Service Manual en - Wind

Service Manual
G2 R13
Document no: ZSM1005840 Revision no.: 16
Issued by: E W EN OEN DES DOC Confidentiality class: Restricted
Approval no.: 105375 Language: EN-US, original
Revision date: 2013-12-18 Applicable law: Country Specific
Siemens Wind Power A/S. All rights reserved.

Copyright
Disclaimer of liability and conditions of use
To the extent permitted by law, neither Siemens Wind Power A/S nor any of its affiliates in the Siemens
group (hereinafter Siemens) gives any warranty of any type, either express or implied, as a result of
the use of this document or parts thereof.
The entire risk of loss, damage or unsatisfactory performance, no matter how this would arise, including
as a result of negligence, rests with the user. In no event will Siemens be liable for damages, including
any general, special, incidental or consequential damages, arising out of the use of the document, the
inability to use the document, the use of data embodied in, or obtained from, the document or the use of
any documentation or other material accompanying the document.
This document has undergone extensive technical approval before being released. Siemens reviews
this document at regular intervals, and includes appropriate amendments in subsequent issues. While
every effort is being made to keep the information herein as accurate and up to date as possible,
Siemens gives no warranty and makes no representation as to the accuracy, reliability, timeliness or
other features of any information contained in the document or data obtained from using the document.
The intellectual property rights of this document are and remain the property of Siemens.
Siemens reserves the right to update this documentation from time to time, or to change it without prior
notice.
Trademarks
All trademarks mentioned herein are the property of their respective owners.

Contents
1 Safety instructions for the wind turbine............................................................................................................ 1-1
2 Technical description.......................................................................................................................................... 2-1
3 Inspection and maintenance program............................................................................................................... 3-1
4 Bolt tightening......................................................................................................................................................4-1
5 Lubrication and wear parts charts..................................................................................................................... 5-1
6 Controller and power installations.....................................................................................................................6-1
7 Tower.................................................................................................................................................................... 7-1
8 Nacelle.................................................................................................................................................................. 8-1
9 Yaw system.......................................................................................................................................................... 9-1
10 Transmission system...................................................................................................................................... 10-1
11 Brakes and hydraulic system in nacelle........................................................................................................11-1
12 Pitch and hydraulic system in hub.................................................................................................................12-1
13 Cooling system................................................................................................................................................ 13-1
14 Components and diagrams.............................................................................................................................14-1
15 Blades............................................................................................................................................................... 15-1

1 Safety instructions for the wind turbine

1.1 Basic health and safety rules for technicians working in Siemens Wind Turbines....................................................1-3
1.1.1 Preface and revisions....................................................................................................................................................1-3
1.1.2 Visitors and access....................................................................................................................................................... 1-4
1.1.3 Disciplinary rules...........................................................................................................................................................1-6
1.1.4 Welfare..........................................................................................................................................................................1-6
1.1.5 Environment..................................................................................................................................................................1-7
1.1.6 Fire prevention.............................................................................................................................................................. 1-8
1.1.7 Vehicles.......................................................................................................................................................................1-10
1.1.8 Communication........................................................................................................................................................... 1-12
1.1.9 Weather forecast.........................................................................................................................................................1-13
1.1.10 Thunderstorms..........................................................................................................................................................1-14
1.1.11 Extreme wind............................................................................................................................................................ 1-16
1.1.12 Wind during installation.............................................................................................................................................1-16
1.1.13 Wind during service work..........................................................................................................................................1-17
1.1.14 Wind force.................................................................................................................................................................1-18
1.1.15 Clothing when working in a turbine........................................................................................................................... 1-19
1.1.16 Working in hot weather............................................................................................................................................. 1-20
1.1.17 Working in cold weather............................................................................................................................................1-21
1.1.18 Working in the turbine............................................................................................................................................... 1-22
1.1.19 Working offshore.......................................................................................................................................................1-26
1.1.20 Working alone........................................................................................................................................................... 1-30
1.1.21 Working at height...................................................................................................................................................... 1-32
1.1.22 Excavations and confined space...............................................................................................................................1-34
1.1.23 Crane work................................................................................................................................................................1-35
1.1.24 Hot work....................................................................................................................................................................1-38
1.1.25 Electrical work...........................................................................................................................................................1-39
1.1.26 Working with chemicals.............................................................................................................................................1-42
1.1.27 Emergency and evacuation.......................................................................................................................................1-44
1.1.28 General emergency procedure................................................................................................................................. 1-47
1.1.29 Evacuation of nacelle................................................................................................................................................1-47
1.1.30 Evacuation photos.....................................................................................................................................................1-48
1.1.31 Fire in turbine............................................................................................................................................................ 1-51
1.1.32 Accident and illness.................................................................................................................................................. 1-51
1.1.33 Environmental accident.............................................................................................................................................1-52
1.1.34 Man overboard..........................................................................................................................................................1-52
1.1.35 Electrical accident..................................................................................................................................................... 1-52
1.1.36 Overspeed.................................................................................................................................................................1-53
1.1.37 Person suffering from hypothermia...........................................................................................................................1-53
1.1.38 Helicopter evacuation................................................................................................................................................1-53
1.1.39 Preparation for helicopter rescue..............................................................................................................................1-54
1.2 Turbine safety instructions.............................................................................................................................................1-55
1.2.1 Safety..........................................................................................................................................................................1-55
1.2.2 Basic safety rules when working in the turbine........................................................................................................... 1-55
1.2.3 Environmental consideration.......................................................................................................................................1-55
1.3 Mechanical safety............................................................................................................................................................1-56
1.3.1 Opening and closing the nacelle hatches................................................................................................................... 1-56
1.3.2 Hook lock on the nacelle hatch................................................................................................................................... 1-56
1.3.3 Casement stay lock.....................................................................................................................................................1-57
1.3.4 Operating handles for opening and closing nacelle hatches (Non-HILT yaw system)................................................1-58
1.3.5 Opening the nacelle hatches (Non-HILT yaw system)................................................................................................1-59
1.3.6 Closing the nacelle hatches (Non-HILT yaw system)................................................................................................. 1-59
1.3.7 Control box for opening and closing nacelle hatches (HILT yaw system)...................................................................1-59
1.3.8 Opening the nacelle hatches (HILT yaw system)........................................................................................................1-60
1.3.9 Closing the nacelle hatches (HILT yaw system)......................................................................................................... 1-60
1.3.10 Manual opening of hatches without voltage in the turbine........................................................................................ 1-60
1.3.11 Locking the rotor on the high-speed shaft.................................................................................................................1-61
1.3.12 Locking the rotor on the low-speed shaft.................................................................................................................. 1-62
1.3.13 Locking the yaw system............................................................................................................................................1-64
1.3.14 Pitch lock...................................................................................................................................................................1-65
Siemens Wind Power A/S. All rights reserved. 1-1 of 70

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1.3.15 Position of emergency stop.......................................................................................................................................1-67

1.4 Electrical safety............................................................................................................................................................... 1-69
1.4.1 Safety precautions when working with electrical installations..................................................................................... 1-69
1-2 of 70 Siemens Wind Power A/S. All rights reserved.

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1.1 Basic health and safety rules for technicians working in Siemens
Wind Turbines
1.1.1 Preface and revisions

The purpose of this set of rules is to function as a reference and supplement to existing instructions
and manuals.
The following safety rules must be followed by all Siemens personnel, subcontractors, and others
carrying out work on Siemens wind turbines and sites under Siemens's overall legal responsibility,
including work managed by Siemens and carried out under Siemens's instructions and supervision.
The "Basic health and safety rules" is a supplement to technical instructions (Assembly Manual,
Service Manual, Work Instructions, and more). The technical instructions must always be followed but
cannot overrule the "Basic health and safety rules".
Siemens urges users of the "Basic health and safety rules" to forward any suggestions for corrections
or improvements to be incorporated in the next revision. Suggestions must be forwarded to Axel
Magnusson (axel.magnusson@siemens.com), Siemens Wind Power A/S in Brande, DK.
Pictures and drawings of turbines are examples. Variations may occur in different turbine types.
This set of rules is Siemens's minimum demands for safety for Siemens employees and
subcontractors when performing tasks within the wind industry. Country-specific regulations are
addressed in the site-specific EHS plans.
Any individual performing a work task is obliged to stop the work if in doubt about the procedure or if
feeling unsafe in the work situation.

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1.1.2 Visitors and access

Unauthorized personnel are not allowed access to the Siemens turbines unless they are accompanied
by an authorized Siemens guest instructor.
Wear a safety helmet when required. Always wear a helmet when:
1. Work is in progress at more than one level, one or more persons work above you.
2. Being on sites where turbines are erected or dismantled.
3. Working with heavy objects which may swing in your direction and accidentally hit you.
4. Working on the outside of the turbine.
5. Working with or near crane operations.
Always wear Siemens supplied and approved personal protective equipment (PPE) complying with the
EHS PPE Standard and the local safety rules or equivalent.
Always wear a chin strap if there is a risk of losing the helmet, for example during high winds, climbs,
and helicopter operations.
Always wear Siemens supplied/approved safety shoes or boots appropriate for the task.
Safety harness
All persons who wish to access a Siemens wind turbine must use an approved, well adjusted, and
inspected fall-safety harness.
Always use harness when:
1. Ascending/descending towers equipped with ladders.
2. Ascending/descending towers with service lift. If one person is in the service lift, the harness
must be brought along. If two persons are in the service lift, the harness must be worn.
3. Staying in towers, on platforms, or in nacelles and there is a risk of falling over the edge (PRO
05.17).
4. Harness must be worn when ever there is a risk of a fall likely to cause injury.
The safety harness incl. accessory equipment is personal equipment, and the parts have been
individually certified.
The internal requirements for personal protective equipment (PPE) & personal fall-protection
equipment (PFPE) are described in DOC 14.34 PPE standard.
Safety equipment must be periodically inspected and certified according to local legislation or at least
every 12 months.
Evacuation equipment
In most turbines, evacuation equipment is already present in the nacelle. If the personnel have the
essential training in the use of such equipment, it is not necessary to bring extra equipment.
If the evacuation equipment is not installed permanently in the turbine, or if the accessing personnel is
unfamiliar with the use of the installed equipment, a set of approved equipment familiar to the
personnel must always be brought. The evacuation equipment must be brought to the nacelle by the
first person entering.
Emergency setup must comply with requirements in PRO 05.17 and associated documents.
Visitors
All persons present on site without a site-related work assignment are defined as visitors.
Personnel not working for, appointed by or contracted by Siemens are not allowed to work on the wind
turbines or the turbine sites.
Visits can only be made with permission from the supervisor or site manager appointed by Siemens.

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Visitors are only allowed access to WTG according to requirements as mentioned in PRO 05.17
appendices 6 and 6B.
Visitors must wear approved clothing and PPE.
A procedure for planning "Visits in turbines" sets the overall requirements for turbine visits. The
instruction for "Guided tours in wind turbines" sets the operational requirements.
Training and safety instruction
Technical training requirements are described in the SWT training level requirements.
Only personnel who have received appropriate instruction and a site introduction are allowed to work
on a Siemens turbine site.
The global basic safety training requirements for work in wind turbines are:
Onshore:
Technical safety
Manual handling
First aid
Basic harness, climb, and rescue training
Electrical awareness (L-AUS or equivalent course)
Offshore:
Requirements as for onshore turbines
Sea survival
Medical certificate
Fire awareness
GWO-recognized training validity according to PRO 05.17 appendix 2.
The validity of the training mentioned above is stated on the training certificates and must be verified
before workplace access is granted.
If a training certificate has expired and the validity date has been exceeded by more than one month,
a full basic training is required.
Exemption
Exemption from training validity requirements can only be granted according to INS 12.17 section 3.3.
Alcohol, drugs, and medication
Siemens enforce a nontolerance policy on alcohol, drugs, illegal substances, and nonprescribed
medication.
Exemption can be granted for use of prescribed medicine. This exemption must be granted by the Site
Manager.
Firearms
Firearms of any kind are not allowed at Siemens turbine sites.
If firearms are necessary to control safety, an exemption can be granted by the management following
the exemption procedure (PRO 14.36 Exemption request).
Smoking
Comply with the site-specific smoking rules and ensure that remains from smoking are properly
extinguished and placed in the designated waste containers.
Smoking is not allowed in Siemens owned or leased buildings and vehicles.

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Fire
No open fire is permitted outside the designated work areas on site.
Leaving the site

Always make sure to inform an authorized person when you leave the turbine site again.
1.1.3 Disciplinary rules

Alcohol, drugs, and smoking
Siemens reserves the right to test for alcohol, drugs, and other illegal substances.
This depends on local legal requirements.
Sanctions
If Siemens's requirements and local legislation are violated, disciplinary sanctions will be imposed
according to local HR procedures.
The line manager is responsible for managing sanctions.
1.1.4 Welfare
General
Siemens's general requirement is that welfare facilities must be aligned with EU Council Directive
92/57 EEC of 24 July 1992 or equivalent.
Water
Bottled drinking water must be available.
Toilets
In general, refer to site-specific arrangements according to site induction and EHS site-specific plan.
Personnel must have access to appropriate toilet facilities.
For work in wind turbines erected in small groups or individually placed turbines outside a pronounced
site area, workers must be shown directions to nearby public toilets and allowed to use service vans/
company cars for transportation.
Hand wash
Personnel must have facilities for cleaning and washing hands.

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1.1.5 Environment
Local conditions
Personnel must always be aware of any specific local environmental restrictions regarding the
surrounding area.
If such restrictions exist, they will be described in the site-specific EHS plan.
Historical monuments
No access for
unauthorized persons
Identified areas of specific scientific or historical interest must be roped off and marked as out of
bounds.
Waste
Flags indicate that there are different or additional country-specific rules regarding this topic.
All waste must be collected in adequate labeled bins or containers with spill containment to ensure
that contamination of soil, groundwater, surface water, or air is avoided.
Only a local approved waste management company is to dispose of the waste produced on site.
Waste must be separated in accordance to the site waste disposal plan or at least in four categories:
Combustible
Household garbage
Hazardous
Special (for example oil, batteries, aerosols, chemicals)
Burning of waste or other materials is forbidden.
Waste must be transported to the site waste storage area according to local legislation and SWP
policy. This must be done at the end of each working day.
It is prohibited to bring waste across country borders without permission.
Pollution
Any pollution of the area and waters is prohibited. See "Emergency Procedures" in case of incidents.
Spills
All spills must be collected and contained according to the specific local spill containment plan, and
reported to the supervisor/site manager to facilitate prompt remedial action.
See "Emergency Procedures/Spill".
Incidents must be reported within 24 hours. (KRIMA)

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1.1.6 Fire prevention

Housekeeping
A high standard of housekeeping is one of the major fire preventive initiatives!
Keep workplaces and other facilities clear of combustible material to the extent possible.
Use of open fire
No open fire is permitted on site outside the designated work areas.
Fire must be prevented on the whole site, including inside wind turbines, transformers, and other wind
related structures, as well as site buildings, offices, storage buildings, and rest areas.
Smoking
Comply with the site-specific smoking rules and ensure that remains from smoking are properly
extinguished and placed in the designated waste containers.
Smoking is not allowed in Siemens owned or leased buildings and vehicles.
Heating, lighting, and cooking

Do not use unauthorized heating, lighting, or cooking arrangements.
Flammable material
Do not place clothing or flammable objects/substances on or near heaters and high-powered
floodlights.
Do not allow flammable material or waste to accumulate.
Use waste type-specific, labeled, and approved containers.
Hot work
All welding, burning, and/or other operations connected with high temperatures have to be authorized
in writing by a responsible person prior to their commencement.
Upon commencement, precautions must be taken, and all necessary fire-preventive measures must
be taken.
Use fire blankets when carrying out work with fire risk, and ensure that appropriate fire extinguishing
means are within reach. See section Hot work (on page 1-38).
Vehicles
Do not park vehicles on dry grass or weeds, but only on roads, designated parking areas, and hard
stands.

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Fire extinguisher
Fire extinguishers must be suitable for the fire hazards in the area. (CO2 is recommended for the WTG,
SCADA room, storage of electrical equipment).
Be familiar with the location and use of fire extinguishers on site.
Study the specific local emergency procedures - site-specific Emergency Response Plan. See "General
Emergency/Fire".

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1.1.7 Vehicles
Approved access roads
Driving off roads is permitted only under special circumstances and when approved by management.
All traffic on site is restricted to designated access roads according to the site-specific regulations, see
"Site induction".
Speed
The speed limit on a turbine site is recommended to be 30 km/h (20 mph).
Local regulations and conditions must be observed and respected, see "Site induction".
Fueling and maintenance
Establish a designated area for fueling and maintenance.
All fuel-operated vehicles and machines must be fueled correctly using proper fuel-dispensing
equipment.
When dispensing fuel, do not leave the vehicle or machine unattended, or alter the pump handle to
pump automatically.
All fuel and/or oil spills must be cleaned up immediately and reported to the supervisor/site manager to
facilitate prompt remedial action.
Maintenance and oil changes on vehicles are only permitted on site in emergency situations.
All replaced parts or oil used in emergency repairs must be contained, labeled, and properly disposed
of.
First aid equipment
First aid kit (dressings, thermal blankets, bandage, and so on)
Appropriate first aid equipment must be available in all Siemens vehicles (owned, rented, or leased)
and refilled as used.
It is the responsibility of the site manager/line manager to ensure that this requirement is fulfilled.
Fire risk/fire extinguisher
Dry powder extinguisher (4 -6 kg)
CO2 extinguisher
Fire blanket
Do not park vehicles on dry grass or weeds, but only on roads, designated parking areas, and hard
stands.
All Siemens vehicles (owned, rented, or leased) must contain a fully charged appropriate fire
extinguisher.
It is the responsibility of the site manager/line manager to ensure that this requirement is fulfilled.
Special purpose vehicles
Drivers of special vehicles, such as extra wide or high vehicles, must only drive onto the site with the
prior agreement of the supervisor/site manager who will advise as to the preferred route and possible
site risks.

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The supervisor/site manager will also arrange for auxiliary vehicles if necessary.
Parking
Parking
Siemens endorse a reverse or drive-through parking policy.

Vehicles must always be parked in designated parking areas.
Establishing designated parking areas has to be a part of the site layout and must also be considered
at temporary sites.
Always ensure that parking a vehicle does not block emergency access/exit points!
On- and offloading
It is recommended to load and offload materials in close proximity to the turbine/place of use.
Parking must always take place at a safe distance from turbines (1/5 of tower height).
Inspection
Vehicles must be appropriately maintained and tires must be fit for purpose.
Perform and document regularly vehicle safety inspections (recommended weekly).

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1.1.8 Communication
Communication
Effective and reliable communication is vital when working in wind turbines.
Cell phone and radio

Technicians must always have means of contacting the emergency dispatch, and to make contact
according to the local Emergency Response Plan (ERP) Appendix 4 in the EHS plan.
At individually standing turbines with no Site-specific ERP, necessary means must be available to
contact the local emergency dispatch center. This may include but not be limited to:
Landline phone
Cell phone
Satellite phone
Using a three-man team to facilitate a messenger/guide function
The line manager and the operation manager hold joint responsibility for ensuring that the lines of
communication are effective in all work situations.
Following any incident: Report through line management, via KRIMA, and consider PRO 18.20.
Radio
Radios must always be available for communication between the technicians in a WTG, and from one
WTG to other turbines at the site.
At sites with a service facility, radio communication must likewise be possible from the individual
turbines to the site office (offshore: from the turbines to the service/safety vessel).
Cell phone
Cell phone will be a backup for radio but not an alternative to radio.
Minimum one cell phone must always be available in the turbine, able to contact emergency dispatch/
site office/service vessel.
IP phone
Some turbines can be equipped with IP phones.
Information will appear from the site-specific EHS plan, the site induction, and the turbine Safety Card
Booklet.
Offshore
Any vessel tasked to operate as site service/safety vessel must have a facility/equipment to contact
the shore-based operation control and the relevant local Search And Rescue (SAR) authorities by
radio.

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1.1.9 Weather forecast

Always monitor an updated weather forecast before starting any work in a WTG.
The site manager/supervisor/lead technician has to decide whether work can be carried out in a safe
manner according to the expected weather condition. The weather forecast must be an essential
element in the final planning of work in a WTG.
Access to or work in a WTG can be compromised by extreme weather conditions like:
Thunderstorms
High winds
Risk of ice/snow falling from WTG
Extreme temperatures (hot/cold)
Sun
Sea state
Weather conditions compromising access cannot be limited to the ones mentioned and must always
be considered in relation to the site-specific conditions.

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1.1.10 Thunderstorms
During thunderstorms, there is a high risk of lightning striking the wind turbine, despite the lightning
protection arrangements. No personnel is supposed to be in turbines during a thunderstorm, but at
some locations thunderstorms can develop rapidly and unexpectedly!
Cracking noises form the anemometer and the area around the weather station indicates a high level
of static electricity in the air and can indicate that a thunderstorm is close.
Leave the turbine immediately if a thunderstorm approaches. Once clear of the turbine, proceed
upwind away from the turbine until at a safe distance. Lightning strikes can potentially cause parts of
the blades to fall to the ground.
If crackling noises are heard from wet blades, the turbine is still charged with static electricity. Do not
approach or touch a wind turbine for at least 15 minutes after a thunderstorm has passed due to the
risk of static electricity on the blades/turbine.
If the turbine has been struck by lightning and visible damage can be identified, cut off the power
supply to the turbine, and contact the Siemens Wind Power Service Department for further evaluation.
A lightning strike can cause an automatic stop, potentially containing damage only to affect the
transient protection block.
Risks during thunderstorms
While working at height on the outside of the turbine, on blades, nacelle, tower, or the meteorology
station, there is a risk of a direct lightning strike or shock from residual lightning current. There is also
a risk of falling as a result of electric shock or as a result of the pressure from the lightning channel.
When inside the yaw section, nacelle or yaw bearing of the turbine, there is a risk of electric shock
from residual lightning current and consequently a risk of falling.
When on ladders in the tower, there is a risk of electric shock from residual lightning current and
consequently a risk of falling.
Standing at ground level next to the tower and on the offshore foundation, regardless of proximity or
direct contact, there is a risk of electric shock from side flashes.
On the access ladder from the offshore foundation to the boat, there is a risk of electric shock from
residual lightning current resulting in a fall.
Fragments from the blades may shoot off as a result of lightning strike which means that staying
underneath the rotor is not advisable.
In general, all platforms inside the tower are safe areas, except at the yaw section and on platforms
with electrical cabinets.
Turbines designed with wooden platforms: Max. 3 persons on a platform.
All other platforms: Max. 6 persons on a platform.
Safety procedure during thunderstorms
If work is in progress in a WTG when a thunderstorm approaches/develops (lightning can be seen, but
no thunder can be heard):
The storm is likely to be approximately 10-30 km away from the turbine. The turbine can be
abandoned as long as it is assessed that the storm is not yet close.
If work is in progress in a WTG when a thunderstorm is identified near the WTG (thunder is heard):
The storm is then likely to be close, 0-15 km away from the WTG. If sparks are observed at the
anemometers, this may be a sign of a thunderstorm approaching.

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You are not likely to have time to abandon the WTG and must quickly proceed to one of the safe
zones indicated in the Turbine Safety Booklet (the platform under the yaw section and at ground
level but not platforms with electrical cabinets). Sit or stand at the center of the platform and do
not touch the tower wall. Inform line manager of your actions.
Do not touch access ladders or lift, see the following illustration.
The storm is usually over when no evidence of thunder or lightning has been observed for 15
minutes.
(1) Safety area
(2) Leave the area
Figure 1.1.10. Safety areas in the turbine
Note: The tower safe areas according to the above illustration must be considered to be for guidance
only, based on the fact that tower configurations can vary.
All tower platforms are grounded and in general classified as safe areas. Stand as far away from
electrical cabinets as possible and never in front of these. Keep cabinet doors closed.
If possible, choose platforms without electrical cabinets. Do not touch the tower, ladder, and electrical
components.

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Thunderstorms offshore
In case of thunderstorms, the service vessel does not sail to the offshore turbines.
If in a turbine when a thunderstorm starts (lightning can be seen, but no thunder can be heard):
Call in the service vessel and abandon the WTG. Follow any instructions given by the vessel
master.
If the service boat is not available at the TP/foundation, stay at the bottom of the tower - do not
touch the tower walls.
Do not under any circumstances jump into the water.
If in the turbine when a thunderstorm is near (thunder is heard):
Follow the same procedure as onshore, retreat to the WTG safe areas. Inform the service vessel
on your actions.
1.1.11 Extreme wind

During storms, hurricanes, and extreme wind in general, access to the wind turbine and site area is
restricted and can under adverse circumstances be forbidden.
1.1.12 Wind during installation

During lifting operations, the lifting supervisor and the crane operator must jointly estimate each
sequence, and evaluate safety.
When erecting or dismantling turbines and moving other major components, such as the generator or
gearbox, by crane, the maximum wind speed limits stated in the installation manual, work instruction,
or lifting plan must be evaluated and considered to be safe for the service technician.
Turbine erection/dismantling are not to take place during high winds. Always evaluate whether there is
a risk of sudden gusts of high winds.

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1.1.13 Wind during service work
Always remember to mount the hatch locking system on hatches when they are opened.
Monitoring and assessments of wind speed is based on measurements made by the turbine
measuring systems, with the hatches closed. Use the average speed of the wind, measured over the
last 10 minutes (600 seconds), for the assessment.
Gusts of wind may influence safety. If wind gusts are assessed to be heavy enough to influence
safety, work must stop.
If the wind is rising, obtain the latest weather forecast from the central monitoring station.
Work must be restricted due to wind according to the following requirements: In worst case situations,
stop working and leave the turbine.
Wind speed limits for work on 300 - 600 kW

For small turbines, it is often necessary to have the hatches open during service work. For these turbines, the following
applies:
Up to 12 m/s (23 kn) / No restrictions

(10 min.)
Above 12 m/s (23 kn) / Do not work on the outside of the rotor
(10 min.)
Above 18 m/s (35 kn) / Do not work in the nacelle

(10 min.)
Above 24 m/s (46 kn) / The turbine stops. Stop working and leave the turbine
(10 min.)
Wind speed limits for work on 1 - 3.6 MW, including Direct Drive technology
In larger turbines, certain types troubleshooting and service work can be performed when the hatches are closed (typically
troubleshooting and service work on the electrical or hydraulic systems). For these turbines, the following applies:

(10 min.)
Above 12 m/s (23 kn) / Do not work on the outside of the nacelle and rotor.
(10 min.)
Note: SWT-2.3-93/101/108 and SWT-3.6-V2 in wind speeds between 12 and
18 m/s (mean value in 10 min.): If the HS rotor lock is engaged, the nacelles
must be yawed to 90 degrees away from the wind direction. If the HS lock
needs to be engaged, then yaw the nacelle to 90 degrees away from wind
direction before engaging HS rotor lock. When the HS rotor lock is engaged,
the wind direction must be observed continuously to ensure that the nacelle
remains positioned 90 degrees away from the wind direction (tolerance +/-30
degrees). The same procedure must be followed before engaging the turner
gear.
Above 18 m/s (35 kn) / Service work and troubleshooting in the nacelle with the hatches closed is allowed.
(10 min.)
Opening of hatches is not allowed. (Hatches can be opened in case of emergency for the purpose
of helicopter evacuation)
Turning of rotor using the turning gear and inserting of rotor locks is not allowed.
Do not work in the hub.
(10 min.)

