so that the wires to the front do not destroyed of fall off Insert Connect battery in box 4 Warning Be careful the box contents 230V s
77. round cables 6 The area must be cordoned off to prevent access by non authorised persons 2 13 Remote control The wind turbine may be operated by remote control by the owner or by NEG Micon s Installation and Service Department This also includes a facility for starting up the wind turbine which is a possible source of injury to personnel inside or near the wind turbine 01 2003 Editor PKR Approval KHG 29 of 90 Ke 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Printout from Extranet amp CD wijl not be Updated Automatically Negagcons WARNING It is important that service personnel turn the service keys or interrupt the telephonic connection before entering the wind turbine in order to disable the remote contro function 2 14 Work permit NOTE Work permit systems typically in connection with electrical work are to be used only in countries where this is required under local regulations and legislation See further information in the project specific Health and Safety Manual 2 15 Maintenance and inspection of cranes lifting equipment safety equipment and devices It is important to ensure that all safety equipment used when installing and servicing the wind turbine is accessible and in good order The responsibility for this rests with I amp S in co operation with the crane company and any external suppliers IMPORTANT If any kind of problem with the equipment i
78. rules Chapter 3 describes the service procedures At the rear of the manual is an appendix with service data service plans checklists and extra component instructions In addition a separate folder contains a drawings appendix for the service manual together with general drawings and parts lists All sections dealing with procedures start with a list of reference documents and specific safety rules It assumed in this manual that users have already read the operating manual for the specific wind turbine and have been trained by the NEG Micon Service Department in wind turbine operation and in dealing with possible error situations The Service Manual has been prepared by the NEG Micon Development and Design Department and Service Department in consultation with NEG Micon suppliers and in compliance with the relevant requirements from the authorities NEG Micon henceforward called NEGM urges users of this manual to forward any suggestions for corrections or improvements so that these can be incorporated into the next revision Revisions of this manual are indicated on the table below This page should always be updated and replaced when the manual is revised The pages are marked either with a project name number and revision date at the base of each page or in the case of standard manuals with a R amp D TIC code at the base of each page opposite the page number Edition Date Remarks 001 06 11 2002 002 27 01 2003
79. s noted contact the supervisor immediately 2 16 Safety instructions 2 16 1 in case of fire In case of fire in the nacelle or control system the plant should be evacuated immediately and the power supply shut down at soon as possible at the maximum cutout in the wind turbine or at the transformer station The manager must be informed without delay if possible so that he can take the necessary precautions in relation to the electricity grid If possible the fire should be put out with the powder extinguisher If the fire cannot be put out the area should be cordoned off and the police fire service service department summoned 2 18 2 In case of runaway operation Runaway operation is almost impossible as it would require several circumstance to happen at once the generator would have to be disconnected or the electricity grid to have gone down only one or none of the blades tips to have turned in the case of overspeed the disk brakes to have failed and the wind speed to be very high However if runaway operation should occur the plant should be evacuated tmmediately and the surrounding area cordoned off Do not attempt to remain behind or save the plant The turbine can be replaced but human life cannot Do not approach within 500 m of a runaway plant 2 16 3 Thunderstorms During a thunderstorm there is a risk of lightning striking the tower despite the lightning protection equipment Side 21 of 90
80. sed to complete the building up process The actual process is as follows 1 Always make sure that the polyester has been accelerated cobalt naphtanate added Mixing 1 2 em with approx 5 drops of catalyst hardener does this If the consistency of the mixture remains constant after 20 30 minutes at 18 20 C the polyester cannot be used until accelerator cobalt naphtanate has been added Contact your polyester supplier 2 Never mix more than can be used within 15 minutes 3 Use 15 20 ml hardener 1 5 2 0 for each kilogram of polyester After thorough mixing t mixture is applied with a brush to the sanded area The fibre glass mat is then placed on top and worked up with a metal roller until the fibreglass is saturated This procedure is repeated until the sanded area is against level with the surrounding area see point 2 4 When the fibre glass laminate has hardened gelcoat is applied layer thickness 0 5 1 0 mm hardener 2 0 2 5 until the entire repaired area is higher than the surrounding areas 5 The repaired area is then wet sanded sandpaper grain size 300 until the repaired area is almost flushed with the surrounding area Sanding is then completed with wet sandpaper grain size 600 NOTE Always remember to use abundant water when wet sanding After the last sanding the repaired area should be polished 2 3 times with wax giving the surface a smooth and glossy finish 2 Hub structure 5 2 1 Visual Inspect