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Wind speed limits for work on the early prototypes of SWT-2.3-113DD

(10 min.)
Above 12 m/s (23 kn) / Do not work on the outside of the nacelle and rotor
(10 min.)
Above 14 m/s (27 kn) / Service work and troubleshooting in the nacelle with the hatches closed is allowed.
(10 min.)
Opening the hatches is not allowed.
Turning of rotor and inserting of rotor locks is not allowed.
Do not work in the hub.
(10 min.)
1.1.14 Wind force

Table 1.1.14. Beaufort scale
Beaufort scale for wind speed and approximate wave height
Beaufort Description term Wind speeds Wave height (m)

number Wind Wave Knots M/s Probable Maximum
0 Calm - <1 0 - 0.2 - -
1 Light air Ripples 1-3 0.3 - 1.5 0.1 0.1
2 Light breeze Small wavelets 4-6 1.6 - 3.3 0.2 0.3
3 Gentle breeze Large wavelets 7 - 10 3.4 - 5.4 0.6 1.0
Moderate
4 Small waves 11 - 16 5.5 - 7.9 1.0 1.5
breeze
5 Fresh breeze Moderate waves 17 - 21 8.0 - 10.7 2.0 2.5
6 Strong breeze Large waves 22 - 27 10.8 - 13.8 3.0 4.0
7 Near gale Large waves 28 - 33 13.9 - 17.1 4.0 5.5
Moderately high
8 Strong gale 34 - 40 17.2 - 20.7 6.0 7.5
waves
9 Storm High waves 41 - 47 20.8 - 24.4 7.0 10.0
10 Violent storm Very high waves 48 - 55 24.5 - 28.4 9.0 12.5
Exceptionally
11 Hurricane 56 - 63 28.5 - 32.6 11.5 16.0
high waves
Exceptionally
12 Hurricane 64 - 71 32.7 - 36.9 14.0 > 16.0
high waves
Exceptionally
13 Hurricane 72 - 80 37.0 - 41.4 > 14.0 > 16.0
high waves
Exceptionally
14 Hurricane 81 - 89 41.5 - 46.1 > 14.0 > 16.0
high waves
Exceptionally
15 Hurricane 90 - 99 46.2 - 50.9 > 14.0 > 16.0
high waves
Exceptionally
16 Hurricane 100 - 109 51.0 - 56.0 > 14.0 > 16.0
high waves
Exceptionally
17 Hurricane 110 - 118 56.1 - 61.2 > 14.0 > 16.0
high waves

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1.1.15 Clothing when working in a turbine
When working at heights, the actual weather and wind conditions can be very different from those on
the ground, and the wind chill factor will typically be far greater.
Before climbing the wind turbine, make sure that personnel are wearing or bringing the right protective
clothing considering temperature, wind, and downpour.
Long-sleeved shirts are recommended, long pants, and closed safety shoes are mandatory.
Employer provides full range of approved work clothing and PPE.
Figure 1.3 Wind chill factor index

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1.1.16 Working in hot weather

Warm and humid weather can affect the body. High temperatures and humidity means that the body is
more likely to dehydrate, and suffer from low blood sugar and minerals such as salt.
Avoid drinking sodas or caffeinated drinks and ensure that you drink plenty of water. It is
recommended that you drink 250 ml/8 oz. of water every 20 minutes. Eat smaller meals with plenty of
water and avoid fatty foods.
When possible, take breaks in shade and adjust your work/rest ratio as outlined in "LSP 05.09 Hot-
Weather Procedure AM". Remember that the "hard work" (changing gearboxes and main shafts)
requires a greater rest/work ratio than "easy work" (meetings, adjustments, and measurement of
equipment).
If feeling exhausted, take longer breaks and consider stopping work. Individuals who are not
accustomed/acclimated to the heat must take extra precautions in adjusting their work to rest ratio. It
may take several days or weeks to become accustomed/acclimated to the hot environment.
Remember that wearing barrier suits (tyvek) will increase the stress on the body and extra precautions
should be taken for individuals unaccustomed/unacclimated to the heat before allowing them to use
the suits.
Do not attempt to ascend/descend a turbine if not feeling well.
See "LSP 05.09 Hot-Weather" procedures and accompanying documentation for further details.
As a guide to assessing the combined impact of heat and humidity, use the matrix (Fig 1.2.16.20),
using an instrument that can measure both. Always remember that the impact of heat and humidity is
individual. These readings are just guidelines and individuals should use their own judgment when
assessing actual risk to themselves and others when managing heat stress.
Sun
Exposure to extreme sunshine for longer periods (individually conditioned) can cause sunburns and
potentially sunstroke.
Wear long sleeves and pants to protect from extreme sunshine. Use high-factor sunscreen and protect
eyes with sunglasses. Wear a hat/helmet to protect head from the sun.
Table 1.1.16. Heat index (apparent temperature)

Relative humidity (%)
Air
temperature

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Heat index (C/F) Risk level Protective measures
Less than 33/91 Lower (caution) Basic heat safety and

planning
33/91 to 39/103 Moderate Implement precautions and

heighten awareness
39/103 to 46/115 High Additional precautions to

protect workers
Greater than 46/115 Very high to extreme Trigger even more aggressive
protective measures
1.1.17 Working in cold weather

Cold weather can affect the body causing exhaustion, frostbite, and potentially hypothermia.
Avoid getting excessively sweaty and dress in multiple-layer clothing.
Take regular breaks in sheltered and preferably heated locations. Drink warm beverage and eat
frequently. If feeling exhausted, take longer breaks and consider stop working.
Pay attention to fingers and feet potentially getting numb and to loss of ability to control extremities like
fingers and feet.
Do not attempt to ascend/descend turbines if not feeling well.
See "LSP 05.43 Cold-weather procedures".
Ice and heavy snow
During cold weather and heavy snow, there is a risk of ice or large clusters of snow falling from the
blades or the nacelle. Especially when a turbine has been stopped in a period with cold weather.
Evaluate weather conditions, and if icing risks are estimated relevant, have the turbine stopped
remotely from a safe distance (> 300 m). Use binoculars (recommended > 10x50 magnification) to
inspect the turbine for ice, standing at a safe distance (1/5 tower height). Do not approach a turbine if
there is any risk of falling snow or ice.
When a turbine has been stopped during weather conditions posing an icing risk, have the turbine
restarted remotely from a safe distance (> 300 m).
Keep the nacelle hatches closed if it is necessary to perform work in the nacelle during weather
conditions posing a risk of ice gathering on the blades.
The risk of falling ice can also be relevant around office buildings, containers, and other high
equipment like cranes, and so on.
Ice also causes slippery conditions, generating various slip hazards for both personnel and vehicles.
During such conditions, it is recommended to bring gravel and a shovel to mitigate risk.
It is the responsibility of the site management/line manager to make proper risk analysis and to
implement appropriate safety barriers ensuring safety during cold-weather periods.

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1.1.18 Working in the turbine
General operating safety requirement

A turbine can only be accessed when accompanied by a technician with a current turbine model
specific competence to control and secure the turbine. Such competence shall be:
Technical and Safety Training requirements:
In EW identified as: "Competent Technician" (Ref. PRO 12.19 & PRO 12.20-Subcontractors)
In E S SR WP identified as: "Maintenance Technician" (Ref. PRO 12.18)
Alternatively:
Task Specific Work Approved (TSWA) to control and secure the turbine according to the
performed task (Ref. PRO 09.05)
The relevant turbine type-specific technical manuals and instructions must always be accessible when
working in a turbine. Check whether the work is covered by work instructions (ZWI) and risk
assessments (RA) or if other safety documentation is relevant. Make sure that the relevant safety
documentation is available before starting the work.
Loose clothing should be avoided and clothing featuring fixed hoods and loose sleeves is prohibited in
turbines.
Always bring your harness to these work locations:
Specific platform
Yaw section
Nacelle
Hub
Inside blade
The appropriate precautions must always be considered in order to protect individuals whenever there
is a risk of sustaining a fall likely to cause injury.
Whenever a fall-arrest system is installed, it must be used as protection against potential falls.
Wooden platform towers: A number of older towers are designed with wooden platforms spaced 6 m
apart. Access between the platforms is provided via 6 m ladder runs, having no fall-arrest system
installed. Access in these WTGs must be performed in compliance with the local legislation in the area
of operation.
Two-person teams
Normally, tasks are assigned for teams of min. two persons. Working alone is only permitted in special
and very restricted circumstances. See Working alone (on page 1-30).
If team members must be isolated from one another, however briefly, they must maintain
communication to assure one another's safety, for example by two-way radio or mobile phone. If the
two persons are so far from each other that they are out of shouting range, a two-way radio or mobile
phone must be used. Always bring a fully charged battery.
If one of the team members needs a break, the work must be interrupted.

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One member of the team must under no circumstances halt the work or leave the area without
informing the other.
Disconnect the remote control
Before climbing above the power unit level, position the turbine remote control switch at the tower
ground level in the "LOCAL CONTROL" system.
If the turbine is connected to a central monitoring system (for example SCADA), the operator must be
informed that the turbine is stopped.
The computer is not a fail-safe computer and disconnecting the remote control does not mean that
the turbine is safe to work on.
Disconnect, de-energize, and lock all energized systems worked on according to the de-energizing,
log out, tag out process described inElectrical work (on page 1-39)
Ascending the tower
Take into appropriate consideration the weather and the weather forecast. See Weather forecast (on
page 1-13)
Switch on the light in the tower.
Hearing protection must be worn when stopping (and starting) turbines with converters.
Stop the turbine and set it to "Local operation" before ascending it. If necessary, for example during
troubleshooting, the turbine can be operated via the hand terminal in the nacelle.
Listen and look for irregularities and check the status on the display before stopping the turbine.
Stop the turbine by pressing the "STOP" button. Do not stop the turbine by disconnecting the main
switch nor by activating emergency stop.
Consult the turbine "Safety Card Booklet" to study the safety features of the specific turbine, and bring
required safety equipment identified not to be present in the turbine.
Study the turbine log book to identify potential abnormalities listed after the previous visit to the
turbine.
Make sure that you have both hands free when climbing the tower.
Limited minor loads can be carried in an approved closed transportation bag, tightened either to the
harness or hanging over the shoulder.
Larger items and heavier loads must be hoisted in approved and closed lifting bags using the service
crane (for smaller turbines a rope).
Due to the risk of dropping something on the person climbing below, helmet with chin strap is
mandatory during ascent/descent.

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In towers with long ladder runs, the first person climbing must be out of sight before the next person
starts climbing.
Max. weight on platform is:
300 kg or max. three persons on wooden platforms.
1,000 kg or max. six persons on steel platforms.
Max. number of persons allowed in the nacelle is six.
Climb slowly. Take a break on one of the platforms if necessary.
Entering and working in the nacelle and hub
Only six persons are allowed in the nacelle at one time.

Remember to mount the casement stay locks, if available, for the nacelle hatches when they are
opened (see the operating instructions in the specific Service manual).
Take note of the wind conditions. See following topics regarding wind:
Weather forecast (on page 1-13)
Thunderstorms (on page 1-14)
Extreme wind (on page 1-16)
Wind during installation (on page 1-16)
Wind during service work (on page 1-17)
Wind force (on page 1-18)
Lock the rotor using the rotor locks before working on the rotor, blades, hub, or the drive system. (Ref.
Operating Instructions in the specific Service manual).
At some sites, it is required to wear harness when working in the nacelle. Such requirements will be
described in the site-specific EHS plan.
Lock the rotor before working on the hydraulic system (Ref: Operating instructions in the specific
Service manual).
Always wear a harness when work involves a risk of sustaining any fall likely to cause injury.
ALWAYS USE ROTOR LOCK WHEN WORKING IN THE HUB.
ALWAYS USE YAW LOCK AND ROTOR LOCK WHEN WORKING OUTSIDE ON THE TURBINE OR
IN THE YAW SYSTEM. (See "Manuals and work instructions".)
Restricting access marking the area

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When working on the outside of the turbine or doing large repair work in the nacelle with hatches
being open or dismantled and a risk of objects falling is relevant, the area surrounding the tower must
be marked with poles and roped off at a radius of 1/5 of the tower height (for example: 80 m tower / 5
= 16 m).
Clearly mark the area, primarily at likely access roads, with signs reading:
Work area!
Work is in progress in the turbine. Authorized access only.
Safety helmets must be worn.
Rotating and moving parts

Only remove covers over rotating and moving parts when it is absolutely necessary and only when de-
energized and appropriately locked. Some work tasks can involve exemptions requiring rotating parts
to be unlocked. For such tasks, follow the work instruction thoroughly and keep a safe distance, be
particular with housekeeping, and eliminate risks of entanglement, squeezing, and cutting.
Remove harness if possible according to the potential risk of falling.
Keep tools, rags, clothes, hair, gloves, and all parts of your body far away from rotating parts and parts
which move when manually rotating the rotor.
Also be careful when yawing. People may be working in the yaw system or outside on the turbine.
After work in the turbine
Clean and remove all loose items from boxes and hub. Close the blade cover plates before leaving the
hub.
All waste materials must be removed and disposed of according to local regulations.
Clean away oil, grease, and other dirt from the nacelle, ladders, and safety equipment.
Ensure all covers on rotating and moving parts are in place. If this is not possible, signage must be
posted at the entrance of the tower to indicate the turbine is not fully functional. It must be entered into
the turbine log book and notified to the operational management.
Shut and lock the nacelle hatches. Double-check that they are locked correctly.
Remember to remove the yaw lock and rotor lock before climbing down.
Ensure that you have all tools with you before climbing down.
Enter date, time, purpose of access, and the ID of personnel into the turbine log book.
If relevant, restart the turbine. (Hearing protection must be worn in turbines with converters.)
Reset to REMOTE CONTROL and notify the operational control.

Switch off the lights in the tower and lock the door before leaving the turbine.

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1.1.19 Working offshore

Precautionary measures
Operational management must plan all work including but not limited to for example survival kit (food,
beverages) and rescue equipment to reflect the numbers of individuals in the turbine at all times.
When working offshore, special considerations must be given to the hazards presented by:
Training & PPE requirements
Risk of falling into water
Evacuation conditions
Weather conditions
Sea state
Ice
Dropped objects
Transfers between the vessel and the transition piece
The sailing coordinator specifies the offshore procedures and coordinates offshore operations with the
vessel masters.
When planning and performing work offshore, special attention must be given to weather forecasting
covering the planned scope of work and transportation, ensuring that personnel exit from the WTG
before weather conditions deteriorate, compromising safety.
Training requirements for access to offshore turbines
Mandatory basic safety training according to PRO 05.17 appendix 2. See Visitors and access (on
page 1-4).
The vessel master
The master of the vessel must consider if sailing is safe and if transfer is safe, according to the
conditions at the specific WTG.
Directions from the vessel master must be adhered to at all times. The master of the vessel holds all
responsibilities regarding the vessel's operation and transportation.
Transfers between vessels and TP foundation
Transfers must be performed in accordance with instructions given in INS 05.13: Transfer between
Vessels and Transition Piece .
Fall-arrest system must be used when climbing TP ladders, and no loads can be carried.

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A transfer operation can be evaluated to be unsafe and the operation aborted. In situations when
transfer from TP is evaluated to be unsafe, the personnel must remain on the WTG until transfer
conditions are evaluated to be safe.
Transfer during reduced visibility
Transfers should in general be planned to be performed in daylight and good visibility.
When required to performed transfers in reduced visibility, for example fog or heavy downpour and
before/after sunset, the following requirements must be fulfilled:
The vessel must provide well illuminated conditions.
When transferring from TP to vessel the transferred person must be able to see the vessel,
before descending the ladder.
Full visibility to ensure that ladder & fall-arrest system are intact (minimum the first platform of
TP, or the nacelle if using internal crane).
It will always be the transferred person who decides whether that person feels safe and is capable of
transfer.
Survival equipment
The requirements for and location of survival equipment for use if stranded on the TP can, depending
on customer decisions, be found in the turbine Safety Card Booklet and the Site induction.
Working less than 1 meter from quay side
Never work alone
Always wear life vest
RA to determine use of immersion suit
Transfer Harbor to Vessel and Vessel to Harbor
Safe access established according to maritime requirements:
No life vest and immersion suit requirement
No Safe access established according to maritime requirements:
Life vest
On vessel
CTV / indoor:
No life vest and immersion suit requirement / vessel regulations
CTV / on deck when not at quay:
According to RA / vessel regulations
Offshore transfer between vessels
Safe access established according to maritime requirements:
No life vest and immersion suit requirement.
No safe access established according to maritime requirements:
Above 12 water temperature:
Life vest + PLB
Below 12 water temperature:
Immersion suit

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Life vest + PLB

Offshore transfer between vessel and Transition Piece
Above 12 water temperature:
Life vest + PLB
Below 12 water temperature:
Life vest + PLB
Immersion suit
Crew finder
A crew finder device capable of tracking the specific frequency of the PLB in use must be installed on
all service vessels.
Rescue from sea
Rescue from sea equipment and instructions for use are found on the TP / foundation.
Man Over Board (MOB) must be part of the vessel emergency procedure which must be trained and
tested periodically.
Safety equipment used offshore
Safety equipment used offshore must be SOLAS and SWP approved, adopted into SWP Global
range of safety equipment, and aligned with the requirements of SWP PPE standard (DOC 14.34).
Offshore crane operations
Crane operations offshore must be considered in relation to the sea state. In general, the listed crane
capacity must be reduced at sea states >2.
Beaufort Description term Wind speeds Wave height

number
Wind Wave Knots M/s Probable Maximum
0 Calm - <1 0 - 0.2 - -
1 Light air Ripples 1-3 0.3 - 1.5 0.1 0.1
2 Light breeze Small wavelets 4-6 1.6 - 3.3 0.2 0.3
3 Gentle breeze Large wavelets 7 - 10 3-4 - 5.4 0.6 1.0
4 Moderate Small waves 11 - 16 5.5 - 7.9 1.0 1.5

breeze
5 Fresh breeze Moderate 17 - 21 8.0 - 10.7 2.0 2.5

waves
6 Strong breeze Large waves 22 - 27 10.8 - 13.8 3.0 4.0
7 Near gale Large waves 28 - 33 13.9 - 17.1 4.0 5.5
8 Gale Moderate high 34 - 40 17.2 - 20.7 6.0 7.5

waves
9 Strong gale High waves 41 - 47 20.8 - 24.4 7.0 10.0
10 Storm Very high 48 - 55 24.5 - 28.4 9.0 12.5

waves
11 Violent storm Exceptionally 56 - 63 28.5 - 32.6 11.5 16.0

high waves
12 Hurricane Exceptionally 64 - 71 32.7 - 36.9 14.0 >16.0

high waves

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13 Hurricane Exceptionally 72 - 80 37.0 - 41.4 >14.0 >16.0

high waves

high waves

high waves

high waves

high waves
Weather conditions
Prior to any offshore operation, the weather conditions at the location must be evaluated based on an
updated weather forecast covering the expected period of operation. It is the responsibility of the
vessel master and the operational control to update constantly the weather forecast for the whole
period of operation.
Sun
Bear in mind that the effect of the sun can be multiplied offshore, and consider appropriate protection.
Thunderstorms offshore
If thunderstorms are forecast once technicians are deployed to the turbines, the master must evaluate
if they can be safely extracted or if the technicians must retreat to a turbine safe area. Any such
decision must be communicated to and acknowledged by the personnel at the turbines.
If the operation is surprised by unexpected sudden thunderstorms:
When lightning can be seen, but no thunder can be heard: Leave the turbine and board the roofed
service boat.
When thunder is heard: Retreat to one of the designated safe areas of the turbine, stay at the center
of the platform - do not touch the tower! (See the turbine Safety Card Booklet). The service vessel will
not approach the offshore turbines.
NEVER jump into the water.
For further details of procedures and safe areas, see Thunderstorms (on page 1-14).
State of sea
It is the responsibility of the vessel master to evaluate the state of sea (wave height, wave pattern, and
current) at the given location. The master must compare the circumstances to the capability of the
vessel and his experience in order to decide if transfer is safe.
Falling objects
In offshore turbines, safety helmets must be worn during all traffic on the TP when work is performed
with nacelle covers opened.
Special safety rules
Special safety rules can be relevant for various offshore turbines, based on location and customer
requirements. Such special safety rules will be described in the site-specific EHS plan and
communicated in the Site induction.

ZSM1005840 / 16
1.1.20 Working alone

Only under special conditions for special simple tasks
In general, working alone is not allowed, and tasks are assigned for teams of minimum two persons.
Work tasks must be planned to prevent or minimize the isolation of team members. For instance out of
sight or shouting range.
If team members need to separate during work, even briefly, they must maintain communication to
assure mutual safety (for example cell phone or radio).
However, under special and very restricted conditions, simple tasks can be performed as an
independent work task, based on a specific risk assessment (PRO 07.01) approved by the line
manager.
Such tasks cannot include:
Electrical work
Hot work
Work involving powered tools
Lifting operations
Heavy manual handling
Work with chemicals
Only competent personnel are allowed to carry out work tasks independently.
Independently performed work tasks will always require a permit to work from the employee's line
manager (see FORM 05.05), and a contact person must always be appointed in writing.
Emergency procedures
Emergency procedures as well as means of and intervals for contact must be agreed and tested.
The recommended interval between calls is 15 minutes, but should be decided with consideration to
the risk associated with the actual work task.
If the contact person is not contacted as agreed, the contact person must:
1. Contact the individual working independently.
2. If unable to obtain contact, proceed according to the agreed emergency procedure for possible
work incident/accident.
In a WTG, independent work is limited to reset procedures.
Before the work starts
Ensure that means of communication are working properly. See Communication (on page 1-12).
Agree on the estimated duration of the task.
Recapitulate the agreed emergency procedures.

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During work
Contact is established upon arrival at the location of work.
Contact is obtained according to the agreed intervals, and documented in a log by both of the
individuals involved.
Contact person must remain close to the worker in order to assist in case of an emergency.

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1.1.21 Working at height

Planning
Always plan assignments at height carefully, and estimate the volume of tools and materials needed.
Check whether the work is covered by work instructions (ZWI) and risk assessments (RA) or if other
safety documentation is relevant. Make sure that the relevant safety documentation is available before
starting the work.
Ensure that all participants hold a valid certificate of Basic climb & rescue training, and that all PFPE
is within inspection period and appropriate for use.
The appropriate precautions must always be considered in order to protect individuals whenever there
is a risk of sustaining a fall likely to cause injury.
Whenever a fall-arrest system is installed, it must be used as protection against potential falls.
If an installed fall-arrest system is identified as defective, it can be accessed and repaired/exchanged
using alternative fall-safety measures based on specific risk assessments, for example double lanyard
climbing. Double lanyard climbing is not accepted as a general mean of access to either turbines or
foundations.
Wooden platform towers: A number of older towers are designed with wooden platforms spaced 6 m
apart. Access between the platforms is provided via 6 m ladder runs without a fall-arrest system
installed. Access in these WTGs must be performed in compliance with the local legislation in the area
of operation.
Make sure that the task is performed in compliance with the requirements of PRO 05.17, considering
the topics:
Safety training
Rescue equipment (Milan hub)
SWP rescue kit
Blade rescue kit
Rescue preparedness
Falling objects
Whenever a risk of falling objects is identified, tools and other loose objects must be secured using a
lanyard or cord suitable for carrying the weight of the object to prevent it from falling. This precaution
covers work in the nacelle with the covers open as well as work on the outside of the tower, and work
inside the tower.

ZSM1005840 / 16
Working at different levels should be avoided, and all work should be planed according to this
requirement. If this is not reasonably practical, special consideration must be paid to the risk of
dropped objects.
Within a radius of 1/5 of the tower height, safety helmets must be worn.
Working on the outside of the tower, nacelle, and blades
The nacelle covers must not be opened at high wind speeds. See Weather.
When the wind turbine is in operation, only inspection is allowed, not actual work. See Weather for
specific information on maximum wind speed.
When working on the outside of the tower, nacelle or on the blades, all tools must be safely fixed to
either the safety belt or a suitable part of the WTG. The yaw section and rotor must always be locked
during work on the outside of the turbine, unless otherwise described in the work instruction.
Whenever work is performed on the outside of a WTG, a safety perimeter with a minimum radius of
1/5 of the tower height must be indicated around onshore WTGs. Signs must be conspicuously
posted, warning against potential falling objects.
Rope access
Some work is performed by using rope access. This work requires trained and certified rope access
technicians (S.P.R.A.T). Rope access work is performed under special safety rules, using specially
described methods exclusively for this particular type of work.

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1.1.22 Excavations and confined space

Excavations
The supervisor/site manager must be informed ahead of any kind of excavation in order to coordinate
with other nearby work.
Hidden installations must be located prior to any excavation.
A work permit must be obtained if excavation is to be carried out near underground cables.
Place clearly visible barricades and warning signs around the excavation site.
Have special focus on the hazards related to vehicles or equipment getting close to the edge.
Slope or support all sides deeper than 1.5 m to prevent cave-ins.
Carefully inspect after rain and/or flooding, or other hazard-increasing occurrences.
Confined space
In European terms, Siemens wind turbines in normal operating conditions do not have areas classified
as confined space. Certain areas within the turbine are classified as areas with restricted movement:
Blades
Hub
Yaw section
Under floor section
Inside the nacelle on the outer side of generator (DD turbines)
Note: Any of the above-mentioned areas can be classified as a confined space area depending on the
nature of work performed. (Consult specific national regulations.)
Turbines designed with basements in offshore foundations have a potential confined space in the
foundation.

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1.1.23 Crane work

Planning
Whenever possible, manual handling should be avoided and mechanical assistance equipment should
be used for lifting.
Lifting must be performed according to the requirements in SWP DOC 14.38 SWP Lifting standard,
distinguishing between simple lifts (using the turbine- or foundation-mounted service cranes) and
complicated lifts (using external cranes for lifting heavy objects).
Using the nacelle or foundation cranes, all loads must be contained in approved and closed lifting
bags or appropriately rigged for lifting by a competent person.
Before lifting with crane, forklift or other mechanical equipment, ensure that the lifting equipment is
certified, and that lifting appliances are within their inspection period.
Only experienced competent personnel may carry out lifting of main components such as tower
sections, nacelle, and rotor.
No persons other than those involved in the lifting procedure may enter the lifting area.
Lifting plan
Lifting not categorized as a simple lift must be performed according to an approved lifting plan. The lift
must be planned by a competent person, and supervised by an appointed lifting supervisor.
Lifting supervisor
The lifting supervisor holds the responsibility of coordinating the lift in cooperation with the crane
operator, and must be able to communicate clearly to the crane operator during all sequences of the
lift.
The lifting supervisor is responsible for ensuring that the lift is performed according to the
requirements of DOC 14.38 and the local legislation, and must ensure that all involved personnel
understand the plan.
The lifting supervisor must be easily distinguishable by wearing a significantly colored vest.
The lifting supervisor is responsible for ensuring that the lifting zone is well marked and cleared of any
unauthorized personnel.
Communication
Establish and maintain good communication between all persons involved. Unless otherwise agreed,
use internationally recognized crane signals.

ZSM1005840 / 16
Signalmen may become hidden in the terrain or by loads, and hand signals may be indistinct over long
distances or in adverse weather conditions. Personnel involved in the lifting procedure must therefore
use two-way radios or cell phones during the lift. Make sure that batteries are fully charged before the
lifting procedure is started.
Certified lifting equipment
Only use certified and approved lifting equipment. Do not use homemade lifting arrangements.
Cranes, service cranes, hoists, and all lifting appliances must be visibly marked with their certification,
the safe working load (SWL), date of latest inspection, who has performed the inspection, and the date
of next inspection.
The responsibility only to use certified and marked lifting equipment rests with the user of the
equipment.
The certificate and user manual of hoists, cranes, and similar lifting equipment must be kept
accessible by the equipment.
Safety during lifts
Only use lifting equipment to manage tasks according to the user manual.
Standing or walking underneath suspended loads is not allowed.
Suspended loads must be supported if work is required underneath.
For offshore lifts, the ordinary specified lifting specifications must be considered reduced in relation to
the sea state.
Hoisting tools
For turbines with no service crane, bring a rope to the nacelle for hoisting tools and materials if
necessary.
Certification for use of mobile cranes and machinery
Machine operators must have a valid and approved license for operating cranes and forklifts.
Rigging
Only a qualified person may carry out rigging. It is the responsibility of this person to determine the
weight and center of gravity of the object and to select suitable lifting equipment.
Carry out a visual inspection of the lifting equipment prior to use. Never use defective equipment or
equipment out of inspection period.
Label defective equipment: DO NOT USE, and ensure that it is appropriately quarantined.
Wind
During crane operations special consideration must be given to wind speed in relation to the
limitations stated in the:
Lifting plan
Work instruction
Installation manual
The lifting supervisor decides in cooperation with the crane operator if the lift can be performed safely
according to weather monitoring.
The risk of sudden gusts of high wind must always be considered. See "Weather"

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Crane signals
The pictures below show the internationally recognized and normally used signals when controlling a
lift.
Only the appointed person may signal to and guide the crane operator.
Table 1.1.23. Hand signals for crane operations
Lower Lower - used at short

Hoist Raise/hoist derrick
distances
Swing left Swing right Telescope out Stop quickly
Use "lollipop" at large

Move load in this direction Telescope in Signal not understood
distances

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1.1.24 Hot work
All welding, burning, flame cutting, metal grinding, heat shrinking, or other operations suitable of
causing high temperatures must be authorized in advance and in writing by the line manager, or an
appointed person who has to fill in the required forms attached to PRO 05.22.
The site manager/leader or line manager must keep a log of all Permits to work using PRO 05.22
appendix 3 Permit to work log.
Fire extinguisher:
Always bring fire extinguishing equipment of a suitable type and volume in reference of the
scope of work/permit to work.
Check that the surroundings are clean from flammable materials and that all oil drip pans are emptied
of oil, grease, paper, and so on, before starting the work. Ignitable items that cannot be removed must
be protected.
Take all precautions against fire! Cover the area surrounding the hot work sufficiently by means of fire
blankets to prevent sparks from causing damage to installations or igniting a fire.
Minimum PPE:
Wear suitable safety Wear head protection Wear eye protection Wear suitable gloves
footwear
Wear long trousers
Wear long-sleeved upper garments
Inform the supervisor/site manager that work involving a risk of fire is being carried out in order to
allow coordination with other work on site.
To avoid fire hazards, all service visits in the turbine, irrespective of purpose, must include cleaning
away rags, empty containers, and so on, and bringing them back to the service building or waste
containers.
Turbines must not be used for storing spare parts and lubricants for later use!

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1.1.25 Electrical work

This set of rules is Siemens's minimum demands for safety for Siemens employees and
subcontractors when performing tasks within the wind industry. Country-specific regulations are
addressed in the site-specific EHS plans.
Electrical work is the work near or on electrical installation. This concerns both:
High-voltage installations (voltage above 1,000 VAC or 1,500 VDC.)
Low-voltage installations (voltage below or equal to 1,000 VAC or 1,500 VDC.)
Note: 1,000 VAC is a phase-to-phase value. 1,500 VDC is the difference between minus and plus.
This set of rules covering electrical work within Siemens Wind Turbines is the minimum requirements
for electrical awareness and safety.
Country-specific regulations are addressed in Local Specific Procedures (LSP).
General rules
Roles and responsibilities
Work on the WTG electrical systems and components may only be performed by duly trained or
supervised personnel who are, as a minimum, holding a current and valid certificate in:
General Electrical Awareness for Low and High Voltage.
Technical and Safety training.
Zero Energy Kit training (under implementation, will be fully rolled out by April 2013).
High-voltage work requires additional training in order to be duly trained and certified.
When performing electrical work, there must always be one Nominated person (according to PRO
12.18 for Service, 12.19 for Projects and 12.20 for Project 3rd party) or Task-Specific Work Approved
(TSWA) present who has the overall responsibility for the work and safety.
Instructed personnel must be supervised by authorized/skilled personnel.
Zero Energy State and live work
All systems must be treated as live until verified to be in Zero Energy State.
Zero Energy State means that there is no power on the system or on any components and is therefore
the safest way of performing work.
De-energizing of equipment must be done by following the Zero Energy Verification procedure:
Energy Isolation process:
Nominate competent person (in writing)
Competent person accepts appointment (in writing)
Plan energy isolation
Identify work area
Identify point(s) of isolation (POI)
Identify points of verification (POV) and select verification methods
Document POI's lock-out point(s) and POV's

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De-energize equipment. (Verify process step forwards in writing)

Lock and tag POI's
Verify 0 energy (test function is in zero state and locked, check measure, etc.)
Perform task
Release equipment for operation
Remove tag and locks from POI's
Re-energize equipment
A Zero Energy State must always be approved by the Nominated person in charge of the work.
Within Siemens Wind Power A/S it is not allowed to work on a live system or components, or where
there is a risk of contacting exposed live parts.
Live work within Siemens Wind Power A/S is not allowed, except for:
Voltage testing, current measurement, and discharging
Error detecting
Replacing and handling of UPS batteries
Risk Assessment
Electrical work must always be planned, and if necessary a risk assessment must be made. Planning
on performing a Zero Energy Verification Procedure requires identification of:
The work area
Points of isolation
Measuring points to verify the Zero Energy State
Extra care must be taken in the space below regarding accidental dropping of tools or parts. Therefore
always make sure that the space below is covered or closed.
When re-energizing electrical systems, all cabinet doors must be closed, access panels must be
correctly fitted, and a proper distance from the cabinet must be held.
Low voltage
Minimum PPE:
Wear suitable safety Wear suitable protective Wear safety harness Wear eye protection
footwear gloves
When performing live work in a wind turbine, the tools and PPE defined for the Zero Energy Kit must
ALWAYS be used as a minimum.
Siemens personnel are ONLY allowed to use equipment and tools approved and issued by Siemens
and if they are duly trained in their use.
Subcontractors must use the equally specified tools and equipment and prove competence in their
use.
The Zero Energy Verification Procedure on a low-voltage installation must ALWAYS be followed:
1. Disconnect the supply source. Switch off or unplug the power on the supply source.
2. Lockout/tagout. Make sure the locks and tags are clearly visible.

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3. Check instrument. Make a hot measurement on a known live source to check the functionality of
your instrument.
4. Prove Zero Energy State. Measure on the disconnected source to make sure it is without energy.
5. Recheck instrument. Make a hot measurement on a known live source to recheck the
functionality of your instrument.
High-voltage systems
Electricity No access for unauthorized persons
Minimum PPE:
Wear safety harness Wear head protection Wear isolated safety footwear Wear safety goggles
Special training concerning high-voltage systems would include:

Cable work
Switching
Commissioning
Troubleshooting
Service work

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1.1.26 Working with chemicals

Hazardous effects
WTG service work involves handling of various chemical products (oil, grease, cleaner, lubricants,
glue, and so on). Some of these products may be hazardous to health, having the potential to cause
eczema and allergic reactions upon repeated skin contact. Other products are hazardous to the health
when breathing the fumes.
Some of the products have no immediate effect. The possible health hazards are often not seen until
long after use of the product.
Material safety data sheet
Warning
Mandatory action
MSDSs are made for each individual chemical product. They contain specific information about the
hazards that are connected with the use of the product. They also give information about first aid,
handling, disposal, and the specific personal protective equipment required.
MSDSs must be well organized, updated, and easily accessible near the work area. For turbines on
shore, this means in the service car. For offshore turbines, the safety data sheets must be found in the
nearest service building and by the vessel master. For storage facilities, this means in the storage.
MSDSs must be available in a language understood by the user.
MSDSs can be obtained online via SWP intranet/Important links/Online MSDS.
Some countries require a Chemical Risk Assessment (COSHH/APB) as a supplement to the MSDS.
Precautions
Emergency
Study the safety data sheets to find out if the product is hazardous to your health.
If the product is harmful to inhale, appropriate PPE must be used and ventilation/exhaust or draughts
must be established according to the instructions in the MSDS.
If skin contact cannot be avoided, protective gloves must be used in accordance to the instructions in
the MSDS. It is important to use the correct type of gloves! Ordinary working gloves (leather) must
under NO circumstances be used as chemical gloves.
First aid equipment and eye wash must be readily available where chemicals are stored and
used.

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Storage
Never store chemicals in unmarked containers.
Always store chemicals well ventilated and in appropriate spill containment.
Always have means of spill collection where chemicals are used and stored.
Always store chemicals well protected against fire
Disposal
Chemical residues and clothes with oil or grease must be disposed of as hazardous waste.

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1.1.27 Emergency and evacuation

Emergency on site
A site-specific Emergency Response Plan (ERP) is prepared for all manned installation and service
sites. The plan is prepared and governed under the responsibility of the customer. The ERP is part of
the EHS plan as appendix 4.
The ERP must be easily accessible in hard copy.
The ERP will give instructions on how to communicate to emergency response assistance and will
include a list of emergency contact numbers for fire department, police, paramedics, site manager,
supervisor, owner, and other relevant persons.
The ERP will give directions on the location of the site, the route to the nearest medical facility, and to
the nearest trauma center.
The ERP will as a minimum address the site response in these situations:
Fire
Injury
Spill
Sabotage
Emergency communication
The ERP must be part of the site induction.
Emergency in the WTG
In newer turbines, the emergency response procedures, the location of the turbine, the turbine
emergency response equipment, and a turbine-specific list of emergency contacts are listed in the
turbine Safety Cards Booklet located in brackets at the nacelle front left side and at ground level of the
turbine.
The turbine Safety Cards Booklet is the Emergency Response Plan of the WTG.
A turbine Safety Cards Booklet has not been produced for older turbines. In these turbines the general
emergency procedures must be followed, see "General emergency procedures".
Emergency training and preparedness
All access to and work in a WTG must be aligned with the requirements of PRO 05.17: Safety
equipment & safety training / rescue preparedness.
Rescue equipment must be available on site in accordance with the requirements in PRO 05.17 and
the ERP.
This PRO regulates the training and rescue preparedness requirements of accessing the Rescue
Zone 1-3. For exact details, this PRO should always be consulted when planning a visit or work in a
WTG.
When accessing a WTG it is the responsibility of the individual to be updated on the emergency
procedures provided by Siemens.
When accessing a WTG, it must be ensured that means and details of contacting emergency
assistance is available.
Emergency response equipment in the WTG
Evacuation equipment, an appropriate type of fire extinguisher, first aid equipment, and eye wash
must always be available when working in a WTG. If not mounted in the WTG, it must be brought
upon access.

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If an individual is not trained in and familiar with the use of the model of evacuation equipment in a
WTG, a model matching the training level of this individual must be brought up on access (visitors are
exempted from this requirement).
The turbine Safety Cards Booklet will list the type and location of emergency equipment in the WTG.
Turbine Safety Card Booklets are located in brackets mounted in the tower at ground level, and in the
front left part of the nacelle.
The type and volume and location of emergency response equipment in a WTG can vary according to
WTG model, country of location, and customer preferences.
The following types of equipment may be found:
Fire extinguishing
equipment
Dry powder extinguisher (4 -6 kg)
CO2 extinguisher
Fire blanket
First aid equipment
First aid kit (dressings, thermal blankets, bandage, and so on)
Eye wash
Evacuation and rescue equipment Sea rescue equipment (offshore turbines)
Emergency equipment type AG 10 (descent Life buoy

only)
Boat hook
Emergency equipment type Milan hub A024
Emergency equipment and rations for personnel stranded on
(rescue / hoist and descent)
WTG
Emergency equipment type Milan hub A020
(descent only)
Emergency equipment type Milan hub RG 10

(descent only)
Emergency equipment type Milan hub RG 10 A

(rescue / hoist and descent)
Emergency equipment type RollGliss (rescue /

hoist and descent)
Stretcher
Some turbines are equipped with a spineboard for evacuation of seriously injured people. Only use the stretcher in
cooperation with personnel trained in Advanced Rescue.
Important: To ensure correct and effective action in case of emergency, it is essential that personnel
are familiar with the emergency response equipment and the rescue equipment available in the
specific WTG.

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Emergency lights
The WTG has emergency lights operating on batteries (UPS) to illuminate the WTG in case of power /
grid failure.
The battery capacity of the emergency light supply is sufficient for at least one hour of operation during
power failure. The batteries are automatically charged by a built-in charger.
Emergency opening of hatches
If the turbine is without power, the nacelle top hatches cannot be operated automatically.
If the hatches are closed and an emergency situation occurs during a power failure, use the marked
emergency hatch in the nacelle. (Pointed out in the turbine Safety Cards Booklet). Alternatively, use
the ladder through the tower for evacuation/emergency exit.
In some of the 2.3 MW VS and in the 3.6 MW type, the hatches can be operated without power. The
hatches are fitted with a manual pump providing the pressure necessary to open the hatches.
Rescue and evacuation from turbine
When working at heights, rescue equipment must always be available. The

equipment can be hoisted with the service crane, elevated by rope, or brought up
through the tower hooked to a full-body harness. If the WTG is fitted with a lift, it
can be brought in the lift.
In some emergencies, for example fire, it may be necessary to evacuate the WTG on the outside.
During external evacuation from offshore WTGs, there is a risk of landing in the water. Should this
happen, disconnect from the evacuation device, swim to the foundation, and hold position until the
rescue vessel arrives.
If a work accident occurs, it may be necessary to rescue a casualty from one of the Rescue Zones 1 -
3.
In case of extreme weather conditions compromising safe evacuation, personnel must evacuate to the
safest area of the WTG depending on the situation. In most situations this will be the ground level of
the tower. Contact the site manager (for offshore turbines, also the vessel master) and follow the
instructions given.
In general, training and equipment are designed for downwards evacuation and rescue.
If the nacelle is safe, it will offer the best opportunity for potential helicopter rescue / evacuation.
In case of serious injuries, helicopter rescue can be relevant due to the nature of injury, deterioration
of the injured person's condition, or the remote location of the WTG.

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1.1.28 General emergency procedure

Procedure:
1 Evaluate the situation and, if possible, stop the accident!
1.1 If evaluated catastrophic and step 1 is not possible, then ALARM and evacuate all
personnel
2 Administer life-saving first aid.
3 Call for assistance (Where to? What? How many? How? Who?)
4 Administer ordinary first aid.
5 Re-evaluate situation and update information.
6 Check on casualties.
7 Place a person at the site entrance or by the main road leading to the WTG, alternatively at
ground level/foundation of the WTG to guide and assist emergency backup. When the immediate
danger is over, contact superiors giving immediate details according to situation and site
organization:
7.1 Line manager/site manager/site supervisor
7.2 Siemens EHS person on site
7.3 EHS representatives from companies involved in the incident
7.4 Siemens's EHS Department at Brande, DK
If a site-specific EHS plan is present, the specific flow of communication will be described in this
plan.
1.1.29 Evacuation of nacelle

Procedure:
1 Assess the situation.
2 Alarm - in accordance with the assessment local emergency services.
3 If passage down through the tower is possible, evacuate via ladder. (Never use lift!)
4 If passage through the tower is blocked:
4.1 Move towards the top of the turbine and stay there until rescue personnel arrive
4.2 Stay in contact with the rescue personnel
5 If possible, open hatches to ensure that fresh air is available.
6 If it becomes necessary to evacuate the nacelle, choose the safest way out.
7 Make sure that the adequate rescue equipment is available.
8 Read through the evacuation procedure and make sure that everybody knows what to do.
9 Find a suitable anchor point and prepare the equipment.
10 Evacuate the turbine.
11 Notify superiors.

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1.1.30 Evacuation photos
Evacuation of turbine - SWT 2.3VS
(1) Attach the equipment to (2) Prepare the escape (3) Step into the leg holes (4) Adjust harness front
the approved anchor harness for use through the opening
(5) Make sure that the back (6) Pull the buckle towards (7) Attach the harness eye to (8) Remove the evacuation
strap is adjusted your body until the harness the evacuation equipment hatch
fits tightly
(9) Throw out the bag to (10) Grab hold of the loose (11) When hanging, let go of (12) Personal harness is first
suspend the rope outside rope and step out of the hatch the rope priority - if possible
opening

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Evacuation of turbine - SWT-3.6_V1
(1) Attach the equipment to (2) Prepare the escape (3) Step into the leg holes (4) Adjust harness front
the approved anchor harness for use through the opening
(5) Make sure that the back (6) Pull the buckle towards (7) Attach the harness eye to (8) Remove the evacuation
strap is adjusted your body until the harness the evacuation equipment hatch
fits tightly
(9) Throw out the bag to (10) Grab hold of the loose (11) When hanging, let go of (12) Personal harness is first
suspend the rope outside rope and step out of the hatch the rope priority - if possible
opening

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Evacuation of turbine - SWT-3.6_V2, SWT-3.6_V3, SWT-4.0
(1) Take out the equipment (2) Attach the equipment to the approved (3) Pull the buckle towards your body
anchor until the harness fits tightly
(4) Throw out the bag to suspend the (5) Grab hold of the loose rope and step (6) When hanging, let go of the rope.
rope outside the hatch out of the hatch opening When reaching the ground, detach
yourself to allow for the next person to
evacuate

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1.1.31 Fire in turbine
Minor fires: Attempt to control with extinguisher. If unsuccessful: Evacuate.

Procedure:
1 Alarm local emergency services.
2 Rescue persons in the turbine.
3 In case of heavy smoke, try to avoid the smoke and try to fight the fire.
4 Gather persons count persons evaluate need of first aid.
5 When everybody is out, stop the turbine at the main switch.
6 When outside, keep away (upwind) from smoke and await assistance.
7 Notify superiors.
Note: Offshore: Do not jump into the water unless absolutely necessary.
1.1.32 Accident and illness
Procedure:
1 Stop the accident/machine.
4 Continue first aid.
5 For chemical accidents, follow the instructions in the Material Safety Data Sheet (MSDS) or the
Control Of Substances Hazardous to Health (COSHH).
6 Assist the rescue personnel.
7 Notify superiors.
8 Consider access restrictions.
9 Leave machines, equipment, and so on, as they are. Do not clean or tidy.
10 Make notes and take pictures to remember details for the upcoming investigation of the accident.
11 Assist in making the accident report.

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1.1.33 Environmental accident
Procedure:
1 Reduce the impact of the accident, if possible.
2 Check for endangered personnel, evacuate if relevant, and administer first aid.
3 Seal off the area to prevent persons from getting hurt.
5 Notify superiors.
6 Continue to reduce the accident - follow the instructions in the Material Safety Data Sheet
(MSDS) or Control Of Substances Hazardous to Health (COSHH).
7 Assist the rescue personnel.
1.1.34 Man overboard
Procedure:
1 Yell Man overboard.
2 Throw out a life buoy and keep an eye on the person.
3 Alarm vessel crew local emergency services (if on a vessel, the crew take over).
4 Try to rescue the person - if possible, get the person out of the water.
5 Administer first aid.
6 Notify superiors.
7 Assist rescue personnel.
1.1.35 Electrical accident
Procedure:
1 Break the circuit. Do not touch the person until the circuit has been broken.
4 Continue first aid.
5 Notify superiors.
6 Persons must always be examined by a doctor.
7 If necessary, arrange for the person to be kept under observation for the next 24 hours.

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1.1.36 Overspeed
Procedure:
1 Evacuate the turbine.
1.1 Get everybody out in so far as possible
1.2 Gather the personnel - count persons
1.3 Get as far away from the turbine as possible
2 If the risk of an accident arises, call emergency services by telephone or cell phone.
3 Notify supervisors.
Note: Offshore: Do not jump into the water unless absolutely necessary.
1.1.37 Person suffering from hypothermia
Procedure:
1 Place the person horizontally.
3 For severe hypothermia (person not reacting when spoken to).
3.1 Provide mouth-to-mouth
3.2 Do not perform chest compressions
5 Warm up the person slowly.
5.1 Take off wet clothes
5.2 Wrap the person in blankets or similar (for example aluminum blankets)
5.3 If possible, use your own body heat to warm up the individual
5.4 Place the person in a warm room, if possible
6 Wrap hands and feet in blankets separated from the body - if possible. Do not place hands and
feet in hot water.
7 Wait for the rescue personnel and assist them.
Important: A person suffering from hypothermia must be brought to a hospital immediately.
1.1.38 Helicopter evacuation

This procedure must be presented to, and accepted by, the local rescue services and the helicopter
rescue unit. Changes may be necessary. The procedure "Preparation for helicopter rescue" should be
taken as an example only.
Procedure:
1 Request helicopter rescue. Local rescue services decide whether helicopter rescue is necessary.
2 Go through the procedure Preparation for helicopter rescue (on page 1-54) for turbine upon
contact, and if possible ask to have the crew briefed on this procedure en route. Give radio
contact details and details about suspected injuries.
3 Carry out the procedure Preparation for helicopter rescue (on page 1-54).
4 If possible, establish communication with the helicopter by radio or telephone.

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1.1.39 Preparation for helicopter rescue

Procedure:
1 Turn the turbine 90 out of the wind and mount the yaw lock.
Note: The illustration is considered a principle for all SAR emergency helicopter approaches.
The procedures are identical regardless of the type of turbine.
2 Position the blades with one blade vertically down mount the rotor lock.
3 Open the hatches and secure them using the hatch lock (if available).
Note: When the helicopter is right above the turbine, there will be heavy winds in the nacelle.
Therefore all personnel must wear harnesses and be secured with lanyards during the rescue.
Safety helmets must be worn, with the chin strap tightened. Ear protectors must be worn if
available.
Beware of static electricity.
4 When the hook is on and you are ready, a clear hand signal must be given to the helicopter.

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1.2 Turbine safety instructions
1.2.1 Safety
Note that the general safety regulations for installation work must always be complied with. See SI
545781: Basic Health and Safety Rules.
1.2.2 Basic safety rules when working in the turbine

When working in the turbine, there are some basic safety rules which ALWAYS must be complied
with!
When accessing the turbine, always set the Remote/Local switch to LOCAL CONTROL and
lock the switch using a suitable lock.
When accessing the turbine by helicopter, enter the nacelle through the hoist zone hatch, set
the Remote/Local switch on the A3 cabinet to "LOCAL CONTROL" and lock the switch using a
suitable lock.
Always wear hearing protection when staying in the turbine during operation.
Tower door is secured from locking from the outside (padlock).
Always press MANUAL STOP before ascent.
Activate the SERVICE VALVE (position 252).
Operate the turbine via MENU 24.
The turbine can only be restarted with the SERVICE VALVE (position 252) deactivated.
Engage the rotor lock when accessing or working in the hub and on the rotor.
Engage the yaw lock when working on the yaw system.
Engage both the rotor and yaw lock when using the crane externally.
When working in the hub while the 108 valves are not set to Service mode, or in case of grid
power loss, there are risks associated with rotating machinery and entrapment; in these
situations, always ensure that you are standing on top of the checker plates; this is particularly
important when performing tasks that require blade pitching.
Before leaving the turbine, remove the lock and set the Remote/Local switch to "REMOTE
CONTROL".
When leaving the turbine by helicopter, remove the lock and set the Remote/Local switch on the
A3 cabinet to "REMOTE CONTROL".
1.2.3 Environmental consideration

At waste disposal, please read the following instructions in the environmental management manual:
Procedure:
1 Waste sorting Service trucks and external storages.
2 Waste sorting and disposal at turbine erection.
3 Waste sorting and disposal at tower installation.

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1.3 Mechanical safety
1.3.1 Opening and closing the nacelle hatches

Important: Before entering the hub and during work on the transmission, make sure that the HS rotor
lock is engaged.
Service valve (252) on the hydraulic station must be positioned in service mode.
1.3.2 Hook lock on the nacelle hatch

Note: Unlock hook locks before opening nacelle hatches
(1) Hook lock on the nacelle hatch

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1.3.3 Casement stay lock

Note: Always use casement stay lock together with lock bush and split pin in both hatches when
working with the hatches open.
(1) Casement stay lock
(1) Lock bush

(2) Split pin

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1.3.4 Operating handles for opening and closing nacelle hatches (Non-HILT yaw
system)
The nacelle hatches are opened by 2 hydraulic cylinders. The opening handles are placed in the left-
hand side of the nacelle. Handle 1 is used for opening hatch 1 and Handle 2 for opening hatch 2. The
hydraulic pump is activated by the start button placed on the A9 cabinet.
(1) Operating handles
(1) A9 cabinet
(2) Start button for hatches
(3) Stop button for crane
(4) Start button for crane
Operating handles for opening and closing

the hatches.
(1) Handle 1
(2) Handle 2
(3) Close
(4) Open

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1.3.5 Opening the nacelle hatches (Non-HILT yaw system)

Procedure:
1 Make sure that hook locks on nacelle hatches are opened.
2 Press and hold Start button for hatches.
3 Pull Handle 1 away from the hatch until Hatch 1 is fully opened.
4 Release Handle 1
6 Release Handle 2 and Start button
7 Lock the casement stays on both hatches.
8 Note: Always use casement stay lock together with lock bush and split pin in both hatches when
1.3.6 Closing the nacelle hatches (Non-HILT yaw system)

Procedure:
1 Important: Make sure that all persons are clear of the hatches when closing them.
2 Remove the locks from the casement stays in both hatches.

3 Press and hold Start button for hatches.
4 Push Handle 2 towards the hatch until Hatch 2 is fully closed.
6 Relieve the cylinders by activating the handles without starting the pump.
7 Close the hook locks on the hatch.
8 Double check that hook locks are locked correctly.
1.3.7 Control box for opening and closing nacelle hatches (HILT yaw system)
The nacelle hatches are opened by 2 hydraulic cylinders. The control box is placed in the left-hand
side of the nacelle. The switch is used for opening hatch 1 and hatch 2. The hydraulic pump is
activated by a start button placed on the control box.
(1) Switch for hatches
(2) Stop button for crane
(3) Start button for crane

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1.3.8 Opening the nacelle hatches (HILT yaw system)

Procedure:
2 Turn and hold the Switch clockwise.
4 Release Handle 1
6 Release Handle 2 and theSwitch
7 Lock the casement stays on both hatches.
8 Note: Always use casement stay lock together with lock bush and split pin in both hatches when
1.3.9 Closing the nacelle hatches (HILT yaw system)

Procedure:
1 Important: Make sure that all persons are clear of the hatches when closing them.
2 Remove the locks from the casement stays in both hatches.