81. sociated Service Plan amp Checklist see Appendix The Service Engineer is responsible for ensuring that work is carried out in accordance with this manual and associated service documents The Area Service Manager is responsible for supervision of the work and may be contacted by the service fitters for further advice and guidance in connection with the service work A Service A Service is executed 1 to 3 months after commissioning A Service is a single event service and will be executed only once in the Service Life Time of the Wind Turbine A Service is executed 1 month according to Service Life Plan B Service B Service is executed 6 months after commissioning and repeated with one year intervals in the Service Life Time of the Wind Turbine B Service is executed 1 month according to Service Life Plan C Service C Service is executed 6 months after commissioning and repeated with one year intervals in the Service Life Time of the Wind Turbine C Service is executed 1 month according to Service Life Plan X Service Extensions In some occasions an extension to service is needed Extensions can be executed only once or repeated through out the Service Life Time of the Wind Turbine NOTE D amp E refers to old naming of service visits at this point in turbine life TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR
82. ssssessesseesnsavsessenscssesssessesssesseaneessssnsssscsscsnsaseenseseeas 6 2 7 Rules for mechanical hoists and crane work 2 7 1 Crane signals 2 8 Rules for two man teains cessescccsecssessessessesssessensecsesecsssseencaecseesesscsussessesaesneavssassueaseessetaneseeneeness 8 29 _ Independent work esccccssscsecsssossesessvescstsenssesstenseesssassassenveaceseaseasansenssasacaueseeassnsseeansassseavessansensass 9 2 10 Rules for electrical work 2 10 General 2 10 2 High voltage 2 10 3 Low voltage 2 11 Tigh temperatures 2 12 EXCAVATION OOOO 20 2 13 Remote control nn cesses esses tsseseeessesseccsesesscatsnsesassnssssessasensssauesascaressseateseesansseesessiesesasssseseenees 20 2 14 Work permit ceccecceccseccsccscssesssteovenecnvssnesnscaeeanesnecnssassssssssesesassucenensesecsansaveaseesnsanscnesapeseesesense 21 2 15 Maintenance and inspection of cranes lifting equipment safety equipment and devices 21 2 16 Safety instructions nnen eencvonneonveanenversverseensensesenannennenennensenntunavsenevvensenenneenenrvenn 21 TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 3of 0 Printout from Extranet amp CO will nol be Updated Aumatically Nac aticone 3 1 3 2 3 3 3 4 4 Yaw system 4 2 43 6 1 Incase of fire TOvEDEIUOTESTOVENEETETONODTSSODTSTONEOO NERO OEVEDTROSEOTRTETESESESENTESEDESTENETOOSESTSTESESESTESTETESTETOTE
83. te 27 01 2003 tor PKR Approval KHG 12 of 96 Printout from Extranet amp CD will not be Updated Automatically Ry Ning atcow 2 3 Safety equipment and personal protection While carrying out work on site suitable personal protection equipment PPE must be worn This includes but is not restricted to the following Safety helmet Safety footwear Ear defenders where appropriate Work gloves where appropriate Electrically insulated gloves where appropriate Clothing suited to weather conditions Safety harness and lines for climbing or work at heights Eye protection as required by the different sub tasks SAAN RYN 9 Masks for tasks involving the mechanical removal of dust or where the air contains spray particles 10 Insulation mats for electrical purposes where appropriate 11 Lowering hoists must be held in service vans and may be taken up when working in nacelles Suppliers must themselves provide all necessary safety equipment for the different tasks unless otherwise specified in the contract with the customer Protective clothing must be kept clean and functional and must be kept in defined locations 24 Prevention of fire Fire must be guarded against on the whole site including inside wind turbines offices and mess rooms Comply with the smoking ban outside the office and stores area Do not use unofficial heating lighting or cooking arrangements Do not place
84. tension in accordance with Installation amp Service Data e Replace defective or corroded bolts and nuts with new rc 725 002GB Service amp Maintenance Manual NM80 amp NM92 Side l Date 27 01 2003 Editor PKR Approval KHG 64 of 90 x NEG Aicon 4 7 5 3 Main cable connection terminal Retighten the terminals in accordance with service plan Torque tension in accordance with Installation amp Service Data Terminal boxes on generator Terminal box for stator circuit Terminal box for rotor circuit ervies amp Maintenance Manual NM80 amp NM92 Side PKR Approval KHG 65 of 90 TEC 725 002 GB Date 27 04 2003 Printout from Exirane amp CD will not be Updated Aulomatically TENG MICO 48 Cooling system REFERENCES Appendix Installation amp Service Data servicing plan component documentation SAFETY EQUIPMENT Safety helmet safety shoes and rubber gloves SAFETY Whenever handling cooler fluid rubber gloves and protective goggles must be worn Coolant must not be handled at temperatures over 40 C In the case of accident flush with plenty of clean water WARNING The system is always under pressure Be careful and always follow instructions when disassembling parts TOOLS Hand pump for cooling system Water cooling system with closed expansion tank 1 Motor 4 Expansion hose 7 Fill and drain cock 2 Pump 5