3 Turn and hold the Switch clockwise.
5 Release Handle 2
7 Release Handle 1 and the Switch
8 Relieve the cylinders by activating the handles without starting the pump.
9 Close the hook locks on the hatch.
10 Double check that hook locks are locked correctly.
1.3.10 Manual opening of hatches without voltage in the turbine

Procedure:
2 Follow instructions in: ZWI1004273, 'Operation of covers and crane without hydraulic pump
pressure'.
3 Follow procedure for 'Opening the nacelle hatches (version A)' or 'Opening the nacelle
hatches (version B)'.
4 Follow procedure for 'Closing the nacelle hatches (version A)' or 'Closing the nacelle
hatches (version B)'.

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1.3.11 Locking the rotor on the high-speed shaft

The rotor on the high-speed shaft must be locked if personnel is working in the hub or on the
transmission system.
Important: : At wind speed between 12 and 18 m/s (mean value in 10 min): If the HS rotor lock is
engaged, the nacelles must be yawed to 90 degrees away from the wind direction. Observe the wind
direction continuously to ensure that the nacelle remains positioned 90 degrees away from the wind
direction (tolerance +/- 30 degrees)
Note: Use the electric turning motor when pushing in the lock bolts. The turning motor must stay
engaged until the lock bolts have been disengaged.
Note: Yaw the turbine out of the wind if the turning motor is unable to turn the rotor.
(1) Position of lock bolts when the rotor is
not locked.
Turn the rotor until the bolts can engage. The rotor is turned using the turning gear.
(1) Lock bolts
(2) Cotter pins
To lock the rotor, lock bolts must be pressed fully home and the cotter pins inserted to lock the lock
bolts.

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1.3.12 Locking the rotor on the low-speed shaft

Only use the low-speed lock when repairing the gear, main shaft, or brake or when it is not possible to
use the high-speed lock.
The purpose of the low-speed rotor lock is to lock the rotor even when the gear or the brake disc is
dismounted.
2 heavy steel shafts are fitted at the bottom of the main bearing housing. These can be inserted into
the flange on the rotor by means of a screw spindle.
Important: Wind speed limit for the low-speed lock is 18 m/s.
Electric turning motor
1. Mount the plug in the outlet on A9 cabinet for crane / hatches. (Only if A9 cabinet exists -
otherwise not needed)
2. Loosen the lock bolt and push the turning motor to engage with the gear wheel.
3. Tighten the lock bolt loosen the brake and start the motor to make the rotor rotate in the wanted
direction using the switch.
(1) Electric turning motor
(2) Lock bolt
(3) Switch
Locking the rotor using the low-speed rotor lock

1. Use the turning motor to turn the rotor until the low-speed rotor lock is able to engage.
2. Check between the hatch and the main bearing to see when the hole in the flange is aligned with
the rotor lock.
3. Stop the turning motor.

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4. Remove the rotor lock cotter pin on both sides.

(1) Low-speed rotor lock
5. Pull the safety lock pin out.

6. Screw in the screw spindle.
Low-speed rotor lock not engaged
(1) Safety lock pin
(2) Screw spindle
(3) Indicator
7. Re-engage the safety lock pin.

8. The screw pin is fully in and the rotor lock is engaged.
Low-speed rotor lock engaged
(1) Safety lock pin
(2) Screw spindle
(3) Indicator

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1.3.13 Locking the yaw system

Important: Use yaw lock system when working on:
The yaw system - yaw claws / teeth.
Reparing the outside if the turbine.
External craning at / on the turbine.
Important: Wind speed limit for the yaw lock is 18 m/s.
(1) Yaw lock
(1) Yaw lock in unlocked position
Procedure:
1 Pull out the lock pin.
2 Push down the yaw brake to lock the yaw ring.
Use Menu 2 > Screen 1 (Manual yawing) in the hand terminal to line up, so the yaw lock is able
to engage.

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1.3.14 Pitch lock

Pitch lock (manual)
The mechanical pitch lock is used when working with the blades in a position which is outside the
range of the automatic pitch lock.
(1) Pitch lock bracket (manual)
Bolt M24 x 160, 10.9
1. Pitch the blade until the pitch lock holes fit the bolts.
2. Mount the pitch lock bolts, and torque-tighten. Torque = 400 Nm.
If the service personal needs to leave the turbine with the manual pitch lock mounted they will need to
come back every 5 days to torque the bolts again to make sure they do not come loose.
(1) Pitch lock (manual)
Position when not in use.

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Pitch lock (hydraulic)

(1) Pitch lock (hydraulic)
See ZWI 1001712 "Access to blade"

Can be activated in Menu 24.

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1.3.15 Position of emergency stop

Position of emergency stop in the nacelle
2 emergency stops are found in the nacelle - one in each side. They are activated by pulling the wire.
(1) Emergency stop in the left-hand side
Emergency stop in the right-hand side

(1) Reset button
(2) Emergency stop wire
Position of emergency stop in the yaw section

(1) Emergency stop

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Position of emergency stop outside the yaw section

(1) Emergency stop
Position of emergency stop in the controller

(1) A2 controller
(2) Emergency stop

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1.4 Electrical safety
1.4.1 Safety precautions when working with electrical installations

For each service visit, the following safety precautions must be followed. For working in the turbine,
"Basic health and safety rules" must be followed. For working with electrical installations, "Electrical
work" in "Basic health and safety rules" must be followed.
WARNING
Prior to commencing work on any circuit, it must be ensured that the work area is de-
energized. See the section "Electrical work" in safety instructions SI545781 "Basic
health and safety rules for technicians working in Siemens Wind Turbines".
Working with live voltage is only permissible for testing or error detecting (see safety rules for
"Electrical work").
CAUTION
If more than one person is working on the voltage section, each person must assure his own
safety by means of his own personal padlock.
Up to six padlocks can be mounted on the main switch locking device.
WARNING
Circuit switching and measurement are LIVE WORK.
NOTICE
Wear ear protection
Hearing protection must be worn at the bottom of the tower during start-up and operation of
the turbine.
High-voltage work may be performed only by approved and certified contractors. Personnel working
with high voltage must possess a valid high-voltage safety awareness certificate.
Only personnel instructed by Siemens Wind Power A/S and with a valid certificate from courses on
Live Low Voltage Electrical Safety, corresponding to the Danish LAUS-classes as a minimum, are
permitted to carry out inspection, testing, and repair of electrical installations and equipment.
The connection of the main switch (circuit breaker) is performed by the controller and must not be
performed manually. For detailed instructions, see ZWI1026419 "Lock out" of main circuit breaker.
These five safety rules must be followed prior to any work on circuit.
The 5 safety rules

1. Disconnect the supply source. Switch off or unplug the power on the supply source.
2. Lockout/tagout. Make sure the locks and tags are clearly visible.
3. Check instrument. Make a hot measurement on a known live source to check the functionality of your instrument.
4. Prove Zero Energy State. Measure on the disconnected source to make sure it is without energy.
Recheck instrument. Make a hot measurement on a known live source to recheck the functionality of your
5.
instrument.

ZSM1005840 / 16

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2 Technical description
2.1 Technical description........................................................................................................................................................2-2
2.1.1 Technical descriptions...................................................................................................................................................2-2
2.2 Technical specifications................................................................................................................................................... 2-4
2.2.1 Rotor specifications.......................................................................................................................................................2-4
2.2.2 Blade specifications...................................................................................................................................................... 2-4
2.2.3 Aerodynamic brake specifications.................................................................................................................................2-4
2.2.4 Load supporting parts in the nacelle............................................................................................................................. 2-4
2.2.5 Transmission system specifications..............................................................................................................................2-5
2.2.6 Mechanical brake specifications................................................................................................................................... 2-5
2.2.7 Generator specifications............................................................................................................................................... 2-5
2.2.8 Grid terminal specifications...........................................................................................................................................2-5
2.2.9 Canopy specifications................................................................................................................................................... 2-5
2.2.10 Yaw system specifications.......................................................................................................................................... 2-5
2.2.11 Controller specifications..............................................................................................................................................2-6
2.2.12 Tower specifications....................................................................................................................................................2-6
2.2.13 Operational data..........................................................................................................................................................2-6
2.2.14 Weight list....................................................................................................................................................................2-7
2.3 Components in the nacelle............................................................................................................................................... 2-8
2.3.1 Components in the nacelle............................................................................................................................................2-8

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2.1 Technical description
2.1.1 Technical descriptions

Rotor
The rotor is a 3 blade self-contained construction mounted upwind of the tower. The power limitation is
by pitch regulation. The rotor speed is variable to maximize aerodynamic efficiency and to reduce
loads on the gear system during power regulation
Blades
The blades are mounted on pitch bearings and can be pitched 82 for shutdown purposes. Each blade
has its own independent fail-safe pitching mechanism capable of pitching the blade under any
operating condition.
Hub
The rotor hub is cast in high-strength cast iron. The hub is fitted on the main shaft with a large flange.
It is sufficiently large to provide a comfortable working environment for 2 service technicians during
maintenance of blade roots and pitch bearings from inside the structure.
Main shaft
The main shaft is placed in the nacelle and is made of constructional alloy steel. The shaft is hollow to
allow for activation of the blade pitching system.
Main bearing
The main bearing is placed in the nacelle and absorbs the rotor thrust and reaction from gravity and
bending moments. It is a spherical roller bearing which is shrink fitted on the main shaft.
Main gear
The gearbox is mounted on the main shaft via a shrink disk connection and is mounted on the nacelle
with flexible rubber bushings, thereby reducing structural noise transfer. The gear is fitted with
temperature monitoring, oil pressure and vibration sensors. The gearbox is a custom-built 3-stage
industrial design. The first, high torque stage is a helical planetary design, providing a compact high-
performance construction. The intermediary and high-speed stages are helical providing the lowest
possible noise level.
Generator
The generator is a fully enclosed asynchronous generator. The generator has a squirrel-cage rotor
without slip-rings. The generator rotor construction and stator winding are designed for high efficiency
at partial loads. The generator is protected with thermal switches and analogue temperature
measurement sensors.
Generator cooling system
The generator is fitted with a ventilation system. The air is circulated internally in the generator via a
heat exchanger which efficiently keeps air temperature internally in the generator separate from the
ambient temperature.
Mechanical hydraulic system brake
The calipers and brake discs are placed on the high-speed shaft in the gearbox. The brake is a
positive-acting brake, which means that, when the brake is activated, hydraulic pressure is built up in
the caliper. The pressure for the brake pads is applied by a piston inside the caliper. When the brake
is released, the hydraulic pressure is relieved from the caliper. Only one hydraulic operating pressure
is used, and braking is therefore always done at full brake torque. The pressure increase will
nevertheless be generated more slowly when the idle brake is applied than when the service brake is
applied.

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Yaw system
The yaw bearing is an externally geared yaw plate sliding on grease lubricated elements which
function as a yaw brake. The yaw system is driven by 8 electric planetary gear motors.
Controller
The turbine controller is a microprocessor-based industrial controller with switch gear, protection
devices and a keyboard and display for easy read-out of status and for adjustment of settings. The
NetConverter system means that the turbine output for the MV transformer is of constant frequency
and voltage. The turbine can be adjusted for all presently existing grid codes. The NetConverter
system means that the turbine output for the MV transformer is of constant frequency and voltage. The
turbine can be adjusted for all presently existing grid codes.
Remote monitoring
The turbine has WebWPS (Wind Power Supervisor) SCADA (Supervisory Control and Data
Acquisition) through which the turbine can be monitored and controlled using a standard Internet
browser. In addition, the turbine has WebCMS monitoring which measures vibrations in the turbine
and compares these measurements to defined reference parameters.
Operation and safety systems
The turbine operates automatically and starts at a mean wind speed of approx. 3-5 m/s. The wind
turbine output increases roughly linearly with the wind speed until the wind reaches 13-14 m/s. Here
the output is limited to the nominal output. If the average wind speed exceeds the maximum limit for
operation of 25 m/s, pitching of the blades shuts down the turbine. When the wind speed drops below
the re-starting limit, the safety systems are reset automatically.

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2.2 Technical specifications
2.2.1 Rotor specifications

Specifications for a 3-bladed rotor with horizontal axis.
Rotor size
Specification
82 93 101 108
Type 3-bladed, horizontal 3-bladed, horizontal 3-bladed, horizontal axis 3-bladed, horizontal axis
axis axis
Position Upwind Upwind Upwind Upwind
Diameter 82.4 m 93 m 101 m 108 m
Swept area 5300 m 6800 m 8000 m 9144 m
Synchronous 6-16 rpm 6-16 rpm 6-18 rpm 6-16 rpm

rotor speed
Power regulation Pitch regulation with Pitch regulation with Pitch regulation with Pitch regulation with
variable speed variable speed variable speed variable speed
Rotor tilt 6 6 6 6
2.2.2 Blade specifications
Specification 82 93 101 108

Type Self-supporting Self-supporting Self-supporting Self-supporting
Blade length 40 m 45 m 49 m 52.6 m
Tip chord 0.8 m 0.8 m 0.8 m 0.5 m
Root chord 3.1 m 3.5 m 3.4 m 3.4 m
Aerodynamic NACA 63xxx / FFxxx NACA 63xxx / FFxxx NACA 63xxx / FFxxx Cxxxxx/SWP-xx/FFA-
profile xx/SWP-xxxx
Material GRE GRE GRE GRE
Surface gloss Semi-mat < 30 / ISO Semi-mat < 30 / ISO Semi-mat < 30 / ISO Semi-mat < 30 / ISO 2813
2813 2813 2813
Surface color Light gray RAL 7035 Light gray RAL 7035 Light gray RAL 7035 Light gray RAL 7035
2.2.3 Aerodynamic brake specifications
Type Full span pitching
Activation Active, hydraulic
2.2.4 Load supporting parts in the nacelle
Hub Nodular cast-iron
Main bearing Spherical roller bearing
Main shaft Alloy steel
Nacelle bed plate Steel

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2.2.5 Transmission system specifications
Coupling, hub / main shaft Flange
Coupling, main shaft / gearbox Shrink disc
Gearbox type Three-stage planetary / helical
Gearbox ratio 1:91
Gearbox lubrication Splash / forced lubrication
Oil volume Approx. 400 liters
Gearbox oil filtering Inline and offline
Gearbox cooling Separate oil cooler
Gearbox designation Winergy PEAB 4456 (Winergy)
Gearbox designation Hansen EH851
Coupling gear / generator Double flexible coupling
2.2.6 Mechanical brake specifications
Type Hydraulic disc brake
Position High speed shaft
No. of calipers 2
2.2.7 Generator specifications
Type Asynchronous
Nominal power 2.3 MW
Protection IP 54
Cooling Integrated heat exchanger
Insulation class F
2.2.8 Grid terminal specifications
Nominal power 2.3 MW
Voltage 690 V
Frequency 50 or 60 Hz
2.2.9 Canopy specifications
Type Totally enclosed
Material Steel
Surface gloss Semi gloss, 30-50, ISO 2813
Color Light gray, RAL 7035
2.2.10 Yaw system specifications
Type Active
Yaw bearing Externally geared slew ring
Yaw drive 8 electric gear motors with frequency converter
Yaw brake Passive friction brake

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2.2.11 Controller specifications
Type Microprocessor
Remote monitoring ADSL / VPN
Controller designation KK WTC - 3.0
Controller manufacturer KK Electronic A/S
2.2.12 Tower specifications
Type Cylindrical and / or tapered tubular
Hub height 80 m or site specific
Corrosion protection Painted
Surface gloss Semi gloss, 30-50 ISO 2813
Surface color Light gray, RAL 7035
2.2.13 Operational data
Cut-in wind speed 4 m/s
Cut-in wind speed (82 m) 3 - 5 m/s
Cut-in wind speed (108 m) 3 - 4 m/s
Nominal power at approx. 13 - 14 m/s
Nominal power at approx. (101) 12 - 13 m/s
Nominal power at approx. (108) 11 - 12 m/s
Cut-out wind speed 25 m/s
Max. 3 sec. gust 55 m/s (standard version)
Max. 3 sec. gust (108) 59.5 m/s (IEC version)
Turbine (93 m) and (101) 59.5 m/s (IEC version)
Turbine (82 m) 70 m/s (IEC version)

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2.2.14 Weight list

The weights given are approximate.
Nacelle, blades, hub, and rotor

Nacelle 82,000 kg
Blade B 40 m (3 blades) 27,600 kg
Hub with bolts 28,000 kg
Rotor including B 40 m blades 54,000 kg
Various Parts
Generator 7,000 kg
Gear with disc and calipers 23,400 kg
Gear with disc and calipers (type: Flender) 22,500 kg
Gear with disc and calipers (type: Hansen) 23,500 kg
Main shaft with bearings 16,000 kg
B 45 blade incl. thread rods (1 blade) 11,400 kg
B 45-01 blade incl. thread rods (1 blade) 10,600 kg
Nacelle transportation frame 5,000 kg
Blade bolts (3 bolts) 1,000 kg
Controller A4 500 kg
Yaw motor / gear complete 200 kg
In-line filter element (215 kg) 150 kg + 75 liters of oil
Pitch cylinder 68 kg
Accumulator 57 kg
Accumulator / pump station 56 kg
Cables in tower 25 kg/m
Power unit
Power unit stand 3,000 kg
Frequency converter (A12) 1,000 kg
Coil (A14) 1,800 kg
Filter board (A11) 300 kg
Controller (A2) 400 kg
Controller / Wps 800 kg
Total weight 7,300 kg

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2.3 Components in the nacelle
2.3.1 Components in the nacelle
Position Component
(1) Spinner
(2) Rotor hub
(3) Blade
(4) Blade bearing
(5) Pitch system
(6) Main bearing
(7) Main shaft
(8) Top control box
(9) Main gear
(10) Disc brake
(11) Brake Caliper
(12) Coupling
(13) Generator with integrated cooling system
(14) Meteorological sensors
(15) Yaw ring

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Position Component
(16) Yaw gear wheel
(17) Yaw gear
(18) Bed plate
(19) Nacelle cover
(20) Hydraulics with integrated collecting tray
(21) Gear oil collecting tray
(22) Gear oil cooler
(23) Hydraulic oil cooler

ZSM1005840 / 16

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3 Inspection and maintenance program

3.1 Service intervals................................................................................................................................................................ 3-2
3.2 Service definitions.............................................................................................................................................................3-3
3.2.1 Service time-line definitions.......................................................................................................................................... 3-3
3.2.2 Service checklists..........................................................................................................................................................3-3
3.2.3 List of work instructions.................................................................................................................................................3-4
3.3 Turbine mounted safety equipment and lifting equipment inspections...................................................................... 3-5
3.3.1 Carrying out turbine-mounted safety equipment and lifting equipment inspections......................................................3-5
3.3.2 Competent person.........................................................................................................................................................3-5
3.3.3 Checklists and work instructions...................................................................................................................................3-5
3.3.4 Measurements.............................................................................................................................................................. 3-5
3.3.5 Safety and environment................................................................................................................................................ 3-5
3.3.6 Statutory inspections.....................................................................................................................................................3-5
3.4 Handling of standstill turbines with no power................................................................................................................3-6

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3.1 Service intervals

The turbines are serviced according to specific service checklists defined for each service interval.
Service intervals
500 hours service
12 months service
Annual service (from year 2 to 19)

ZSM1005840 / 16
3.2 Service definitions
3.2.1 Service time-line definitions
500 hours maintenance:
Module Earliest time to perform Must be completed no later than Comments

(hours) (hours)
Bolt 250 2000 Hours are counted only if the

Service 250 2000 generator is connected to the grid
12 months and subsequent annual maintenance:
Module Earliest time to perform Must be completed no later than
Bolt 3 months after previous Bolt module 13 months after previous Bolt module
Service 3 months after previous Service module 13 months after previous Service module
3.2.2 Service checklists

The following checklists are to be used for scheduled inspection and maintenance:
Period Service module checklist Bolt inspection module (Optional) De-icing module
checklist checklist
500 hours ZCH1009384 ZCH1009380
12 months ZCH1037583 ZCH1038778 ZCH1039748
Year 2 ZCH1037584 ZCH1038779 ZCH1039749
Year 3 ZCH1037586 ZCH1038780 ZCH1039749
Year 4 ZCH1037587 ZCH1038781 ZCH1039749
Year 5 ZCH1037588 ZCH1038782 ZCH1039749
Year 6 ZCH1037589 ZCH1038783 ZCH1039749
Year 7 ZCH1037590 ZCH1038784 ZCH1039749
Year 8 ZCH1037591 ZCH1038785 ZCH1039749
Year 9 ZCH1037592 ZCH1038786 ZCH1039749
Year 10 ZCH1037593 ZCH1038787 ZCH1039750
Year 11 ZCH1037594 ZCH1038788 ZCH1039749
Year 12 ZCH1037595 ZCH1038789 ZCH1039749
Year 13 ZCH1037596 ZCH1038790 ZCH1039749
Year 14 ZCH1037597 ZCH1038791 ZCH1039749
Year 15 ZCH1037598 ZCH1038792 ZCH1039749
Year 16 ZCH1037599 ZCH1038793 ZCH1039749
Year 17 ZCH1037600 ZCH1038794 ZCH1039749
Year 18 ZCH1037601 ZCH1038795 ZCH1039749
Year 19 ZCH1037602 ZCH1038796 ZCH1039749
Please check Wind Turbine Documentation\Service on Workspace to find relevant checklists for
Statutory check,lifting instructions and TMSE documentation for the service visit or request relevant
documentation for your service visit from your usual contact person in Siemens Wind Power.

ZSM1005840 / 16
3.2.3 List of work instructions
Title of work instruction Work instruction number

Access to blade ZWI1001712
Adjusting the yaw position indicator by use of GPS ZWI1020784
Aligning and adjusting the generator with fixture laser ZWI566637
Alignment and adjustment of generator with dial gauge ZWI1004240
Bolt tightening by Tensioner ZWI544243
Change of gear oil ZWI1002351
Extraction of gear oil sample ZWI524866
Extraction of hydraulic oil sample ZWI1003658
Gear inspection ZWI1010663
Lock out of main circuit breaker ZWI1026419
Mounting of turning gear ZWI549498
Operation of covers and crane without hydraulic pump ZWI1004273

pressure
Replacement of yaw gear oil ZWI1002353
Replacement of brake pads on HS brake ZWI1017103
Replacement of lightning cards and inspection after lightning WI535403

stroke
Service work instruction for service crane ZWI1021733

ZSM1005840 / 16
3.3 Turbine mounted safety equipment and lifting equipment

inspections
3.3.1 Carrying out turbine-mounted safety equipment and lifting equipment

inspections
Work instructions and checklists for turbine-mounted safety equipment (TMSE) and lifting equipment
inspections can be found on Workspace at Internal Wind Turbine Documentation (IWTD) in the folders
"TMSE" and "Lifting Equipment". All inspections applicable to the turbine being serviced should be
completed at 12 months, annual, and five-year service cycles.
3.3.2 Competent person

Competent persons must have successfully completed the training required for the specific inspection
they are to complete. This information can be found in the document "TMSE and Lifting Equipment
Overview" available at Workspace > IWTD > Service in either the "TMSE" or "Lifting Equipment"
folders. Competent persons must be able to document their qualifications. If you doubt whether you
are competent to carry out the statutory inspection, contact the person who is responsible for the site.
3.3.3 Checklists and work instructions

All checklists and work instructions are aligned and approved by the corresponding manufacturers.
They are component-specific and therefore valid for all turbines with the installed equipment. It is the
responsibility of the person who performs the inspection to use the latest and most recently updated
version of the ZWI and ZCH found on IWTD. Where specific torque settings are needed, they are
stated in the work instruction. Where no torque settings are stated, use the general torque settings
found in the Service Manual chapter Bolt Tightening. Pictures and drawings provided are examples.
There can be variations in different turbine types. The position of safety equipment in the turbine
depends on the turbine type. The specific positions of the safety equipment can be found in the
Turbine Safety Booklet.
The checklists must be completed and signed by the technician who performs the inspection, and a
permanent marker should be used for signing labels. When the checklists are complete, they must be
delivered to the person who is responsible for the site. This person must be notified if any component
fails its inspection such that further action can be taken.
The person who is responsible for the site must store the checklists in a secure location on-site during
the turbine's lifetime according to the site instructions (FORM 09.23 Onshore & FORM 09.24
Offshore).
The signed checklists must be available either in electronic copy or in hard copy.
3.3.4 Measurements
All measurements are given in SI units.
3.3.5 Safety and environment

The general safety and environmental instructions for service and installation work SI545781 Basic
health and safety rules for technicians working in Siemens Wind Turbines must always be followed.
3.3.6 Statutory inspections

The TMSE and lifting equipment inspections do not always meet local legal requirements.
The TMSE and lifting equipment inspections can be used in many cases to replace or reduce the
scope for statutory inspections but this is dependent on the local legal requirements and restrictions
within the area. The regional EHS will provide guidance where needed on local regulations.

ZSM1005840 / 16
3.4 Handling of standstill turbines with no power

Please refer to the following documents available on Workspace > IWTD > Service
ZWI:
ZWI1034214 Handling of standstill turbines with no power
ZCH:
ZCH1034884 12 months grid outage procedure
ZCH1034883 6 months grid outage procedure
ZCH1034791 KK cabinets standstill
ZCH1034788 Preparation for standstill period
ZCH1034790 Preparation for start-up
ZCH1034789 Service interval for standstill

ZSM1005840 / 16
4 Bolt tightening
4 Bolt tightening
4.1 Bolt tightening general......................................................................................................................................................4-3
4.1.1 Bolt tightening in general...............................................................................................................................................4-3
4.1.2 Bolt types...................................................................................................................................................................... 4-4
4.1.3 Bolt definitions...............................................................................................................................................................4-6
4.1.4 Replacement of main components................................................................................................................................4-8
4.1.5 Two-stage bolt tightening..............................................................................................................................................4-8
4.1.6 Lubrication of bolts........................................................................................................................................................4-9
4.1.7 Procedure for lubrication of foundation bolts...............................................................................................................4-11
4.1.8 Bolt inspection procedures .........................................................................................................................................4-11
4.1.9 Approved tightening tools............................................................................................................................................4-12
4.1.10 Using hydraulic tightening tools................................................................................................................................ 4-12
4.1.11 Bolt tightening - standard values...............................................................................................................................4-13
4.2 Torque values.................................................................................................................................................................. 4-14
4.2.1 Torques for hydraulic fittings.......................................................................................................................................4-14
4.2.2 Torques for fittings BSP.............................................................................................................................................. 4-15
4.2.3 Torques for fittings O-lock...........................................................................................................................................4-16
4.2.4 Torques for fittings JIC unions.................................................................................................................................... 4-17
4.2.5 Torques for bolts......................................................................................................................................................... 4-18
4.2.6 Tightening torques in controller...................................................................................................................................4-19
4.2.7 Tightening torques in converteam converter...............................................................................................................4-20
4.2.8 Tightening torques in ABB converter.......................................................................................................................... 4-20
4.3 Specific values in the hub...............................................................................................................................................4-21
4.3.1 H10 Blade- Blade bearing...........................................................................................................................................4-21
4.3.2 H20 Blade - Hub bearing.............................................................................................................................................4-21
4.3.3 H30 Hub - Spinner plate .............................................................................................................................................4-21
4.3.4 H31 Spinner bracket - Reinforcement plate ...............................................................................................................4-22
4.3.5 H32 Spinner plate - Nose cone...................................................................................................................................4-22
4.3.6 H33 Hub cabinet (A6) - Spinner plate / console .........................................................................................................4-22
4.3.7 H34 (SWT-2.3-82VS/93) Covers in nose cone........................................................................................................... 4-23
4.3.8 H34 (SWT-2.3-101/108) Covers in spinner.................................................................................................................4-23
4.3.9 H40 Distance block for pitch cylinder - Blade bearing ................................................................................................4-23
4.3.10 H41 Plate for pitch cylinder - Blade bearing .............................................................................................................4-24
4.3.11 H42 (SWT-2.3-82VS/93) Mounting plate - Root bracket, PUR bushings .................................................................4-24
4.3.12 H42 (SWT-2.3-101/108) Mounting plate - Root bracket, PUR bushings...................................................................4-24
4.3.13 H43 (SWT-2.3-82VS/93) Mounting plate - Root bracket, mounted rigidly ............................................................... 4-25
4.3.14 H44 (SWT-2.3-82VS/93) Accumulator brackets....................................................................................................... 4-25
4.3.15 H44 (SWT-2.3-101/108) Accumulator brackets........................................................................................................ 4-25
4.3.16 H45 (SWT-2.3-82VS/93) Blade block for hydraulic pitch.......................................................................................... 4-26
4.3.17 H45 (SWT-2.3-101/108) Blade block for hydraulic pitch........................................................................................... 4-26
4.3.18 H46 (SWT-2.3-101/108) Plate for blade block - beam for accumulator rack............................................................ 4-26
4.3.19 H47 (SWT-2.3-101/108) Beam for accumulator rack - accumulator brackets.......................................................... 4-27
4.3.20 H48 (SWT-2.3-101/108) Root bracket (PUR) .......................................................................................................... 4-27
4.3.21 H50 Pitch lock........................................................................................................................................................... 4-27
4.3.22 H51 (SWT-2.3-82VS/93) Manual pitch lock ............................................................................................................. 4-28
4.4 Specific values in the nacelle.........................................................................................................................................4-29
4.4.1 A10 Canopy - maintenance crane ..............................................................................................................................4-29
4.4.2 A11 Warning lights - canopy top cover....................................................................................................................... 4-29
4.4.3 A12 Wind vane and anemometer ...............................................................................................................................4-29
4.4.4 A13 Wind vane stand..................................................................................................................................................4-30
4.4.5 A17 A4 KG18 alu terminal/Bolts in copper bus bar ....................................................................................................4-30
4.4.6 A18 Terminals on generator (ABB).............................................................................................................................4-30
4.4.7 N10 Hub - main shaft ................................................................................................................................................. 4-31
4.4.8 N20 Main bearing housing - bed frame.......................................................................................................................4-31
4.4.9 N21 Main bearing housing - bed frame (front) ........................................................................................................... 4-31
4.4.10 N22 Main bearing housing - bearing cover (rear) .................................................................................................... 4-32
4.4.11 N23 Clamping ring - main shaft.................................................................................................................................4-32
4.4.12 N24 Bearing cover - seal ring (front /rear).................................................................................................................4-32
4.4.13 N25 Labyrinth ring (option) .......................................................................................................................................4-33
4.4.14 N30 Gear support - bed frame ................................................................................................................................. 4-33

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4 Bolt tightening
4.4.15 N31 Caliper plate-Gearbox ...................................................................................................................................... 4-33

4.4.16 N32 Shrink disc - low speed .....................................................................................................................................4-34
4.4.17 N33 Shrink disc - high speed.................................................................................................................................... 4-34
4.4.18 N40 Yaw clamp - bed frame .....................................................................................................................................4-34
4.4.19 N41 Yaw clamp adjusting bolts (vertical) ................................................................................................................. 4-35
4.4.20 N42 Yaw clamp adjusting bolts (horizontal) .............................................................................................................4-35
4.4.21 N50 Bed frame - canopy brackets (front)..................................................................................................................4-35
4.4.22 N51 Bed frame - canopy brackets (rear) ..................................................................................................................4-36
4.4.23 N52 Canopy brackets - canopy (front)...................................................................................................................... 4-36
4.4.24 N53 Canopy brackets - canopy (rear) ......................................................................................................................4-36
4.4.25 N54 Cover for canopy bracket ................................................................................................................................. 4-37
4.4.26 N55 Hatch - canopy hinges ......................................................................................................................................4-37
4.4.27 N56 Canopy - canopy top cover................................................................................................................................4-37
4.4.28 N57 Canopy - canopy rear end ................................................................................................................................4-38
4.4.29 N58 Cylinder bracket - hatch ....................................................................................................................................4-38
4.4.30 N60 Yaw gear - bed frame .......................................................................................................................................4-38
4.4.31 N71 Generator feet - generator.................................................................................................................................4-39
4.4.32 N72 Coupling - generator to gearbox .......................................................................................................................4-39
4.4.33 N73 Brake calliper - calliper plate ............................................................................................................................ 4-39
4.4.34 N74 High speed Centrifugal Unit (HCU)................................................................................................................... 4-40
4.4.35 N75 Generator beam - reinforcement bar.................................................................................................................4-40
4.4.36 N76 Cable bracket for generator cables .................................................................................................................. 4-40
4.4.37 N77 Generator spacing plate ................................................................................................................................... 4-41
4.4.38 N80 Hydraulic stand..................................................................................................................................................4-41
4.5 Specific value for the tower............................................................................................................................................4-42
4.5.1 T10 Tower top flange - Yaw ring ................................................................................................................................4-42
4.5.2 T20 Tower / Tower (L-flange)......................................................................................................................................4-42
4.5.3 T30 Foundation bolts (T-flange) .................................................................................................................................4-43
4.5.4 T50 Tower damper .....................................................................................................................................................4-43
4.5.5 T60 Platforms .............................................................................................................................................................4-43
4.5.6 T62 Cable cleat...........................................................................................................................................................4-44

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4 Bolt tightening
4.1 Bolt tightening general
4.1.1 Bolt tightening in general

The bolts in wind turbines are tightened to specific values. Overtightening may cause the bolts to
break during tightening or during operation of the turbine. Undertightening may cause the bolts to
come loose during operation of the turbine. If the procedures described in this chapter are followed, it
is safe to operate the tools, and bolts will last the entire lifetime of the turbine. If the procedures are not
followed, it can cause serious injury to personnel, and the bolts may break during tightening or during
operation.

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4 Bolt tightening
4.1.2 Bolt types

Table 4.1.2.1 Bolt specification table
Type ISO HV Stainless
Property class 8.8 10.9 12.9 10.9 70 80
Marking Bolt 8.8 10.9 12.9 10.9 70 80
Nut 8 10 12 10 70 80
Washer No marking HV
Standard Bolt ISO 4014 EN14399-4
ISO 4017
Nut ISO 4032 EN14399-4
Washer ISO 7090 EN14399-6
Width across Normal Large Normal

flats
Lubrication Yes, on friction surfaces No, but if an HV bolt Yes, on friction surfaces
is loosened, it must
be relubricated with
Never-Seez before
tightening
Threadlocker If specified in work instruction No If specified in work

instruction
Assembly 8.8: Washer on friction surfaces Always 2 washers. Always 2 washers. Nut
marking visible
10.9: Always 2 washers. Nut marking visible Face the chamfered
side of the washer
towards the bolt
head / nut. Nut
marking visible
Reuse Yes, but relubricate Yes, but relubricate Yes, but relubricate
Property class
Normal steel bolts are of property class 8.8/10.9/12.9, which describes the strength of the bolt. 8.8
is the weakest and 12.9 is the strongest. Stainless steel bolts are of property class 70/80. 70 is the
weakest and 80 is the strongest.
Marking
The property class is stamped into the bolt head and nut. Most bolts also have information about
manufacturer and batch number.
The following information can be found on a bolt head:
8.8 - property class 8.8
10.9 - property class 10.9
HV - indicating an HV type
A2-70 - Stainless steel grade A2 - Property class 70
A4-70 - Stainless steel grade A4 (acid proof) - Property class 70
The following information can be found on a nut:
8 - property class 8
10 - property class 10
The following information can be found on a washer
Manufacturer identification

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4 Bolt tightening
Standard
Relevant standard for the individual bolt types, see "Bolt specification" table.
Width across flats
ISO bolts and nuts have standard widths across flats.
HV bolts and nuts have large widths across flats.
Always use HV nuts and washers with HV bolts. HV nuts are pre-lubricated, see the chapter
Lubrication.
Never mix HV and ISO products.

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4 Bolt tightening
4.1.3 Bolt definitions

Bolted joints
Two or more parts clamped together with bolts.
Tighten
The term tighten refers to the use of both torque and tension tools. Tighten means to apply the
tool, adjusted to the correct pressure or setting, on the bolt or the nut. When tightening procedures
are being performed, it is important to observe if there is relative movement between the bolt and
the nut. If the bolt is mounted in a threaded hole, movement must be observed between the bolt
head and the surface underneath the bolt head. If movement is observed, the bolt is loose and the
whole joint must be retightened.
Figure 4.1.3.1 Tightening with torque tool (Nm)
Figure 4.1.3.2 Tightening with tension tool (kN)
Loose bolt
A bolt is loose if the nut can be rotated relative to the bolt by performing a tightening procedure. If
the bolt is mounted in a threaded hole, it is loose if the bolt head can be rotated by performing a
tightening procedure. If one bolt in a joint is loose, the whole joint must be retightened.

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4 Bolt tightening
Nut standoff
The length of thread from the nut to the end of the bolt. When torquing, the nut standoff must as a
minimum be 1xP, where P is the pitch of the thread.
Nut standoff when torquing = minimum
1xP, where P is the pitch of the thread
Figure 4.1.3.3 Nut standoff
Torque tool
A calibrated tool that can tighten a bolt by applying a torque.
The torque tool can be either a manually operated torque wrench or a hydraulic powered torque
wrench.
Tension tool
A calibrated tool that can tighten a bolt by applying a force. See AI-WI 544243.
Length of engagement when tensioning: The length of engagement is the length of the thread and
the bolt and the bushing respectively in the tension tool which are engaged with each other.
When a tension tool is used, the length of engagement between the tension tool and the bolt must
as minimum be 0.8 x bolt diameter. The length of engagement is measured by letting the bushing
of the tension tool rest on the bolt and then measuring the length of engagement as the distance
between the bottom edge of the tool and the surface into which the bolt is tightened.
Length of engagement when
tensioning = 0.8 x the bolt diameter
Figure 4.1.3.4 Tension tool

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4 Bolt tightening
4.1.4 Replacement of main components

After main component replacement, or if all the bolts in a joint are loosened, all bolts in the joint must
be tightened as when first assembled.
After 500 hours of operation, the component must be serviced according to the checklist for 500-hours
service after main component replacement.
Thereafter, the component follows the standard service intervals matching the rest of the turbine.
4.1.5 Two-stage bolt tightening

Two-stage bolt tightening is done on some of the bolt connections at first assembly. This is done to
minimize the need for retightening the bolt connection.
If a bolt or a whole bolt connection which has been tightened in two stages at first assembly is
loosened, it must be tightened in two stages when tightened again.
It is stated in the chapter "Bolt tightening - specific values" if a bolt connection has to be tightened in
two stages.
Two-stage bolt tightening is done the following way:
1. Mount all bolts in the joint either finger tight or with a power tool that delivers no more than
maximum 50% of the final torque.
2. Tighten all bolts 75% of the final torque. For circular bolted joints, cross-tighten if possible. A
deviation of +- 10% is allowed.
3. Tighten all bolts 100% of the final torque. For circular bolted joints, cross-tighten if possible.
Torque deviation as defined by the SWP calibration department. No waiting time is required
between steps 2 and 3.
When using tensioner for two-stage bolt tightening, the force should not be reduced to 75% the first
time, but be 100% both times.
The standard torque values and corresponding 75% torque values can be seen in the table below.
Table 4.1.5.2 Standard torque values and corresponding 75% torque values
Bolt type Hot-dip galvanized Stainless bolts, and bolts
mounted in aluminum
Property class 8.8 10.9 All property classes
Size 100% torque 75% torque 100% torque 75% torque 100% torque 75% torque
(Nm) (Nm) (Nm) (Nm) (Nm) (Nm)
M6 9 - 13 - 6 5
M8 21 16 30 23 14 11
M10 42 32 60 45 29 22
M12 75 56 100 75 52 39
M16 175 131 250 188 125 94
M20 350 263 450 338 250 188
M24 600 450 800 600 425 319
M30 1150 863 1650 1238 800 600
M33 1550 1163 2200 1650 - -
M36 2000 1500 2800 2100 - -
M42 3200 2400 4500 3375 - -
M48 4700 3525 6500 4875 - -
M56 - - 10000 7500 - -
M64 - - 15000 11250 - -

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4 Bolt tightening
4.1.6 Lubrication of bolts

The purpose of lubrication is to achieve a high and equal pretension in all the bolts in a joint. It is
important to lubricate all the bolts in a joint evenly and alike.
On black bolts like foundation bolts, the lubrication is also used as corrosion protection.
All foundation bolts must be lubricated every year with Never-Seez. If any corrosion is present, use a
wire brush to remove it, before adding new Never-Seez.
If corrosion on nuts has developed to a serious grade, they must be replaced and lubricated. Check
that all caps are in place. replace if missing.
The different bolt types must be lubricated in the following way:
Hot-dip galvanized bolts must be lubricated with Never-Seez.
Stainless bolts must be lubricated with Anti-Bloc.
Bolts tightened into aluminum must be lubricated with oil.
HV bolts have prelubricated nuts and must not be lubricated further. If an HV bolt is loosened, it
must be relubricated with Never-Seez before tightening.
Bolts must be lubricated on the thread of the bolt and under the moving part. As a rule, the bolt
assembly must be tightened by rotating the nut, and lubrication is therefore also required under the
nut.
Grease-based lubricants such as Never-Seez and Anti-Bloc must be applied in an even coat with a
brush. They must cover the entire surface of friction.
(1) On the thread
(2) Under the nut
Figure 4.1.6.5 Hot-dip galvanized bolt and nut (tZn)
Hot-dip galvanized bolt lubrication on the thread and under the nut.
If a bolt is mounted into a threaded hole or if tightening on the nut is impossible, the bolt must be
lubricated under the bolt head and tightened on the bolt head.

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4 Bolt tightening
(1) Under the bolt

(2) On the thread
Figure 4.1.6.6 Hot-dip galvanized bolt (tZn)
Hot-dip galvanized bolt lubricated under the bolt head and on the thread.
Threadlocker
Sometimes threadlocker (for example Loctite or Holdtite) is applied to the bolts before assembly.
This is normally only done in the production. If threadlocker is used, lubrication is not allowed.
Assembly
Match property classes of bolts and nuts:
8.8 bolt with class 8 nut
10.9 bolt with class 10 nut
HV bolts, nuts, and washers must be from the same manufacturer. The manufacturer name is
clearly marked on HV bolts, nuts, and washers. It is not allowed to fit a bolt with a nut or washer
from a different manufacturer.
HV washers are chamfered on one side. The chamfered side of the washer must face towards the
bolt head and the nut.
For galvanized bolts greater or equal to M22 with a property class of 10.9 or larger, HV washers
must always be used.
Reuse
If a bolt has been tightened with a torque tool and then loosened, it can be tightened again if it is
relubricated on the thread and under the moving part.
If an HV bolt is loosened, it must be relubricated with Never-Seez before tightening.
Bolts, nuts, and washers with visible damage must be discarded and replaced with new ones.
Locknuts
If a hot dip galvanized bolt (tZn) is fitted with a locknut, it must be tightened as a hot-dip galvanized
bolt (tZn) and lubricated with Never-Seez.
Bolt extensions
Bolt extensions are used for achieving the right proportion between bolt diameter and grip length.
A bolt extension must be placed under the washer under the bolt head.

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4 Bolt tightening
4.1.7 Procedure for lubrication of foundation bolts

All foundation bolts and nuts must be lubricated every year with Never-Seez.
Procedure:
1 Check for corrosion on foundation bolts and nuts.
(If corrosion is found, it must be removed with a wire brush before applying Never-Seez.)
2 Check that the corrosion on the foundation bolts and nuts has not resulted in a seriously reduced
strength quality.
(If the corrosion on the foundation bolts or nuts is serious, the corroded bolts and nuts must be
replaced and the new ones lubricated.)
3 Check that all rubber caps on the bolts are in place.
4.1.8 Bolt inspection procedures

The service program specifies various types of service procedures depending on which service is
being performed. The service procedures include the following:
Tighten all bolts
All bolts in the joint must be tightened.
Tighten every Xth bolt
For example, tighten every third bolt. The specified fraction of the bolts must be tightened. If one of
the bolts in the joint is loose, all the bolts in the joint must be tightened.
(1) Tighten every third bolt
Figure 4.1.8.7 Example of tightening sequence
Visual inspection
Visual inspection is performed by grasping the number of bolts defined in the checklist to ensure
that the bolts are not broken.
Figure 4.1.8.8 Visual inspection

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4 Bolt tightening
4.1.9 Approved tightening tools

A tool is approved for use if it carries a calibration mark.
Figure 4.1.9.9 Example of calibration mark
Tools without a calibration mark must not be used.

Pumps and tightening tools of the same make must be used. For example, a Hytorc pump must not be
used together with a Plarad tightening tool. This applies even if the components have been individually
approved and carry calibration marks.
Calibration of tightening tools and hydraulic pumps
Torque tools and pumps must be calibrated according to calibration department specifications.
This is usually every six months. The equipment is marked with the calibration due date and the
date must be checked before use. If the calibration date is overdue or the calibration label is
missing, do not use the equipment.
Tension tools must be calibrated before a maximum number of cycles. The maximum number of
cycles varies from 2,000 to 8,000 depending on the tool and is written on the counter on the tool.
Check that the cycle counter is working and below the maximum number of cycles before use.
Check of hoses on tools
Hydraulic hoses must be checked, according to calibration department specifications, at least
every six months. The equipment is marked with the check due date, and this date must be
checked before use. If the check date is overdue or the label is missing, do not use the equipment.
4.1.10 Using hydraulic tightening tools

The following steps are only intended as a guide. For a more thorough explanation, consult the
relevant work instructions on the subject.
Procedure:
1 Find the joint in the specific tightening values table.
If in doubt, check the joint ID number and graphics.
2 Find the size, type, and property class of the bolt in the turbine, and check that it is the same in
the table.
3 Find the tension or torque value for the tool, and decide which tool to use.
4 Find the calibration certificate for the tool, and check that the tool ID matches.
5 Read the pressure, and adjust the hydraulic pump.
6 Tighten the bolts.
7 Check regularly throughout the tightening process that the pressure is correct.

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4 Bolt tightening
4.1.11 Bolt tightening - standard values

When tightening with the torque tool, use the values below. In special cases, other values must be
used. These values are stated in the tables "Bolt tightening - specific values".
Table 4.1.11.3 Bolt tightening standard values

Stainless Width across flats
bolts and
Bolt type Hot-dip galvanized bolts
tightened into
aluminum
8.8 10.9 All property
Property class Normal Large
classes
Size Nm Nm Nm mm mm
M6 9 13 6 10 -
M8 21 30 14 13 -
M10 42 60 29 16 -
M12 75 100 52 18 -
M16 175 250 125 24 27
M20 350 450 250 30 32
M24 600 800 425 36 41
M30 1150 1650 800 46 50
M33 1550 2200 50
M36 2000 2800 55 60
M42 3200 4500 65 70
M48 4700 6500 75 80
M56 - 10000 - 85 90
M64 - 15000 - 95 100
Tensioning: When tightening with the tension tool, always use the tightening values from Bolt
tightening - specific values.

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4 Bolt tightening
4.2 Torque values
4.2.1 Torques for hydraulic fittings

Lubricate and torque tighten hydraulics fittings according to specifications.
Make sure to use the necessary safety equipment when working with gear / hydraulic oil. Avoid to
introduce dirt into hydraulic components and gearbox bearings.
Note:
NOTICE
Wear personal safety equipment
Keep the work area clean to avoid getting dirt on the fittings.
Keep hoses and fittings plugged when they are not being used.
Torques for gear oil flanges, fittings and cooler
Gear oil flanges - cooler

Gear oil flanges (steel) Water cooler clips
(aluminum)
Nm Nm Nm
65 75 20
Torques for valves :
SWT-2.3-82 VS SWT-2.3-93 SWT-2.3-101 SWT-2.3-108

Position
Nm Nm Nm Nm
101 80 80 80 80
102 15.5 (M6 x 40) 15.5 (M6 x 40) 15.5 (M6 x 40) 15.5 (M6 x 40)
103 40 40 50 50
107 35 35 35 35
108 22 (M8 x 60) 22 (M8 x 60) 22 (M8 x 60) 22 (M8 x 60)
109 10 (M6 x 90) 50 50 50
116 9.3 (M6 x 65) 40 40 40
117 10 (M6 x 30) 10 (M6 x 30) 10 (M6 x 30) 10 (M6 x 30)
119 10 (M6 x 90) 50 50 50
120 9.3 (M6 x 70) 60 90 90
130 - 5.4 (M5 x 45) 5.4 (M5 x 45) 5.4 (M5 x 45)
Accumulator bleed valve: 25 - 30 Nm
Note: Always lubricate fittings with the same type of oil as used in the system (lubricate thread, cone/
bearing surface and union nut)

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4 Bolt tightening
4.2.2 Torques for fittings BSP

Note: Always clean and lubricate the fittings before assembly with the same type of oil as is used in
the system. Lubricate thread, cone/contact face, and union. Fittings must always be lubricated with the
same oil as the one flowing through them (lubricate the thread, cone/contact face, and union).
(1) Thread of BSP
Torques for RG/BSP fittings in blocks

Thread size of fittings Outside diameter of the Tightening torque in
Tightening torque in steel
RG/BSP thread aluminum
inches mm Nm Nm
1/8 9.7 18 14.4
1/4 13.1 35 28
3/8 16.6 70 56
20.9 90 72
3/4 26.4 180 144
1 33.2 310 248
1 1/4 41.9 450 360
1 47.8 540 432
2 59.6 680 500
Torques for RG/BSP VSTI plugs in blocks

Thread size of fittings Outside diameter of the Tightening torque in
Tightening torque in steel
RG/BSP thread aluminum
inches mm Nm Nm
1/8 9.7 13 13
1/4 13.1 30 28
3/8 16.6 60 56
20.9 80 72
3/4 26.4 140 140
Torques for BSP unions on hoses and fittings

Outside diameter of the Wrench openings for Tightening torque in
Thread size of fittings BSP
thread unions aluminum
inches mm mm Nm
1/4 13.1 19 25
3/8 16.6 22 50
20.9 27 70

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4 Bolt tightening
Torques for BSP unions on hoses and fittings

Outside diameter of the Wrench openings for Tightening torque in
Thread size of fittings BSP
thread unions aluminum
inches mm mm Nm
3/4 26.4 32 110
1 33.2 41 140
1 1/4 41.9 50 200
1 48 57 300
4.2.3 Torques for fittings O-lock

Note: Always clean and lubricate the fittings before assembly with the same type of oil as is used in
the system. (Lubricate thread, cone/contact face, and union.) Fittings must always be lubricated with
the same oil as the one flowing through them (lubricate the thread, cone/contact face, and union).
(1) O-lock
Torques for O-lock unions on hoses, fittings, and pipes

Outside diameter of the Wrench openings for
Thread size Tightening torque
thread unions
inches mm mm Nm
9/16 UNF 14.3 17 20
11/16 UNF 17.5 22 50
13/16 UNF 20.7 24 65
1 UNF 25.4 30 80
1 3/16 UNF 30.2 36 115
1 7/16 UNF 36.6 41 170
1 11/16 UNF 42.7 50 250
2 UNF 50.8 60 300

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4 Bolt tightening
4.2.4 Torques for fittings JIC unions

Always clean and lubricate the fittings before assembly with the same type of oil as is used in the
system. (Lubricate thread, cone/contact face, and union.) Fittings must always be lubricated with the
same oil as the one flowing through them (lubricate the thread, cone/contact face, and union).
(1) JIC unions
Figure 4.2.4.12 Tightening torques for JIC unions
Torques for JIC unions on hoses, fittings, and pipes

thread unions
inches mm mm Nm
7/16 JIC 11.1 14 - 17 25
9/16 JIC 14.3 19 35
3/4 JIC 19 22 - 24 55
7/8 JIC 22.2 25.4 - 27 75
1 1/16 JIC 27 32 110
1 5/16 JIC 33.3 38 - 41 175
1 7/8JIC 47.6 55 - 60 340
2 1/4 JIC 57.1 65 380
2 JIC 63.5 75 450
Torques for stainless JIC unions

thread unions
inches mm mm Nm
3/4 JIC 19 22 - 24 60
7/8 JIC 22.2 25.4 - 27 100
1 1/16 JIC 27 32 150

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4 Bolt tightening
4.2.5 Torques for bolts
Torques for bolts (metric thread) in blocks

Bolts Tightening torque in steel Tightening torque in aluminum
8.8 and stainless Nm Nm
M4 2.9 2.3
M5 5.7 4.6
M6 9.8 7.8
M8 21 19
M10 42 38
M12 75 65
M14 100 100
M16 175 158

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4 Bolt tightening
4.2.6 Tightening torques in controller

Important: For working in the turbine the "Basic Health and Safety Rules" must be followed.
Pull test
Avoid over tightening the terminal screws, by pulling at the individual wires to check that they are
properly fixed. Check visually for blue discoloration of bolts, cable lugs and bus bars. These
torques must be applied unless otherwise specified in the work instruction.
Components Thread Torque Relay

Nm Nm
Bolt M5 5
Bolt / Insulator M6 8
Bolt M14 86
Bolt M16 129
Insulator M16 80
Mounting plate bolt - Eldon / Hva M8 12
Cubic busbar nut piece M10 40
Cubic busbar holder - bolt M8 20
KG18 (alu terminal) M10 40
Bolt / bolt terminal 95 mm M10 15
Bolt / bolt - 150 / 185 / 240 mm M12 20
Thyristor SKKT 161 M8 10
Thyristor SKKT 213 M8 10
Thyristor TT 170 M8 12
Thyristor SKKT 132 / 162 M6 5
ABB SACE S3H 160 (fishplate) M8 9
ABB SACE S4N 250 (fishplate) M8 9
ABB SACE S5N 400 (fishplate) M10 18 6
ABB SACE S3N 630/800 M6 6 6

(fishplate)
ABB SACE S7S1250/1600 M10 32 6

(fishplate)
ABB SACE S7S 1250/1600 M12 56 6

(fishplate)
Varistor V15 M6 4 6
Varistor DEHNGUARD M6 7
Fuse base OFAX M5 5
ABB A300 - 30 Contacter M10 18
ABB EH370 - Earth terminal M10 18
ABB EH550 - Earth terminal M10 18
ABB EH 1200 - Earth terminal M10 18
ABB A9, A12 A26 Contactor M3.5 1
ABB A26 Contactor M5 2.8
ABB A30, A40 Contactor M8 4
ABB A45 - A75 Contactor M8 6

ZSM1005840 / 16
4 Bolt tightening
Components Thread Torque Relay

Nm Nm
ABB A95, A110 Contactor M10 18
Ferraz - Shawmut Fuse holder 2 Integrated screw - not 2.5

P (J211056) applicable
Ferraz - Shawmut Fuse holder 3 Integrated screw - not 2.5

P (Z216682) applicable
Schneider Compact NS100 M6 10
Torque settings for electrical connections are placed in the frequency converter.
4.2.7 Tightening torques in converteam converter

This torque table for electrical connections
is placed in the frequency converter.
Components Thread Torque Nm Torque lbfft
Bolt M8 13 10
Bolt M10 33.5 25
Bolt M12 50 39
4.2.8 Tightening torques in ABB converter
Components Thread Torque Nm Torque lbfft
Bolt M5 3.5 2.6
Bolt M6 9 6.6
Bolt M8 20 14.8
Bolt M10 40 29.5
Bolt M12 70 52
Bolt M16 180 133

ZSM1005840 / 16
4 Bolt tightening
4.3 Specific values in the hub
4.3.1 H10 Blade- Blade bearing

The checklists contain references to the joint ID.
If the threading (nut standoff) is not long enough for tension tool, the whole joint must be tightened
with torque tool 2000 Nm.
Two-stage bolt tightening

Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M36 10.9 425 55
4.3.2 H20 Blade - Hub bearing

All bolts are tensioned, but it is allowed to torque a few bolts (2800 Nm) if there is no room for tension
tools near the cylinder rack.
If the threading (nut standoff) is not long enough for tension tool, the whole joint must be tightened
with torque tool 2800 Nm.

Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M36 10.9 670 X
4.3.3 H30 Hub - Spinner plate

Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M30 10.9 1650 46

ZSM1005840 / 16
4 Bolt tightening
4.3.4 H31 Spinner bracket - Reinforcement plate


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M24 8.8 600 36
4.3.5 H32 Spinner plate - Nose cone


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M12 8.8 75 19
M16 8.8 175 24
4.3.6 H33 Hub cabinet (A6) - Spinner plate / console

Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M12 8.8 75 19
M24 8.8 600 36

ZSM1005840 / 16
4 Bolt tightening
4.3.7 H34 (SWT-2.3-82VS/93) Covers in nose cone


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M8 Stainless 14 13
4.3.8 H34 (SWT-2.3-101/108) Covers in spinner


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M8 Stainless 14 13
4.3.9 H40 Distance block for pitch cylinder - Blade bearing


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M30 8.8 1150 46 X

ZSM1005840 / 16
4 Bolt tightening
4.3.10 H41 Plate for pitch cylinder - Blade bearing


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M36 8.8 2000 55
4.3.11 H42 (SWT-2.3-82VS/93) Mounting plate - Root bracket, PUR bushings


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M20 8.8 40 30
4.3.12 H42 (SWT-2.3-101/108) Mounting plate - Root bracket, PUR bushings


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M16 8.8 125 36

ZSM1005840 / 16
4 Bolt tightening
4.3.13 H43 (SWT-2.3-82VS/93) Mounting plate - Root bracket, mounted rigidly


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M20 10.9 450 30
M24 10.9 800 36
4.3.14 H44 (SWT-2.3-82VS/93) Accumulator brackets


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M12 Stainless 52 19
4.3.15 H44 (SWT-2.3-101/108) Accumulator brackets


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M16 8.8 75 24

ZSM1005840 / 16
4 Bolt tightening
4.3.16 H45 (SWT-2.3-82VS/93) Blade block for hydraulic pitch


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M12 8.8 75 19
M12 Stainless 52 19
4.3.17 H45 (SWT-2.3-101/108) Blade block for hydraulic pitch


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M12 8.8 75 19
M12 Stainless 52 19
4.3.18 H46 (SWT-2.3-101/108) Plate for blade block - beam for accumulator rack
Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M12 8.8 45 19

ZSM1005840 / 16
4 Bolt tightening
4.3.19 H47 (SWT-2.3-101/108) Beam for accumulator rack - accumulator brackets


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M16 8.8 175 24
4.3.20 H48 (SWT-2.3-101/108) Root bracket (PUR)


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M12 Stainless 52 Insex 10
4.3.21 H50 Pitch lock


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M30 10.9 1650 46
M30 8.8 1150 46
M12 8.8 75 19

ZSM1005840 / 16
4 Bolt tightening
4.3.22 H51 (SWT-2.3-82VS/93) Manual pitch lock


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M24 10.9 800 Insex 19

ZSM1005840 / 16
4 Bolt tightening
4.4 Specific values in the nacelle
4.4.1 A10 Canopy - maintenance crane


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M16 8.8 175 24
4.4.2 A11 Warning lights - canopy top cover


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M12 Stainless 52 19
4.4.3 A12 Wind vane and anemometer


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M12 8.8 45 19

ZSM1005840 / 16
4 Bolt tightening
4.4.4 A13 Wind vane stand


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M10 8.8 42 17
4.4.5 A17 A4 KG18 alu terminal/Bolts in copper bus bar

(1) A17 Bolts in copper bus bar (M12)
(2) A17 KG18 alu terminal (M10)

Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M10 40 17
M12 56 19
4.4.6 A18 Terminals on generator (ABB)

Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M12 75 19
M16 100 24

ZSM1005840 / 16
4 Bolt tightening
4.4.7 N10 Hub - main shaft


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
36 10.9 2800 60
4.4.8 N20 Main bearing housing - bed frame


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M24 8.8 1150 46 X
4.4.9 N21 Main bearing housing - bed frame (front)


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M24 8.8 300 36

ZSM1005840 / 16
4 Bolt tightening
4.4.10 N22 Main bearing housing - bearing cover (rear)


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M24 8.8 600 36
4.4.11 N23 Clamping ring - main shaft


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M24 12.9 800 Allen 19 X
4.4.12 N24 Bearing cover - seal ring (front /rear)


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M8 8.8 21 13
M12 8.8 75 19

ZSM1005840 / 16
4 Bolt tightening
4.4.13 N25 Labyrinth ring (option)


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M10 8.8 42 17
4.4.14 N30 Gear support - bed frame


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M33 8.8 1550 50 X
4.4.15 N31 Caliper plate-Gearbox


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M24 10.9 800 36

ZSM1005840 / 16
4 Bolt tightening
4.4.16 N32 Shrink disc - low speed


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M33 12.9 2400 50
4.4.17 N33 Shrink disc - high speed


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M20 10.9 450 30
4.4.18 N40 Yaw clamp - bed frame


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M30 8.8 1150 46 X

ZSM1005840 / 16
4 Bolt tightening
4.4.19 N41 Yaw clamp adjusting bolts (vertical)


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M30 8.8 250 46
4.4.20 N42 Yaw clamp adjusting bolts (horizontal)

Horizontal adjustment bolts should never be adjusted at normal service, danger of decentering the
nacelle.

Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M16 8.8 10 24
4.4.21 N50 Bed frame - canopy brackets (front)


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M30 8.8 1150 46 X

ZSM1005840 / 16
4 Bolt tightening
4.4.22 N51 Bed frame - canopy brackets (rear)


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M30 10.9 1650 46 X
4.4.23 N52 Canopy brackets - canopy (front)


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M24 8.8 600 36 X
M30 8.8 1150 46 X
4.4.24 N53 Canopy brackets - canopy (rear)

Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M30 8.8 1150 46 X

ZSM1005840 / 16
4 Bolt tightening
4.4.25 N54 Cover for canopy bracket


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M10 8.8 42 17
4.4.26 N55 Hatch - canopy hinges


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M16 125 24
4.4.27 N56 Canopy - canopy top cover


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M20 8.8 350 30

ZSM1005840 / 16
4 Bolt tightening
4.4.28 N57 Canopy - canopy rear end


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M20 8.8 350 30
4.4.29 N58 Cylinder bracket - hatch


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M16 Stainless 125 24
4.4.30 N60 Yaw gear - bed frame


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M16 10.9 250 24
M16 12.9 300 24

ZSM1005840 / 16
4 Bolt tightening
4.4.31 N71 Generator feet - generator


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M24 8.8 600 36
4.4.32 N72 Coupling - generator to gearbox


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M20 10.9 490 30
4.4.33 N73 Brake calliper - calliper plate

Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M20 8.8 350 30

ZSM1005840 / 16
4 Bolt tightening
4.4.34 N74 High speed Centrifugal Unit (HCU)


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M8 Stainless 14 Insex 6
4.4.35 N75 Generator beam - reinforcement bar


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M16 8.8 175 24
4.4.36 N76 Cable bracket for generator cables


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M12 8.8 75 19

ZSM1005840 / 16
4 Bolt tightening
4.4.37 N77 Generator spacing plate


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M24 8.8 600 36
M30 8.8 1150 46
4.4.38 N80 Hydraulic stand


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M8 Stainless 14 13

ZSM1005840 / 16
4 Bolt tightening
4.5 Specific value for the tower
4.5.1 T10 Tower top flange - Yaw ring


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M30 8.8 1150 46
M30 10.9 1500 46
4.5.2 T20 Tower / Tower (L-flange)


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M36 10.9 2800 60
M42 10.9 4500 960 70
M48 10.9 6500 1260 80

ZSM1005840 / 16
4 Bolt tightening
4.5.3 T30 Foundation bolts (T-flange)

Special tensioning values may apply to specific sites. Refer to the site documentation, and use the site
-specific value if it differs from the generic value stated here.

Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M42 8.8 400 65
M42 (German
8.8 460 65/70
standard)
M48 (Tychowo,
Suwalki & 8.8 550 75
Sieversdorf)
M48 8.8 630 75
1-3/8" 150 KSI 400 2-1/4"
4.5.4 T50 Tower damper


Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M16 8.8 175 24
4.5.5 T60 Platforms

Bolt type
Property class
Torque
Tension
Width across flats
Nm kN mm
M10 8.8 42 17
M12 8.8 75 19
M16 8.8 110 24

ZSM1005840 / 16
4 Bolt tightening
4.5.6 T62 Cable cleat


Bolt type
Property class
Torque
Tension
Width across flats

Nm kN mm
M10 Stainless 30 16

ZSM1005840 / 16
5 Lubrication and wear parts charts

5.1 Lubrication rules................................................................................................................................................................5-2
5.2 Gear oil............................................................................................................................................................................... 5-3
5.2.1 Frequency of gear oil samples......................................................................................................................................5-3
5.2.2 Sampling of gear oil...................................................................................................................................................... 5-3
5.2.3 Replacing gear oil......................................................................................................................................................... 5-3
5.2.4 Replacing yaw gear oil..................................................................................................................................................5-3
5.3 Hydraulic oil....................................................................................................................................................................... 5-4
5.3.1 Frequency of hydraulic oil samples...............................................................................................................................5-4
5.3.2 Extracting hydraulic oil sample......................................................................................................................................5-5
5.3.3 Replacing hydraulic oil................................................................................................................................................ 5-11
5.3.4 Replacing hydraulic oil on a system with external cooler............................................................................................5-12
5.4 Lubrication charts........................................................................................................................................................... 5-13
5.4.1 Lubrication chart main gear (Winergy / Hansen).........................................................................................................5-13
5.4.2 Lubrication chart for main bearing...............................................................................................................................5-13
5.4.3 Lubrication chart labyrinth seals on main bearings (option)........................................................................................5-13
5.4.4 Lubrication chart for yaw plate and pinion...................................................................................................................5-13
5.4.5 Lubrication chart for yaw gear.....................................................................................................................................5-14
5.4.6 Lubrication chart generator bearings with central lubrication system......................................................................... 5-14
5.4.7 Lubrication chart blade bearings with central lubrication system................................................................................ 5-14
5.4.8 Lubrication chart hydraulic oil on pumping station for pitch system and brake........................................................... 5-14
5.4.9 Lubrication chart chain hoist (service crane)...............................................................................................................5-15
5.4.10 Fluid chart frequency converter.................................................................................................................................5-15
5.5 Wear part charts.............................................................................................................................................................. 5-16
5.5.1 Wear part chart for in-line-filter for gear oil..................................................................................................................5-16
5.5.2 Wear part chart for off-line oil filter CC-Jensen........................................................................................................... 5-16
5.5.3 Wear part chart for air filter main gear........................................................................................................................ 5-16
5.5.4 Wear part chart for gear oil hoses...............................................................................................................................5-16
5.5.5 Wear part chart pressure filter on hydraulic pumping station......................................................................................5-16
5.5.6 Wear part chart return filter on hydraulic pumping station.......................................................................................... 5-17
5.5.7 Wear part chart air filter on hydraulic pumping station................................................................................................5-17
5.5.8 Wear part chart hydraulic hoses................................................................................................................................. 5-17
5.5.9 Wear part chart battery replacement...........................................................................................................................5-17

ZSM1005840 / 16
5.1 Lubrication rules

Important: It is extremely important that the lubrication procedures are followed.
1. Take care that no dirt gets into the lubricant.
2. Flush the "easy grease pump" and hoses well with the correct grease type before use.
3. Never use the first stroke of a grease gun.
4. Wear protective gloves according to the applicable material safety data sheet when handling
lubricants.
5. The lubricants contain solvents which cause skin irritation or a rash.
6. Always collect rags, empty packaging, and so on, and dispose of them properly. Keep the
environment clean.
For main bearings, always use the easy grease pump.
1. Always clean up the extra grease that is pressed out through the seals.
For blade bearings:
Hydraulic oil cannot be allowed to enter the blade bearing or make contact with the blade bearing
seals. If a hydraulic oil leak occurs in the hub, it is mandatory to flush the blade bearing grease system
in accordance with the instructions in "Procedure for oil spillage in the hub", in "Chapter 12: Pitch
system".

ZSM1005840 / 16
5.2 Gear oil
5.2.1 Frequency of gear oil samples
500 hours service Take a sample of the gear oil and analyze it. If the results of the analysis indicate an oil
change is required this should be done as soon as possible. When replacing the gearbox, a
500 hour service must be performed on the gearbox.
Every year service Take a sample of the gear oil and analyze it. If the result of the analysis indicate an oil change
is required, this should be done as soon as possible. If the oil is not analyzed, it must be
changed every 2 years. Oil samples for analysis can be taken at any time if required (for
example in case of over speed or unusual noise).
5 year service The oil must be changed.
5.2.2 Sampling of gear oil

Oil samples are taken in order to analyze the gear oil for contents of iron, chrome and dirt particles.
The results of this analysis provide information about the condition of both gearbox and lubricant.
See "ZWI524866 Extraction of gear oil sample".
5.2.3 Replacing gear oil

See "ZWI1002351 change of gear oil". Remember to take oil sample before and after replacement.
5.2.4 Replacing yaw gear oil

See "ZWI1002353 Replacement of yaw gear oil".

ZSM1005840 / 16
5.3 Hydraulic oil
5.3.1 Frequency of hydraulic oil samples

The condition, of the hydraulic system and of the oil, is monitored by sampling oil as indicated below:
Yearly service Check up after oil filling, and if needed by the condition of the hydraulic system
Service after 5 years The oil must be changed

ZSM1005840 / 16
5.3.2 Extracting hydraulic oil sample
WARNING
Hydraulic system
To avoid impurity in the hydraulic system, always clean the hydraulic hoses and valves, before
dismounting the hydraulic components.
Mount hydraulic plugs on the hoses and components after dismounting.
Oil spillage may occur. Have cotton rags ready when disconnection the hoses.
WARNING
Hydraulic oil: Risk of eye injuries!
Wear eye protection when working on hydraulic systems.
WARNING
Hydraulic oil: Risk of skin irritation!
Wear gloves when working on hydraulic systems.
Sampling procedure must be performed by two persons in collaboration.

When sampling oil for analysis, it is very important to carry it out under as clean conditions as
possible. An oil sample does not require much external dirt to distort the test result significantly.
If the weather is windy or it rains, close the nacelle hatches and doors.
Use vinyl gloves without talcum. The vinyl gloves must be new and not coming from a pocket with fluff.
The vinyl gloves must be packed in a clean plastic bag or similar packaging. Do not use any other type
of gloves, as loose fibers from textile or leather gloves will pollute the sample.
Note: All samples must be returned to regional unit within 14 days.
Procedure:
1 Open the ball valve (14).
Ball valve (14)

ZSM1005840 / 16
2 Fit a test hose on the test nipple (32).
Test nipple (32)
3 Lead down the test hose into an empty can.
Empty can
4 Start the hydraulic pump in MENU 24 > Screen 7
Hand terminal

ZSM1005840 / 16
5 Close carefully the ball valve (14) until the wished flow from the test hose down into the can is
reached.
6 Extract the oil sample.
6.1 Draw 0.5 liters into the can.

6.2 Without stopping the oil flow, fill the sample bottle.
Note: Hold the test hose away from bottle, and avoid any dirt from the hose to fall into
the glass.
6.3 Turn off the hydraulic pump in MENU 24 > Screen 7

6.4 Close the sample bottle immediately to prevent contamination.

ZSM1005840 / 16
7 Fill in the accompanying label for the sample bottle before taking more samples.
7.1 Select Your Oil Sample Type: Tick off Hydraulic.

7.2 Site Name: Name of the site at which the turbine stands.
7.3 Sample No.: Preprinted on the label.
7.4 Turbine No.: Found on the number plate on the nacelle.
Turbine number: The

number plate is located on
the left-hand side of the top
cover of the nacelle
7.5 Fluid Full Name: Found on the oil sticker or batch sticker at the hydraulic station.
Oil label: Located either on

the hydraulic station block or
on the hydraulic station tank
Full name of fluid: The entire
writing on the label
Manufacturer: The first text
on the label before the
hyphen
7.6 Total Operation Hours: Found in the hand terminal.

7.7 Date of Last Exchange: Do not fill out this field when extracting hydraulic sample.

ZSM1005840 / 16
7.8 Component No.: Serial No.
Sample from the hydraulic

station: The serial number
label is located on the
hydraulic station block
Component number: The
first 7 digits after Serial No.
at the bottom of the label
Sample from the blade

station: The serial number
label is located on the
hydraulic station block
Component number: The
first 7 digits after Serial No.
at the bottom of the label
7.9 Manufacturer: Found on the oil sticker or batch sticker at the hydraulic station.
7.10 Hydraulic Sample from: Tick off in the box where the oil sample has been extracted.
7.11 Sample Date: The date on which the sample was extracted.
7.12 Service: Tick off if the oil sample has been extracted as part of service.
7.13 Special: Tick off if the oil sample has been extracted outside service.
7.14 Operator Initials: Initials of the person extracting the oil sample.
8 Attach the label to the sample bottle.

ZSM1005840 / 16
9 Close the ball valve (14).
10 Remove the test hose.

ZSM1005840 / 16
5.3.3 Replacing hydraulic oil

Oil must be filtered through a 3 micrometer absolute filter before filling up. Oil delivered from
Siemens Wind Power A/S in plastic containers are pre-filtered.
It is a precondition for the procedure that the blue valve (252) is in "service" position.
The service crane must be positioned with the extension boom far back and the lifting boom
lowered as much as possible in order to get as much oil as possible back into the hydraulic tank.
When changing oil, it is important to ensure that the entire oil quantity is changed.
Procedure:
1 The rotor is positioned in suitable position for hub access, and secured by applying the HS rotor
lock.
2 Make a sample of the hydraulic oil in the appropriate sample bottle according to procedure
described in the service manual.
3 Activate the emergency stop.
4 Open ball valve (14) and system accumulator is emptied.
5 Switch the service valve (252) to "operation" mode in order to empty the accumulators in the
brake system.
6 Empty the tank by mounting a hose connection to the drain valve at the bottom of the tank. The
oil can be pumped into 25 L canisters or directly down through waste oil hose to a truck.
7 Switch the service valve (252) back to "service" mode.
8 Drain the pitch accumulators. Open the ball valve pos. 27 on the hydraulic valve block, and close
the ball valves (108) in the hub. Drain the accumulators by activating valve (117) one blade at the
time.
9 Empty the oil from the hydraulic tank. When the tank is empty, the drain valve at the bottom of
the tank can be closed and the drain hoses dismounted.
10 Exchange the pressure filter and the return oil filter. Potential pollution on the magnetic indicator
stick is noted in the checklist.
11 Refill the tank with the new hydraulic oil. Dismount the blind plug on the return filter house. The
tank is refilled through the return filter. The tank is replenished until the max level.
12 Re-pressurize the pitch accumulators by closing ball valve (14) and activating the hydraulic
pump. The oil level must be observed during the pumping as replenishing the tank until max level
can be necessary.
13 Empty the pitch cylinders from old oil, it must be directed to the waste oil canisters or hose. By
dismounting the return oil hose by the T-gate and fit a blind plug in the hydraulic valve block.
14 Empty the pitch cylinders by entering menu 24, screen 6 in the hand terminal. One blade at the
time is now pitched slowly into operation. Control the speed by opening ball valve (108) in the
hub. The oil is captured in a suitable waste oil canister. The blade must subsequently be pitched
back in stop by utilizing the accumulator pressure and the cylinders are hereby replenished with
new oil. Repeat the procedure on the remaining 2 blades.
15 Stop the pump when the system is re-pressurized, and the return oil hose can be fitted to the
hydraulic valve block again. The fitting is tightened according to torque values.
16 Close ball valve (27) again and the ball valves (108) in the hub are left fully open.
17 After checking oil level, the turbine can be started up for a 5 min. test run. The oil level must
subsequently be re-checked.

ZSM1005840 / 16
5.3.4 Replacing hydraulic oil on a system with external cooler

Procedure:
1 Disconnect the tank hose on the pumping station from the cooler and place the hose in the
container.
2 Operate the pump with bypass valve (25) opened for 5 seconds.
3 Fill the tank with the correct amount of new oil.
4 Remove the jumper from the level sensor on the tank.

ZSM1005840 / 16
5.4 Lubrication charts
5.4.1 Lubrication chart main gear (Winergy / Hansen)

Important: Only use lubricants stated in this chart.
Main gear (Winergy / Hansen)
Lubrication at the time of delivery Tribol 1710 - VG320 / Castrol Optigear Synthetic X VG 320
First interval lubrication After 500 hours of operation take a sample of the gear oil and send it to the oil
manufacturer for analysis. Any further action depends on the analysis.
Periodical lubrication Annual sampling of the gear oil and subsequent analysis by the supplier. Any further action
depends on the result of the analysis.
Interval between lubrications If the oil is not analyzed, it must be changed every 2 years.
Replacement of lubricant The oil must be changed every 5 years.
Lubricants quantity Approx. 575 liters including cooling system
5.4.2 Lubrication chart for main bearing

Main bearing
Component / System Main bearing with central lubrication system
Lubricant at the time of delivery KLBER PLEX BEM 41-141
First interval After one year of operation
Periodical interval Every year
Lubricant Rubber seal: Klberplex BEM41-301 / Felt ring: Klberplex BEM41-141
Quantity Approx. 10 kg
Remarks Always lubricate the main bearing first, then the labyrinth seals (option)
5.4.3 Lubrication chart labyrinth seals on main bearings (option)

Labyrinth seals on main shaft bearings

Component / System Labyrinth seals on main shaft bearings
Lubricant OPTIMOL OPTIPIT
Quantity Approx. 200 g distributed among all grease nipples
5.4.4 Lubrication chart for yaw plate and pinion
Lubrication chart for yaw plate and pinion

Component / System Yaw claws, sliding shoes and teeth on yaw plate and yaw pinion (With central lubrication
system)
Lubricant at the time of delivery OPTIMOL OPTIPIT
Lubricant OPTIMOL OPTIPIT
Quantity Approx. 5 kg

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5.4.5 Lubrication chart for yaw gear

Yaw gear
Lubricant at the time of delivery TRIBOL 1710 - VG320 or Castrol Optigear Synthetic X VG 320
First interval Change the oil after 5 years of operation
Periodical interval Every 5 years
Lubricant TRIBOL 1710 - VG320 or Castrol Optigear Synthetic X VG 320
Quantity 7 + 1 liters (1 liter in the oil reservoir)
5.4.6 Lubrication chart generator bearings with central lubrication system

Generator bearings with central lubrication system

Lubricant at the time of delivery KLBER PLEX BEM 41 - 132
First interval After 1 year of operation
Lubricant KLBER PLEX BEM 41 - 132
Quantity 1 kg
5.4.7 Lubrication chart blade bearings with central lubrication system

Important: Only use lubricants stated in this chart. Do not overfill the system.
Blade bearings with central lubrication system

Lubricant at the time of delivery Shell Rhodina BBZ
Lubricant Shell Rhodina BBZ
Quantity 6 kg
5.4.8 Lubrication chart hydraulic oil on pumping station for pitch system and brake
Pumping station for pitch system and brake

Lubricant at the time of delivery MOBIL DTE 13M or Castrol Hyspin AWH-M 32 or for cold climate usage Arctic: Shell
Tellus Arctic oil 32)
First interval Change the oil after 5 years of operation
Lubricant MOBIL DTE 13M or Castrol Hyspin AWH-M 32 cold climate usage Arctic: Shell Tellus
Arctic oil 32)
Quantity 225 liters
Remarks The oil types MOBIL DTE 13M and Castrol Hyspin AWH-M 32 may be blended

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5.4.9 Lubrication chart chain hoist (service crane)

Chain hoist (Service crane)

Lubricant at the time of delivery KEMA VET - 68 Sterile oil
First interval After 1 year
Lubricant KEMA VET - 68 Sterile oil
Quantity Approx. 0.5 liters
Remarks Estimate the amount of oil needed
5.4.10 Fluid chart frequency converter

Important: Only use fluids stated in this chart.
Frequency converter
Fluid at the time of delivery Antifreeze liquid type BASF Glysantine G30
First interval Change after 7 years of operation
Fluid Antifreeze liquid type BASF Glysantine G30
Quantity Not specified
Remarks Mixing ratio: 1 part pure antifreeze liquid to 2 parts tap water. Cold climate mixing ratio: 1
part pure antifreeze liquid to 1 part tap water.