85. test e Check sensor for Shaft brake hot input 508 on TOTZ in control panel e Check sensor for Shaft brake worn input 509 on TOI2 in control panel 6 2 5 Others heck sensor Gear oil level input input 506 on TOI 2 in control panel heck sensor Gear oil filter clogged input input 613 on TOI 2 in control panel eck sensor Off line filter clogged input input 512 on TOI 2 in control panel eck sensor Drip tray level input input 625 on TOI 2 in control panel is normally OFF Open main panel door this shall trip the stator circuit breaker and the input Main pane door open shall be low TOI 1 506 naca 2 e Check rotor RPM signals with a screwdriver noting that the Puls 1 is flashing correctly on TAC85 and also measured by the TAC e Check generator RPM signals with a screwdriver noting that the Puls 1 is flashing correctly on TAC84 Puls 2 on TAC 85 Also note that the TAC measures generator RPM Count pulses per revolution both on rotor and generator Check that it matches what is typed in the computer in Configuration gt Set generator speed parameters gt Generator pulses revolution Configuration gt Set rotor speed parameters gt Rotor pulses revolution 6 2 6 Control panel and other junction boxes e Check for loose wires a Retighten wiring terminals e Check the box for dirt and signs of leakage Top box opened in
86. the main bearing and the yaw bearing Automatic lubrication system mounted next to the Lubrication point and grease feed line on the main hydraulic station for the yaw brakes bearing house EE 4 3 3 1 Inspecting the system IMPORTANT Do not use trichlorethylene perchlorethylene or similar solvents for cleaning the system NOTE Whenever work is done on the lubrication unit particular attention should be given to absolute cleanliness Dirt in the system will cause problems 4332 Oil level Oil pump and filter NOTE Functional test please see later chapter e Check the oil pump for direction of circulation and leakage e Check oil level and refill if necessary DO NOT mix oil types see Installation amp Service Data Change filter according to service plan Take oil sample according to service plan and procedure described for gear oil e Renew oil according to Installation amp Service Data amp serviceplan 4 3 3 3 Hoses and fittings e Check the hoses for leaks and fittings for tightness a 4 3 4 Main shaft and main bearing bolts 4341 Bolt joint blade hub main shaft Retighten the bolts in accordance with service plan Torque tension in accordance with Installation amp Service Data e Replace defective or corroded bolts with new in accordance with specifications After tightening apply corrosion protection to bolt heads and cover with caps TIC 725 002 GB Service amp Maintenance Manua
87. ther is predicted try to postpone the work if possible NOTE the rotor lock is designed for parking a wind turbine for a period e g while replacing a major component The rotor lock is dimensioned for 25 m s If wind speeds have been higher than this over the parking period the bolts in the rotor hub assembly and those between the bearing housing and the base rame must be closely checked for damage especially on their threads and if any damage is observed replaced before wind turbine operation recommences TIC 725 002 GB Service amp Maintenance Manual NM80 amp N Date 27 01 2003 Editor PKR Approval K Piniout from Extranet amp CD wil noi be Updated Automatically Side 23 of 99 Neo micon SAFETY PRECAUTIONS Work on mounting or dismounting the rotor lock may not be carried out at wind speeds over 10 m s TOOLS Always bring an extra power supply so that mounting can be completed in the event that the wind turbine s power supply fails 2 16 7 Instructions for use of safety equipment e Instructions for use of fa urbine e See Operating Manual for further information on safety equipment and notices ote that some of the sa and not included in the s 2 17 Service instructions Safety Equipment SAFETY EQUIPMENT He met and protective footwear and fall protection protection equipment and lowering equipment are located in the wind ety equipment and noti
88. tive or corroded bolts with new After tightening apply corrosion protection to t Retighten the bolts in accordance with service Service Data e bolt heads and provide with caps enerator hub lan Torque tension in accordance with Installation amp Replace defective or corroded bolts with new in accordance with specifications After tightening apply corrosion protection to the bolt heads an fit caps Service amp Maintenance Manual NM80 amp NM92 Side Date 27 01 2003 Editor PKR Approval KHG 55 of 90 VEG MIGON 4 6 4 Cover e Visual check of cover for damage e Check bolts on cover for tightness Cover for high speed shaft brake disc upper part brake Cover for coupling being removed disc lower part and shaft part 4 7 Generator REFERENCES Appendix Installation amp Service Data SAFETY EQUIPMENT Safety helmet and safety shoes SAFETY PRECAUTIONS No work on the generator while the turbine is in operation Generator Shaft Generator body Rubber damper Terminal box stator Terminal box rotor Sensor ND a RS WN aD Ventilation of slip ring compartment TIC 725 002 GB Service amp Maintenance Manual NM80 amp NM92 Date 27 01 2003 Editor PKR Approval KHG Printout from Extranet amp CD will not be Undated Automatically EG MICON 4 7 4 Alignment of generator e Ifthere are any signs that

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