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5.5 Wear part charts
5.5.1 Wear part chart for in-line-filter for gear oil
Component / system In-line filter for gear oil
Type In-line filter type FA2000
First interval After 500 hours of operation
Wear part In-line filter type FA2000
Quantity 1 filter element
5.5.2 Wear part chart for off-line oil filter CC-Jensen
Component / system Off-line oil filter CC-Jensen
Type Off -line filter for CC-Jensen
Wear part Off-line filter type CC-Jensen
5.5.3 Wear part chart for air filter main gear
Component / system Air filter for main gear
Type Air filter
Wear part Air filter
5.5.4 Wear part chart for gear oil hoses
Component / system Gear oil hoses
Periodical interval Replaced every 10 year
Wear part Gear oil hoses
5.5.5 Wear part chart pressure filter on hydraulic pumping station
Component / system Pressure filter on hydraulic pumping station
Type Pressure filter
First interval After 12 months of operation
Wear part Pressure filter

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5.5.6 Wear part chart return filter on hydraulic pumping station
Component / system Return filter on hydraulic pumping station
Type Return filter
First interval After 12 months of operation
Wear part Return filter
5.5.7 Wear part chart air filter on hydraulic pumping station
Component / system Air filter on hydraulic pumping station
Type Air filter
Wear part Air filter
5.5.8 Wear part chart hydraulic hoses
Component / system Hydraulic hoses
Periodical interval Every 10 years the hydraulic hoses must be replaced
Wear part Hydraulic hoses
5.5.9 Wear part chart battery replacement
Product Battery type Quantity
Converter ABB CR2032 2
WTC-3 MAIN COMPUTER Tekcell 3.6V 1
Aviation Light Back-up, UPS 12h UPS4 2
Emergency Light NI-CD SC1800mAH 6
UPS standard (Old) Battery rack 8
UPS standard (New) 8-G12V16AH10EP 8

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6 Controller and power installations

6.1 Electrical system............................................................................................................................................................... 6-2
6.1.1 Electrical system........................................................................................................................................................... 6-2
6.1.2 Controller switch boards ...............................................................................................................................................6-3
6.1.3 Checking controller switch board after repair................................................................................................................6-6
6.1.4 Replacement of cables..................................................................................................................................................6-6
6.1.5 Checking emergency lightning .....................................................................................................................................6-7
6.1.6 Checking emergency stops...........................................................................................................................................6-8
6.1.7 Checking heating element in generator........................................................................................................................ 6-8
6.1.8 Checking heating elements in the gear box..................................................................................................................6-9
6.1.9 Checking heating element in the hydraulic system (option)..........................................................................................6-9
6.1.10 Checking heating element in controllers................................................................................................................... 6-10
6.1.11 Checking varistors in power unit............................................................................................................................... 6-10
6.1.12 Checking cables in the controller switchboards and generator.................................................................................6-11
6.1.13 Checking the aluminum cable joints at the tower joints for damage......................................................................... 6-12
6.1.14 Testing the electronic vibration sensor (G sensor)....................................................................................................6-13
6.1.15 Testing the TCM X/Y module (Option) ..................................................................................................................... 6-14
6.1.16 Checking TCM modules ...........................................................................................................................................6-15
6.1.17 Testing the idle mode at grid drop simulation........................................................................................................... 6-17
6.1.18 Testing the LMU (automatic test)..............................................................................................................................6-17
6.1.19 Visual inspection of TLC (Turbine Load Control)...................................................................................................... 6-18
6.2 Servicing lightening protection system........................................................................................................................ 6-19
6.2.1 Checking lightning protection cables and detector......................................................................................................6-19
6.2.2 Checking carbon sliding shoes................................................................................................................................... 6-20
6.2.3 Checking brushes at main shaft..................................................................................................................................6-22
6.2.4 Checking brushes at yaw ring.....................................................................................................................................6-22
6.2.5 Checking the tower lightning protection...................................................................................................................... 6-23
6.2.6 Replacing lightning cards............................................................................................................................................6-24
6.2.7 Replacing lightning detector battery (option)...............................................................................................................6-26
6.3 Servicing Uninterruptible Power Supply (UPS)............................................................................................................ 6-27
6.3.1 Replacing the battery of UPS rack type...................................................................................................................... 6-27
6.3.2 Replacing the battery of UPS tower type (older turbines)........................................................................................... 6-28
6.3.3 Resetting UPS batteries..............................................................................................................................................6-29
6.3.4 Checking and adjusting the UPS................................................................................................................................ 6-30
6.4 Servicing aircraft warning lights.................................................................................................................................... 6-31
6.4.1 Checking aircraft warning lights.................................................................................................................................. 6-31
6.5 Servicing filters, fans and detectors..............................................................................................................................6-33
6.5.1 Replacing filters in controller cabinets.........................................................................................................................6-33
6.5.2 Replacing fan in frequency converter for yaw gear (option)........................................................................................6-33
6.5.3 Testing of smoke detector...........................................................................................................................................6-34
6.5.4 Testing the visibility meter...........................................................................................................................................6-35
6.5.5 Resetting max. and min. temperature in temp. sensors..............................................................................................6-35

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6.1 Electrical system
6.1.1 Electrical system

The purpose of the low voltage installation is to connect the turbine generator to the grid and transport
the active power produced by the generator from the generator to the turbine transformer. It is also
designed to control, regulate and monitor all functions related to the operation of the turbine in order to
ensure the maximum output of the turbine production capacity within the general specifications of the
turbine.

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6.1.2 Controller switch boards

The turbine control system consists of a number of large subordinate switch boards and cabling
between these, including junction boxes.
Figure 6.1.2.14 Controller switch boards (Non-HILT yaw

system)

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Figure 6.1.2.15 Controller switch boards (HILT yaw

system)
All controller switch boards are marked with a label indicating the name, position and version of the
switchboard in the turbine.
In the example the item no. V3023-A1-042 designates the following.
V3023 = name of controller switchboard, for a WTC-3 2.3 MW turbine.
A1 = Position of controller in the turbine. A1 is the power panel in the bottom section of the tower.
042 = Version
(1) Name of controller
(2) Position of controller in the turbine
(3) Version
Figure 6.1.2.16 Example of switchboard label
Electrical installation in the nacelle
Control Panels in the Nacelle (Non-HILT yaw system)
Cabinet Description
A3 Main computer and relay switchboard
A6 Hub computer
A9 Crane / hatch, hydraulic control and so on
A18 Frequency converter for yaw motors. Manual yaw switch control.

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Control Panels in the Nacelle (HILT yaw system)
Cabinet Description
Main computer and relay switchboard
690V 30 A CEE female plug
A3 Breaker for 230 Volt
Breaker for 690 Volt
Manual yaw switch control
A6 Hub computer
Electrical installation in the top tower section
Connection and Transformer Panel in Top Tower Section
Cabinet Description
A4 Switchboard cable connections between switch boards in tower bottom and nacelle
Electrical installation in bottom tower section
Power Unit
Cabinet Description
A1 Grid supply and main circuit breakers
A2 UPS, hand terminal and computer
A11 Grid filter
A12 Frequency converter for power control and regulation of turbine power
A14 Filter reactor for grid

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6.1.3 Checking controller switch board after repair

After repairing the controller switch board, the following check procedures must be performed.
Circuit switching and measurement are "LIVE WORK".
Important: See controller diagram of the turbine for de-energizing the switch board.
See yellow sign for de-energized condition of the switch board. If an error occurs in the controller, the
status display on the monitor must be specified in the work report.
Example of sign mounted on the main switch board (A1) in the power unit located in the tower bottom
section.
Procedure:
1 Tighten up all relevant screws and bolts with a torque wrench using tightening torques as
specified in "Tightening torques in controller".
2 Check that all ribbon cables and multiple connectors are correctly connected.
3 Visually check that all cable eyes in the main current connections are correctly crimped (no sign
of overheating).
4 Visually check that all clamps on the auxiliary relays are mounted correctly.
5 Check for correct main grid voltage and phase sequence.
6 Check that the software in the turbine computer is in accordance with the turbine's specifications.
6.1.4 Replacement of cables

When cables are replaced the following must be observed.
Cable type Fixed cables Flexible cables Radius of bending (mm)
Rubber, H07RNF LS0H 4xd 6xd
1 x 240 mm2, 36 mm 4xd 6xd 150
1 x 300 mm2, 39 mm 4xd 6xd 160
3 x 70 mm2, 44 mm 4xd 6xd 180
LIHCH 10 x d 15 x d
LIHH 10 x d 15 x d
LIYCY 10 x d 15 x d
Optical fiber 2-pair and 3-pair 18 x d 7.5 / 8.5
Optical fiber 4-pair 10 x d 10
Optical fiber 6-pair 20 x d 12.5
Type 110CY 6xd 20 x d
Aluminum cable (3 x 150) 10 x d 15 x d
Legend: d = diameter of cable

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6.1.5 Checking emergency lightning

A specific number of the light fixtures have batteries for emergency light supply in order to ensure
emergency lightning in the turbine in case of power failure. In emergency light fixtures with 2
fluorescent tubes, only 1 tube is connected to the back up battery for the emergency lightning. The
capacity of the batteries for the emergency light supply is for approx. 1 hour of operation in case of
power failure. The batteries are automatically kept charged by an integrated charger.
Procedure:
1 Check emergency light fixtures.
This graphic is only an example,

and may not be valid for all turbines.
(1) Hpfi service light
1.1 Switch off Hpfi relay for light.

Results: The emergency lights must now function for minimum 15 minutes
1.2 Replace the batteries in the emergency light fixtures if they do not function for the
specified time
2 Check the HPFI relay.
2.1 Press the Test-button (1) once every year to test the function (Power off)
2.2 If the relay doesn't work, the relay need to be replaced.

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6.1.6 Checking emergency stops

Procedure:
1 Check the emergency stops.
2 Activate 1 emergency stop at a time and check for error message on hand terminal.
3 Reset the fault in the hand terminal.
4 Proceed with the rest of the emergency stops.
6.1.7 Checking heating element in generator

Before you begin: This check is performed when the turbine is stopped. 1 x 400 W heating element
int the generator is connected to the terminal row in the A3 controller located in the nacelle.
Procedure:
1 Change parameter UP2200 to maximum value.
This is done in Menu 19 in the hand terminal.
2 See "Controller diagram" to find correct measure point.

3 Measure the current in the heating element with a clamp ammeter on one of the wires from the
terminal in the A3 controller.
Important: After test the parameter UP2200 must be set to default value.
Results: The current must be within the range 1.74 0.2 A.

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6.1.8 Checking heating elements in the gear box

In order to activate the heating elements go to:
Procedure:
1 Menu 30 "test switches".
2 Press ESC.
3 Go to output control in Menu 25.
4 Find gear oil heating output in the controller documentation.
5 Use the arrow keys to find the required output.
6 Press "." to activate output.
7 See controller diagrams to find correct measure point.
8 Measure each of the 3 heating elements with clamp. ammeter in the A3 cabinet.
The reading must show a consumption of 1.0 0.2 A on each heating element
9 After testing reset the WTC via the hand terminal Menu 3.
Measuring consumption with

ammeter in the A3 Cabinet
6.1.9 Checking heating element in the hydraulic system (option)

Procedure:
1 Measure with a clamp. Ammeter.
Results: 1 x 785 W, 2 x 690 V power consumption must be 3 A 0.3 A.

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6.1.10 Checking heating element in controllers

Procedure:
1 Adjust the thermostat (red) in order to turn the heating element on.
2 Check that the fan on the heating element is running, and the heating element gets warm.
3 Adjust the thermostat again after checking.
The heating element is cut in at approx. +5 C and cut out at approx. +9 C
6.1.11 Checking varistors in power unit

Procedure:
1 Check that the "ok" marks on the varistors in power unit are green.
(1) "OK" marks on varistors

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6.1.12 Checking cables in the controller switchboards and generator

Procedure:
1 Visually check 690 V cables in the controller switchboards and generator.
2 Check generator cables for cracks and surface changes.
3 Visually check for cracks and loose bolts on generator cable brackets.
4 Note any cracks or changes in the check list under remarks and notify the Service Department at
Siemens Wind Power A/S.
5 Switch off the main breaker before removing the cover.
6 Remove cover and check for loose cables and any signs of overheating.

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6.1.13 Checking the aluminum cable joints at the tower joints for damage
All aluminum cable joints in the wind turbine must be inspected for marks and cuts from the cable
ladders. There must not be any cuts in the cable insulation from the side members of the cable of the
cable ladders. If the cables have visible cuts, this must be reported to the Service Department at
Siemens Wind Power A/S for further action. If possible, append the report with pictures with
measurements indicating the scope of the damage.
Procedure:
1 Cuts are defined as open "gashes" where the cable insulation is damaged.
2 Marks are defined as changes in the structure of the insulation material as if the cables have
been exposed to heating.

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6.1.14 Testing the electronic vibration sensor (G sensor)

The G sensor (frequency-dependent) registers oscillations in the turbine. If these oscillations exceed
those expected during ordinary turbine operation, a signal is sent to the WTC, and the turbine is shut
down.
Procedure:
1 Engage the HS rotor lock.
2 Unscrew the cover and loosen the 4 screws in the corners of the box (inside) to dismount the G
sensor box.
3 Start the turbine with the HS rotor lock engaged - wait until the blades are in operation mode and
the brake is disengaged.
4 Activate the G sensor by shaking the box.
5 Shake the box with a frequency of approx. 2 cycles per second (2 Hz), a distance of 50 mm.
After approx. 30 seconds the relay should "click" and the WTC registers an error in the hand
terminal.
6 Stop the turbine in the hand terminal.

8 Refit the G sensor.
(1) G sensor fitted in the nacelle

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6.1.15 Testing the TCM X/Y module (Option)

Before you begin: Only start testing if module is installed
Procedure:
2 Loosen the 3 screws and remove the TCM module.
3 Start the turbine with the HS rotor engaged - wait until the blades are in operation mode and the
brake is disengaged.
4 Activate the TCM module by shaking it.
5 Shake the module with a frequency of approx. 2 cycles per second (2 Hz), a distance of 50 mm.
After approx. 30 seconds the relay should "click" and the WTC registers an error in the hand
terminal.
6 Stop the turbine in the hand terminal.

8 Apply grease to the bottom surface of the TCM module, and refit the TCM module.
(1) Main bearing cover

(2) TCM module on main bearing

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6.1.16 Checking TCM modules

Procedure:
1 Visually check the TCM module.
(1) TCM module on generator

2) Guard
(1) TCM module NDE

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(1) TCM module at the front of the

gearbox
4 Visually check the TCM module
(1) TCM module at the rear of the

gearbox

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6.1.17 Testing the idle mode at grid drop simulation

Procedure:
2 Connect the manometer to test nipple (227).
3 Turn the blue service valve to position "operation".
4 Start the turbine with the HS rotor lock engaged - wait until the blades are in operation mode ,
and the brake is disengaged - read out 0 bar on the manometer.
5 Proceed to Menu 29 in the hand terminal.
5.1 Press arrow up once until you reachGrid drop simulation
5.1 Press "." in order to activate test.
6 The blades must now pitch to stop position.
7 Wait app. 1 minute. The brake must engage.
7.1 Read out: 80 bar +/- 5 bar on the manometer.
8 Wait 30 -60 sec. the brake must disengage.
9 Read out 0 bar on the manometer.
Results: Now the idle mode function had been tested with a grid drop simulation.
6.1.18 Testing the LMU (automatic test)

Independent monitoring of the LS shaft is incorporated through the WTC3 as an additional safety
measure. Monitoring is performed through Low Speed Monitoring Unit (LMU).
Perform automatic test of Low Monitoring Unit (LMU) at service.
Procedure:
1 Switch 608.S1 in A3 cabinet must be positioned in service mode.
2 Activate LMU test in hand terminal Menu 24 > Screen 22.
Results: Test result has to show OK.
3 Set switch 608.S1 in A3 cabinet in operation mode.

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6.1.19 Visual inspection of TLC (Turbine Load Control)

Conduct visual inspection
Procedure:
1 Visually check the TLC components and cables
Load sensors, (1) Leeward and (2)

Windward side
Amplifier

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6.2 Servicing lightening protection system
6.2.1 Checking lightning protection cables and detector

Procedure:
1 Check that cables for lightning protection are intact and without damage at gear box suspension,
generator, hatches, hub, controller switchboards and so on.
2 Check the lightning detector. If a trip-out has occurred the possible cause must be assessed. The
remaining steps can be skipped.
If the trip-out is assessed to be caused by an error, the turbine may be reset and restarted.
If the trip-out is assessed to be caused by lightning, the turbine must be inspected for
damage before performing a restart. Continue with step 3 and 4.
3 Inspect the area around the 6 lightning receptors on each blade.
Use strong binoculars. The receptors on the blades are placed in pairs, one pair 24 m from the
root, another pair 32 m and a third pair at the tip of the blade (lightning rod).
Typical traces of lightning are:
Melted areas on the receptors
Melted areas at the top or on the side of the lightning rod
Stripes in the blade fiber glass in the area around the receptor
Results: Slightly damaged receptors and still functional receptors are not replaced.
4 Replace receptor as soon as possible if more than 90 % damage of the surface.
5 Damaged receptors must be sent to the Electrical Department at Siemens Wind Power A/S with
a specification of the turbine no. and blade no.
6 Check the magnetic lightning cards in the blades, at the aircraft warning lights and at the wind
vane stand for burns.
Results: If lightning damage is found, all lightning cards must be replaced and returned to
Siemens Wind Power A/S.

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6.2.2 Checking carbon sliding shoes

The procedure is performed for the following lightning protection systems:
Between nacelle bedplate and tower.
(1) Carbon sliding shoe
Between main shaft and nacelle.

Between blade and hub.


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Procedure:
1 Check that the carbons move correctly by lifting them and checking that they are able to move
fully onto the contact surface.
Results: The carbons must be easy to move and have a clearance of mm all way round. If the
carbons do not move easily without jamming, the holders and carbons must be cleaned with
sandpaper (do not use emery) until the gap is appropriate.
2 Check the length of the carbons.
Results: Replace the carbons if the length is less than 25 mm.
3 Check the spring on the carbon sliding shoe.

(2) Spring
(3) Carbon
(4) Adjustment 3 mm 1 mm
(5) Spark arrester
Results: If the spring has recoiled unevenly or hangs on the edge of the holder, the carbon
sliding shoe must be replaced.
4 Check the distance between the carbon sliding shoe and the contact surface. See figure in
previous step.
Results: It must be adjusted to 3 mm 1 mm.
5 Check the distance between the spark arrester and the contact surface.
(1) Spark arrester (hub)

(2) Adjustment 3 mm 1 mm
Results: It must be adjusted to 3 mm 1 mm.

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6.2.3 Checking brushes at main shaft

The brushes are part of the lightning protection system of the main shaft.
Procedure:
1 Check that the brushes are intact and placed correctly. They must not touch the main shaft. The
distance has to be 1mm +1-0mm.
They must not touch the segments of the low speed locking device:
Both brushes need be as close as possible (almost touching) to the segments they are facing
during check.
Please do not adjust the brushes so that they touch again due to copper dust which will be
produced
Replace the brushes if they are worn.
6.2.4 Checking brushes at yaw ring

The brushes are part of the lightning protection system of the yaw ring.
Procedure:
1 If necessary, adjust the brushes to provide a slight contact.
2 Check that the brushes provide contact between the yaw ring and tower flange.
3 If necessary, adjust the brushes to provide a slight contact. If the brushes cannot be adjusted
because they are worn, they must be replaced.
4 Replace the brushes if they are worn or can not be adjusted.

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6.2.5 Checking the tower lightning protection

Procedure:
1 Check that lightning protection (equipotential bonding) has been fitted on the flanges at the tower
joints.
(1) Lightning protection
2 Check the lightning protection at the aluminum floor plate.
(1) Lightning protection

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6.2.6 Replacing lightning cards

Procedure:
1 Remove the old card and insert a new one in the card holder.
(1) Lightning card and holder
2 Return the old card to Siemens Wind Power A/S.

Fill in the label on the card with the following information:
Turbine no. and name (if used)
Date of fitting and date of replacement
Measuring point. For blades, the serial no. must be stated
The initial of the service technician
The cards must be kept away from magnetic materials to avoid damage of the magnetic pattern
that may make the read-out unreliable. Minimum distance depends on the strength of the
magnetic material.
Do not put cards in a tool box. Place them in a plastic bag or similar.
Lightning cards are mounted at the following places:
In each blade approximately 1 m from the blade root.
(1) Lightning card in blade

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Lightning rods at aircraft warning lights. This card also protects the visibility meter.
(1) Lightning card at warning
lights
On the ground cable for the wind vane holder.

(1) Lightning card on ground
cable

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6.2.7 Replacing lightning detector battery (option)

Procedure:
1 Disconnect the cables and change the battery.

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6.3 Servicing Uninterruptible Power Supply (UPS)
6.3.1 Replacing the battery of UPS rack type

The Uninterruptible Power Supply (UPS) (Rack Type - Live Work) is placed in a separate
compartment in the controller and mounted in a rack. The UPS is connected to three cables placed in
the connector.
Master UPS with 8 batteries (and optional 8 battery modules).
(1) UPS - Rack Type
Procedure:
1 Press "OFF" on the front panel to interrupt the UPS.
(1) Grid OK
(2) UPS online (green)
(3) Load OK (green)
(4) 85 - 105 % load (yellow)
(5) Battery status (all green
indicates 100 %)
(6) UPS offline (green)
(7) > 105 % load (red)
Results: Yellow diode lights up.

2 Disconnect the 3 cables from controller to UPS.
3 Replace batteries.
4 Test connections of individual parts of UPS.
5 Connect supply to UPS.
6 Press "ON" to start UPS.
Results: Yellow diode switches off.

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6.3.2 Replacing the battery of UPS tower type (older turbines)

The Uninterruptible Power Supply (UPS) (Tower Type - Live Work) is placed in a separate
compartment in the controller. The UPS is connected to 3 cables placed in the connector.
Master UPS with 3 batteries (and optional 8 battery modules).
(1) UPS - Tower Type

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6.3.3 Resetting UPS batteries

Before you begin: A laptop with a copy of the reset software is required to reset UPS batteries. The
reset software is included in a zip file (Reset-batt.zip), which can be found on the WPST network and
copied to the service technician's laptop.
Procedure:
1 Connect the laptop to Com 3 port on the back of the UPS. A serial cable is used
(30989+30989+A9B10003209).
2 Double click the Reset-batt.zip file to open it and execute the reset software.
Results: The "Batterie" dialog box will open.

3 Change Com-Port to 1 and Slave adresse to 00.
4 Click read battery age.
Results: The set battery age to 0 button will be activated.
5 Click set battery age to 0.
Results: The display on the back of the UPS will show "go \ 0" which means that the reset was
successful. If not, try again.

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6.3.4 Checking and adjusting the UPS

The procedure is performed 2 times.
Procedure:
1 Stop the turbine.
2 Count the number of battery modules in the A2 cabinet (rack). If there is an additional controller
switch board next to A2 cabinet with batteries for aviation warning lights, marine light system and
foghorn, they must be included in the count.
3 Press and hold OFF button on the UPS until it sends an acoustic signal.
The LEDs in the battery circuit will switch on for approx. 1 second. Then the number of battery
modules is indicated for approx. 1 second.
(1) ON
(2) OFF
If an incorrect number of modules is indicated, go to next step.

If the correct number of modules is indicated, the test has completed. Go to last step.
4 Press OFF within 3 second the number of times as there are modules connected and hold the
button until an acoustic signal is given.
Results: The adjustment has now been saved. The number of modules indicated on the UPS is
now the same as connected.
5 Press ON to start the UPS again.

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6.4 Servicing aircraft warning lights
6.4.1 Checking aircraft warning lights

The 230 VAC supply for the aircraft lights is connected to a central UPS backup facility. The UPS can
supply the aircraft warning lights for one hour in case the turbine is not connected to the grid.
The aircraft warning lights are checked visually and can be checked as a result of aircraft warning light
error messages (optional) that are transmitted over the network to Siemens Wind Power A/S central
management system.
The following messages can be sent:
Aircraft warning light error This error message is sent in case of:
1. Error on lights.
2. Defect light bulb.
3. Communication error.
Service message This error message is sent when the light bulb needs to be
replaced soon.
GPS message This error message is sent when there is no communication

with the satellite. Synchronization of lights may be affected.
The error message will cease as soon as the communication
is restored.
See the datasheet for the aviation light (ECN22349).

Procedure:
1 Check that the aircraft warning light works.
(1) Aircraft warning light
Change the light bulb if necessary.

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2 Check that the light is leveled on the fixture.
(1) Bubble level on aircraft warning

light

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6.5 Servicing filters, fans and detectors
6.5.1 Replacing filters in controller cabinets

Procedure:
1 Remove the filter holder from the controller cabinets.
(1) Filter
2 Replace the filters.
6.5.2 Replacing fan in frequency converter for yaw gear (option)

If A18 cabinet exist in the nacelle replace the fan.
Procedure:
1 Disconnect the power supply (24 VDC and 400 VAC).
2 Wait 5 minutes while the DC link energy discharges.
3 Replace the fan.
Filter and fan in the controller

cabinet A18

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6.5.3 Testing of smoke detector

All personnel performing electrical isolation need at least Maintenance (MT) competencies or
equivalent (level 7) and have updated electrical awareness training.
If the detector is placed near uninsulated live parts, the work area must be de-energized according to
insulation procedure in "Basic health and safety rules" instruction in this manual, and local rules.
Smoke detectors placed in cabinets capsulated to class IP2X (finger safe) can be dismounted and
remounted (no tools allowed in the cabinet) without performing electrical insulation.
Note: Removing covers from IP2X cabinets if needed will most likely cause a significant reduction in
capsulation class, and an electrical insulation procedure will be required.
Procedure:
1 Use a Smoke Pencil to activate the smoke detector (red light on).
2 Check alarm in hand terminal.
3 Reset smoke detector by dismounting from base and make sure there is no smoke let in the
detector before remount.
4 Reset alarm in hand terminal.
Examples where electrical cabinet needs to be de-energized before testing:
Example 1
(1) Smoke detector
(2) Shield
(3) Live parts

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Example 2
(1) Smoke detector
(2) Shield
(3) Live parts
5 Move on to the next smoke detector.
6.5.4 Testing the visibility meter

Before you begin: The test is only possible in clear weather, that is when the lights are emitted with
low intensity, see "AI/WI 535909".
The visibility meter is an optional accessory.
Procedure:
1 Hold a piece of milky plastic between the gap on the visibility meter and ensure that the aircraft
warning lights change to high intensity.
If the lights do not change to high intensity, then the fault must be identified and corrected.
6.5.5 Resetting max. and min. temperature in temp. sensors

Reset the max. and min. temperature annually and whenever work has been done on temperature
sensors.
Procedure:
1 Go to Menu 7 in the hand terminal.
2 Press the right arrow key until resetting is possible.
3 Press "." to reset.

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7 Tower
7 Tower
7.1 Service-points in tower..................................................................................................................................................... 7-2
7.1.1 Checking foundation bolt caps and railings...................................................................................................................7-2
7.1.2 Inspecting tower door and surroundings.......................................................................................................................7-3
7.1.3 Anchorage points in the tower.......................................................................................................................................7-9
7.1.4 Bolt tightening and tension in the tower........................................................................................................................ 7-9
7.1.5 Checking welds and paint work in tower.......................................................................................................................7-9
7.1.6 Repair procedure for towers........................................................................................................................................7-10
7.1.7 Checking platforms and brackets................................................................................................................................7-10
7.1.8 Checking tower damper.............................................................................................................................................. 7-11
7.1.9 Visual check of the dehumidifier in the tower..............................................................................................................7-12
7.1.10 Check of dehumidifier hoses.....................................................................................................................................7-13

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7 Tower
7.1 Service-points in tower
7.1.1 Checking foundation bolt caps and railings

Procedure:
1 Visually check the foundation bolt caps for damage, and manually check whether they are fitted
tightly on the bolts. If the caps are not tight on the bolts, they must be refitted or replaced.
The caps must only be screwed on to the bolts. Never hammer the caps on.
2 Visually check for cracks and damage to foundation / grouting and railing (option).
Results: If any cracks or damage is observed, contact the Service Department at Siemens Wind
Power.

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7 Tower
7.1.2 Inspecting tower door and surroundings

This inspection of the door and its surrounding components is necessary to ensure the environmental
and structural integrity of the turbine. Optimal turbine operation requires that cooling and
dehumidifying systems operate in an environment that is relatively sealed off from the outside
elements. Electrical and lubrication systems can be significantly degraded by the presence of airborne
contaminants, such as dirt, dust and other particles. Gaps around joints and flanges, in and around the
door and turbine tower wall, can degrade the ability to control temperature and humidity in a turbine
as well as enabling the ingress of dust particles and other airborne contaminants. Gaps must be
sealed to maintain the environmental and functional integrity of the turbine.
The photographs in this procedure are generic and are used for indicative purposes only; the turbine
that you are working on might differ from the types depicted in photographs shown here.
Procedure:
1 Inspect the staircase, external tower platform and railing to ensure that there is no damage and
that everything is secure. Tighten any loose bolts as necessary.
2 If the tower door incorporates a filter, inspect this and replace it if necessary.
3 Inspect the tower door frame to ensure that it is sealed. Seal any gaps if necessary.
An example of a gap that is the

result of a buckled tower door
frame; gaps such as this must be
sealed.
4 Ensure that the door closes securely so that the turbine is protected from air, dust, and water
ingress.

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7 Tower
5 Ensure that the door locking mechanism functions correctly and take corrective actions where
necessary, for example, if the mechanism does not move freely or is difficult to operate.
If the door-handle mechanism does

not move freely, or is difficult to
operate, it might be necessary to
disassemble it, and to file and
lubricate the shaft and bore.
If the door-handle mechanism does

not move freely, or is difficult to
operate, filing and lubricating the
handle shaft and bore can fix the
problem.
6 Ensure that the door moves freely and without impediment, that the movement is not stiff, and
that it can be opened and closed with little effort. If moving the door is difficult, identify the
problem and take corrective action. For example, it might be necessary to disassemble the door
and to use a file or sandpaper to enable the door to move smoothly.

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7 Tower
7 Enter the tower, close the door, turn off the lights, and observe if sunlight is coming in under or
around the door frame. If sunlight is visible around the door frame, adjust the number of washers
and tighten the door bolts to eliminate this.
Example of a door not closing

properly. Gaps such as this can
significantly degrade the
performance of the cooling and
dehumidifying systems and enable
contaminant particles to enter the
turbine, potentially degrading
electrical and lubrication systems.
The door fit can be adjusted by

varying the number of washers.

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7 Tower
The door fit can be adjusted by

tightening the bolts.
8 Ensure that the rubber seal around the door frame is undamaged and securely attached. Replace
or secure the rubber weather seal, if necessary.
A well-fitted rubber weather seal in a

tower door frame.

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7 Tower
Example of poorly fitted rubber

weather seal, where the tower is not
adequately protected from air or
water ingress.
If the rubber seal below the door

frame is damaged, replace it with
EPDM rubber.

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7 Tower
9 Ensure that there are no unplugged holes in, around or below the tower door. Seal any holes or
leaks.
Example of an unplugged hole

below the tower door that must be
sealed off (1). Note the cooling hose
that has been properly sealed (2).
10 Inspect any hoses, joints, and gaps around or below the tower door for leaks or damage, for
example, in the flexible section of the transformer cooling duct.
Transformer cooling duct
Gapssuch as the one shown here

around the transformer must be
sealed.

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7 Tower
7.1.3 Anchorage points in the tower

Always use the yellow anchor eyes mounted in the tower.
For repair work where platforms need to be removed, the tower has been prepared for fitting of extra
eye bolts (yellow plastic plugs are fitted instead). The eye bolts are included in the repair kit to be used
for the job and these must be mounted before starting the work.
7.1.4 Bolt tightening and tension in the tower

See "Bolt tightening".
A sign inside the tower indicates if the bolts in the tower have been tensioned.
7.1.5 Checking welds and paint work in tower

Welds in and around flanges must be inspected to ensure that any cracks forming in these areas are
discovered as soon as possible. Cracks in these areas are unacceptable. All welds in and around
flanges require 100 % visual inspection both inside and outside.
When you inspect these areas it is important that:
Before you begin:
1. All surfaces are completely clean
2. The light conditions are satisfactory
3. Since the welding check is only visual, the entire seam must be very thoroughly checked
Procedure:
1 Visually check welds in and around the door.
2 Visually check the bottom flange inside and outside.
3 Check the tower paint work for signs of corrosion. If there are signs of corrosion, please contact
the Service Department at Siemens Wind Power.

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7 Tower
7.1.6 Repair procedure for towers

For repair procedure, see ZWI1031806: "Repair of paint on steel - Onsite".
7.1.7 Checking platforms and brackets

Procedure:
1 Visually check the platforms and brackets for damage and tighten the bolts in accordance with
"Bolt tightening".
1.1 Pay special attention to welded brackets placed close to round and long seams in the
tower.
1.2 Check the welding of these brackets and their immediate vicinity for cracks and other
damage.
2 Notify the Service Department at Siemens Wind Power if any cracks are found.
3 Check all brackets placed closer to the round and long seams than approx. 3 times the width of
the welding must be checked.
Example:
(1) Brackets placed on/close to
welded round/long seam.

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7 Tower
7.1.8 Checking tower damper

This component is an optional component. The following procedure is to performed only if the
component exists in the turbine.
Procedure:
1 Check the tower damper visually for damage.
Example:
(1) Bearer bolts
2 Re-tighten the bearer bolts.

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7 Tower
7.1.9 Visual check of the dehumidifier in the tower

The dehumidifier in the power unit is an option installed in some turbines.
Procedure:
1 Check the dehumidifier - annual check.
1.1 Test that the dehumidifier starts and stops when turning the hygrostat up and down.
1.2 Set the hygrostat to 40%.
1.3 Hold a hand by the wet air outlet and check whether hot air is streaming out.
(1)Hygrostat (40%)
(2)Dehumidifier.
2 Check the rotor in the dehumidifier - annual check.

2.1 Check that the dehumidifier is operating (fan blowing).
2.2 Disconnect the wet air outlet connection.
2.3 Using a flashlight, look into the wet air outlet to the left to see the rotor turning very
slowly.
2.4 Reconnect the wet air oultet connection.
(1) Wet air outlet connection

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7 Tower
Rotor
3 Replace filter for dehumidifier - annual.
(1) Filter.
3.1 When mounting a new filter, the arrow on the filter must point towards the dehumidifier.
7.1.10 Check of dehumidifier hoses

Procedure:
1 Check visually that the hose routings are as short and direct as possible. If necessary, adjust the
hose routings to improve the air flow
2 If there is a low point on the wet air hose, ensure that a 4 mm hole has been drilled in the hose.
If not, drill such a hole.
3 Make sure that the dry air hose is not choked by cable binders, as this will impede the air flow.
4 Any excessively long hose runs must be cut to ensure that hose routings are as short and
straight as possible.
5 Replace any damaged hoses as necessary.

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7 Tower

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8 Nacelle
8 Nacelle
8.1 Service-points in nacelle...................................................................................................................................................8-2
8.1.1 Checking the hatch safety wire and sealings for hatches............................................................................................. 8-2
8.1.2 Inspection of emergency hatch..................................................................................................................................... 8-3
8.1.3 Checking the tower / nacelle rubber for sealings.......................................................................................................... 8-4
8.1.4 Checking visually and testing dehumidifier................................................................................................................... 8-5
8.1.5 The liquid level of the tower damper in the nacelle.......................................................................................................8-6
8.1.6 Conversion table for liquid level in tower damper......................................................................................................... 8-6
8.1.7 Measuring the liquid level in tower damper...................................................................................................................8-7
8.1.8 Topping-up the tower damper.......................................................................................................................................8-7

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8 Nacelle
8.1 Service-points in nacelle
8.1.1 Checking the hatch safety wire and sealings for hatches
Procedure:
1 Visually check the hatch safety wires for damage.
2 Visually check that all sealings are intact and firmly attached.
(1) Wire
(2) Sealings
(3) Sealings

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8 Nacelle
8.1.2 Inspection of emergency hatch
NOTICE
Wear safety harness!
Procedure:
1 Remove the emergency hatch.
It must be possible to remove the hatch without any use of tools.
2 Inspect the edge of the opening for cracks.

If cracks are found this must be reported to Siemens Service Department or Site management.

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8 Nacelle
8.1.3 Checking the tower / nacelle rubber for sealings

Procedure:
1 Check that the rubber collar is fitted correctly and intact
2 Lubricate with Optipit between the rubber sealings.

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8 Nacelle
8.1.4 Checking visually and testing dehumidifier

Procedure:
1 Check visually that the dehumidifier works.
1.1 Test the hygrostat by adjusting it up and down
1.2 Check that the dehumidifier starts and stops
2 Adjust hygrostat to the original level (40 %).
3 Change the air filter annually.
(1) Dehumidifier
(1) Dehumidifier salt filter
When a new filter is fitted, the arrow on the filter must point towards the dehumidifier.

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8 Nacelle
8.1.5 The liquid level of the tower damper in the nacelle

The volume of liquid in the tower damper is determined by the oscillation frequency of the tower and
may therefore vary from tower to tower. The tower frequency for the turbine on which the liquid level is
being measured must be known to ensure that a correct measurement is obtained. The oscillation
frequency can be read in the hand terminal Menu 16 > WTC Service Setup (page 1) > WTC
Character Data: Tower > Tower frequency: x,xx Hz . When the tower frequency of the turbine is
known, use the conversion table to determine if the tower damper contains the correct volume of
liquid.
8.1.6 Conversion table for liquid level in tower damper

Sloshing tower damper in 2.3 MW nacelle (1750 x 1330 mm)
Tower frequency Damper volume Liquid height
Hz Liter cm
0.24 169 7
0.25 185 8
0.26 202 9
0.27 218 9
0.28 234 10
0.29 250 11
0.30 267 11
0.31 284 12
0.32 303 13
0.33 323 14
0.34 344 15
0.35 365 16
0.36 388 17
0.37 412 18
0.38 436 19
0.39 460 20

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8 Nacelle
8.1.7 Measuring the liquid level in tower damper

Procedure:
1 Find the liquid container of the tower damper in the nacelle under the coupling close to the oil
filter.
2 Measure the liquid level by means of a tape measure against the recommended liquid level
(specified in the conversion table).
When you measure there is a tolerance on 5 mm.
(1) Plug for liquid container

(2) Tape measure
3 Unscrew the plug from the tower damper.

4 Insert a clean dipstick vertically into the filling hole until it reaches the bottom of the tower
damper.
5 Pull out the dipstick.
6 Measure the liquid level on the dipstick with a tape measure.
8.1.8 Topping-up the tower damper

Procedure:
1 Use a BASF Glysantin mixture in the tower damper.
2 Use 33 % mixture in standard turbines and a 50 % mixture in cold climate turbines.
3 See the site setup to determine turbine type.

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8 Nacelle

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9 Yaw system
9 Yaw system
9.1 Safety..................................................................................................................................................................................9-2
9.1.1 Safety precautions working in yaw section................................................................................................................... 9-2
9.2 Description of the yaw systems....................................................................................................................................... 9-3
9.2.1 Yaw system ..................................................................................................................................................................9-3
9.3 Lubrication......................................................................................................................................................................... 9-4
9.3.1 Checking the central lubrication system........................................................................................................................9-4
9.3.2 Refilling the lubrication system for the yaw system.......................................................................................................9-5
9.4 Yaw position.......................................................................................................................................................................9-7
9.4.1 Yaw position indicator .................................................................................................................................................. 9-7
9.4.2 Maintaining yaw position indicator................................................................................................................................ 9-7
9.4.3 Adjusting the yaw position indicator..............................................................................................................................9-8
9.4.4 Adjusting the yaw position indicator by use of GPS......................................................................................................9-8
9.5 Yaw motor/gear..................................................................................................................................................................9-9
9.5.1 Yaw motor and yaw gear.............................................................................................................................................. 9-9
9.5.2 Checking the yaw gear oil level...................................................................................................................................9-10
9.5.3 Dismount the yaw gear............................................................................................................................................... 9-10
9.5.4 Tightening yaw gear bolts........................................................................................................................................... 9-11
9.5.5 Tightening bolts in the yaw claws................................................................................................................................9-11
9.5.6 Testing of yaw motor/gear...........................................................................................................................................9-12
9.5.7 Procedure for testing yaw motor/gear.........................................................................................................................9-13
9.6 Adjusting yaw brake torque............................................................................................................................................9-14
9.7 Cable Twist indicator.......................................................................................................................................................9-18
9.7.1 Inspecting the cable twist switch.................................................................................................................................9-18
9.8 Wind vane and anemometer...........................................................................................................................................9-19
9.8.1 Checking the wind vane and anemometer..................................................................................................................9-19
9.8.2 Testing the heating elements on wind vane and anemometer....................................................................................9-23

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9 Yaw system
9.1 Safety
9.1.1 Safety precautions working in yaw section

For each service visit the safety precautions described below must be followed.
Important: For working in the turbine the "Basic Health and Safety Rules" must be followed.
Before you begin:
WARNING
Tower/Yaw System
Entanglement hazard.
Use the manual yaw lock when:
Working on the yaw claws, yaw teeth or yaw motor brakes
Performing repairs on the outside of the turbine
Using an external crane in close proximity to the turbine

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9 Yaw system
9.2 Description of the yaw systems
9.2.1 Yaw system

In the yaw system there are two versions of yaw motors:
High-slip and low-torque (HILT) motor
Non-HILT motor
In the Non-HILT yaw system, motors are controlled by a frequency converter located in A18 cabinet,
while the HILT yaw system has high-slip low-torque special motors fitted with a spring-applied brake,
and this system is controlled directly from on/off relays in A3 cabinet . The brake is engaged when the
nacelle is not yawing, thus holding the nacelle in the desired position. The yaw system will slip if there
are very large loads or no power.

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9 Yaw system
9.3 Lubrication
9.3.1 Checking the central lubrication system

Lubrication of the yaw pinion, yaw gear wheel, sliding shoe holders and sliding shoes.
Procedure:
1 Check lubrication and wear of the teeth.
2 Check visually couplings for leaks at pump, distributor block and inlet.
3 Start the lubrication system.
4 Use the hand terminal Menu 24 > Screen 15.
5 Press "." for start.
6 Press "." for stop.
7 Read "grease total" , when the automatic lubrication is running.
8 Check that it increases when activated Menu 24 > Screen 15 in hand terminal.
9 Check the "low level sensor" by removing the plug from the lubrication system.
10 After 10 min. the controller shall come up with a fault in the hand terminal.
Central lubrication system for sliding

shoe holders, yaw pinion and yaw
gear wheel.
The counter can be reset in the hand terminal MENU 24>Screen 18

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9 Yaw system
9.3.2 Refilling the lubrication system for the yaw system
Figure 9.3.2.84 Lubrication in yaw section
Important: Dirt and impurities in the grease is not accepted as this will cause the pump element to
malfunction. Temperature of the grease must not be too low as this may result in the agitator having
trouble getting the air out of the product. The specific temperature depends on the type of grease. For
volume and type of grease see "Lubrication chart".
Procedure:
1 Check for correct grease type see "Lubrication chart", and screw the grease cartridge into the
base of the easy grease pump.
2 Flush the easy grease pump and hose with the correct grease type.
(1) Grease cartridge
3 Connect the hose to the quick acting coupling of the lubrication system.
4 Fill the grease container for the central lubrication system.
Do not overfill.

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9 Yaw system
5 Disconnect the hose after refilling.
(1) Filling hose connected to the

lubrication system

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9 Yaw system
9.4 Yaw position
9.4.1 Yaw position indicator

The yaw position indicator prevents overtwisting and subsequent breaking of both the main power
cables and the controller cables.
1. Untwisting will only take place if the wind speed is below 3.5 m/s. When the cables have twisted
1.5 revolutions, the turbine untwists the cables.
9.4.2 Maintaining yaw position indicator

Procedure:
1 Check that the direction read out in the hand terminal display, Menu 24 > Screen 5, is correct
compared to the nacelle position measured with a compass.
When the turbine nose cone is pointing north, the yaw position indicator readout in the hand
terminal must be 0 , Menu 24 > Screen 5.
2 If this is not the case, adjust the yaw position indicator as described in Adjusting the yaw position
indicator.
3 Check that the cables are not excessively twisted.
(If cables are excessively twisted they must be untwisted and the nose cone must point north.)
4 Check that the yaw position indicator is correctly tightened and that the nylon gear wheels are
properly meshed.

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9 Yaw system
9.4.3 Adjusting the yaw position indicator

Procedure:
1 Use a compass to find North of the nacelle. Yaw the nacelle towards north, until the nose cone is
pointing north, the cables must hang as straight as possible, maximum half round twisted.
2 See Menu 24 > Screen 5 in the hand terminal.
3 Remove the cover from the yaw position indicator.
(1) Yaw position indicator
4 Loosen the 4 screws and push the large gear wheels away from the small gear wheel.
(1) Screws
(2) Direction to push the large gear
wheel.
5 Turn the large gear wheel until the yaw position indicator is at 0 and R (revolutions) is 0 . The
direction read out is shown in the hand terminal Menu 24 > Screen 5.
6 Push the large gear wheel back into mesh with the small gear wheel (not too tight).
7 Tighten the 4 screws and mount the cover.
9.4.4 Adjusting the yaw position indicator by use of GPS

See ZWI-1020784 "Adjusting the yaw position indicator by use of GPS"

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9 Yaw system
9.5 Yaw motor/gear
9.5.1 Yaw motor and yaw gear

There are two versions of yaw motors. In the Non-HILT yaw system, motors are controlled by a
frequency converter located in A18 cabinet, while the HILT yaw system has high-slip low- torque
motors fitted with a spring-applied brake, and this system is controlled directly from on/off relays in A3
cabinet.
(Non-HILT yaw system)
(1) Yaw motor
(2) Yaw gear
(3) Bleed valve
(4) Oil drain valve / oil filling valve
(5) Upper sight glass
(6) Lower oil sight glass
(HILT yaw system)

(1) Yaw motor
(2) Yaw gear
(3) Bleed valve
(4) Brake

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9 Yaw system
9.5.2 Checking the yaw gear oil level

This procedure only applies to Non-HILT yaw motors.
Procedure:
1 Check the oil level on the oil level gauge.
The oil level must be between the lower and upper sight glass.
If the bottom sight glass is not full, add oil until it is just visible in the top sight glass.
2 When adding oil. Connect the hose from a pressurized oil container to the oil drain / filling valve
(4).
For correct oil type - see chapter 5 in section 'Lubrication charts'.
3 Follow the procedure in the work instruction, ZWI1002353, 'Replacement of yaw gear oil'.
9.5.3 Dismount the yaw gear

Procedure:
1 Use the 3 external pull-out bolts when dismounting the yaw gear.
(1) Pull-out bolt

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9 Yaw system
9.5.4 Tightening yaw gear bolts

Procedure:
1 Tighten the bolts according to "Bolt tightening".
(1) Yaw gear
2 Lubricate according to "Lubrication chart".
9.5.5 Tightening bolts in the yaw claws

Procedure:
1 Tighten the adjustment bolts according to "Bolt tightening".
(1) Yaw claw

(2) Bolts for yaw claws
(3) Adjustment bolts (vertical)
(4) Adjustment bolts (horizontal)

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9 Yaw system
9.5.6 Testing of yaw motor/gear
WARNING
Prior to commencing work on any circuit, it must be ensured that the work area is de-
energized. See the section "Electrical work" in safety instructions SI545781 "Basic
health and safety rules for technicians working in Siemens Wind Turbines".
Working with live voltage is only permissible for testing or error detecting (see safety rules for
"Electrical work").
To detect a malfunction yaw motor/gear measuring of power consumption needs to be performed in

either the A18 or A3 cabinet depending on yaw system.
Circuit breaker panel in A18 cabinet
Measuring point for power consumption
for the Non-HILT yaw system
Circuit breaker panel in A3 cabinet

Measuring point for power consumption
for the HILT yaw system

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9 Yaw system
9.5.7 Procedure for testing yaw motor/gear

Use a clamp ammeter to measure the power consumption on each motor.
Procedure:
1 Measure the power consumption on each motor and each phase in A18 or A3 cabinet with a
clamp ammeter.
2 Check and record the power consumption on each motor.
(All yaw motors must have power consumption)
3 Verify that no single yaw motor has a power consumption of 30% above the others.
(In case this happens, repair or replace affected yaw gear/motor)

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9 Yaw system
9.6 Adjusting yaw brake torque

The photographs in this procedure are generic and are used for indicative purposes only; the turbine
that you are working on might differ from the types depicted in photographs shown here.
Procedure:
1 Disconnect and lock switch for yaw motor on AA3 Controller.
2 Remove the ventilator cover on the motor.
(1) Ventilator cover

(2) Ventilator fan
3 Remove the fan using 2 screwdrivers or other suitable tools.
Push outwards

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9 Yaw system
4 Check brake rotor thickness using a sliding gauge. If rotor thickness is below 8 mm the motor/
brake needs to be replaced.
5 Measure air gap using a feeler gauge. The air gap should be measured at 3 locations. If the air
gap is more than 0.55 mm, the brake needs to be readjusted.
6 Adjust air gap if necessary.

6.1 Unscrew the Allen screws until slightly loose.

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9 Yaw system
6.2 Screw the threaded sleeves into the stator. Turning 1/6 revolution counter-clockwise
reduces the air gap by approximately 0.15 mm.
6.3 Tighten the Allen (10Nm) bolts and check air gap. The adjusted air gap should be
between 0.3 - 0.4 mm.
7 Loosen the yaw motor brake using 2 spanners to "lift" the brake.
Lift upwards
8 Mount "special nut" for turning the yaw motor shaft.
Special nut mounted on shaft

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9 Yaw system
9 Adjust the brake torque with a hook wrench, so the yaw motor shaft can not turn when the torque
wrench is set to 20 Nm. Adjust the brake torque with a hook spanner so the yaw motor shaft can
turn when the torque wrench is set to 22 Nm.
Note: Max allowable adjustment height of the adjustment ring is 12.6 mm.
10 After brake adjustment, refit rubber sleeve.

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9 Yaw system
9.7 Cable Twist indicator
9.7.1 Inspecting the cable twist switch

The cable twist switch is mounted at the top of the tower. The function of the cable twist switch is to
stop the turbine when the nacelle has turned 2.5 revolutions either CW or CCW.
(1) Cable twist switch with a weight
connected to the wire.
Procedure:
1 Visually inspect the cable twist switch and the steel wire for correct installation.
2 Check the switch eye and wire for wear and replace if necessary.

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9 Yaw system
9.8 Wind vane and anemometer
9.8.1 Checking the wind vane and anemometer

Procedure:
1 Check that the wind vane and anemometer are securely fastened.
2 Cups are correctly fitted and intact.
(1) Anemometer
(2) Wind Vane
3 Fold down the wind vane stand.
Note: "Basic Health and Safety Rules for technicians working in Siemens Wind Power Turbines",
SI 545781, always apply.
4 Secure a double fall arrester to the back of harness, and to both anchor bolts at the rear of the
turbine.

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9 Yaw system
5 Remove the bolt through the middle of the wind vane stand.
6 Remove the top bolt at the root of the wind vane stand.
7 Loosen the bottom bolt, just enough to allow movement of the wind vane stand.
(1) Top bolt

(2) Bottom bolt

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9 Yaw system
8 Remove the cable cover.
9 Lift the wind vane stand with a crowbar, using the wind vane fixing bracket as support.
Be careful not to damage the cables with the crowbar.
10 Hook on the crane hook to the eye.

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9 Yaw system
11 Slowly tilt the wind vane stand forward, while making sure that the cables are not stressed.
If necessary, cut the cable ties at the rear end to allow the cables to move.
12 Gently lower the wind vane stand onto the generator while making sure that the cables are not
stressed.
If necessary, cut the cables ties at the rear end to allow the cables to move.

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9 Yaw system
13 Raise the wind vane stand again following the opposite procedure.
9.8.2 Testing the heating elements on wind vane and anemometer

This component is an optional component. The following procedure is to be performed only if the
Procedure:
1 Activate heating via Menu 2 Screen 5 in the hand terminal.
2 Spray cooling spray directly on the temperature sensor.
3 Check that the heating elements get warm.
CAUTION: The heating elements might be very hot.

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9 Yaw system

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10 Transmission system
10.1 Main bearing...................................................................................................................................................................10-2
10.1.1 Main bearing............................................................................................................................................................. 10-2
10.1.2 Refilling the lubrication system for the main bearing.................................................................................................10-3
10.1.3 Emptying and clean the drip plate.............................................................................................................................10-4
10.1.4 Removing discharge grease..................................................................................................................................... 10-5
10.1.5 Lubricating the labyrinth seals...................................................................................................................................10-5
10.1.6 Checking the central lubrication system for the main bearing...................................................................................10-6
10.2 Main gear........................................................................................................................................................................10-7
10.2.1 Inspection of the main gear.......................................................................................................................................10-7
10.2.2 Checking the oil level in the gearbox........................................................................................................................ 10-8
10.2.3 Checking oil level sensor for the gearbox................................................................................................................. 10-9
10.2.4 Checking the pressure transducer for gearbox oil pressure................................................................................... 10-10
10.2.5 Checking the gear oil pump for leakage..................................................................................................................10-11
10.3 Service frequencies on idle pump system................................................................................................................ 10-12
10.3.1 Service frequencies on idle pump system...............................................................................................................10-12
10.3.2 Checking oil flow through idle pump and cleaning pipe strainer in Winergy Gear.................................................. 10-13
10.3.3 Checking the oil flow through the idle pump in a Hansen Gear.............................................................................. 10-14
10.3.4 Checking the magnetic rod (Hansen gear only)......................................................................................................10-15
10.3.5 Cleaning and checking gear and hydraulic oil cooler..............................................................................................10-16
10.3.6 Replacing the air filter for the gearbox.................................................................................................................... 10-19
10.3.7 Cleaning the ball valve filter for bleeding of the in-line filter....................................................................................10-20
10.3.8 Replacing the off-line filter for the gearbox............................................................................................................. 10-22
10.3.9 In-line oil filter for gearbox.......................................................................................................................................10-24
10.3.10 Replacing the in-line oil filter for the gearbox........................................................................................................10-25
10.4 Generator......................................................................................................................................................................10-32
10.4.1 Generator................................................................................................................................................................10-32
10.4.2 Checking the generator suspension........................................................................................................................10-32
10.4.3 Checking the central lubrication of the generator bearings.....................................................................................10-33
10.4.4 Refilling the lubrication system for the generator bearing.......................................................................................10-34
10.4.5 Emptying the drip plates on the generator.............................................................................................................. 10-36
10.4.6 Cleaning the bearing insulation on the generator................................................................................................... 10-37
10.4.7 Measuring resistance at D-end where carbons are mounted................................................................................. 10-38
10.4.8 Measuring the bearing insulation at D-end where carbons are lifted ..................................................................... 10-39
10.4.9 Checking the CENTA coupling................................................................................................................................10-40
10.4.10 Checking the generator alignment........................................................................................................................ 10-41
10.4.11 Checking the HCU manually.................................................................................................................................10-44

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10.1 Main bearing
10.1.1 Main bearing

The main bearing is placed in the nacelle and absorbs the rotor thrust and reaction from gravity and
bending moments. It is a spherical roller bearing which is shrink fitted on the main shaft.
(1) Main bearing
(2) Central lubrication system for main
bearing

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10.1.2 Refilling the lubrication system for the main bearing

For correct grease type, see "Lubrication chart".
(1) Main bearing lubrication system
Procedure:
1 Refill the main bearing lubrication system with the easy grease pump.
The temperature of the grease must not be too low as this may result in difficulties for the
agitator in getting the air out of the product. The specific temperature depends on the type of
grease.
Dirt and impurities in the grease is not accepted as this will cause the pump element to
malfunction.
1.1 Check for correct grease type and screw the grease cartridge into the base of the easy
grease pump
1.2 Flush the pump and hose with the correct grease type
1.3 Connect the hose to the quick-acting coupling on the lubrication system.
1.4 Fill the grease container for the central lubrication system.
Do NOT overfill.

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1.5 Disconnect the hose after refilling.
(1) Filling hose connected to

the lubrication system
10.1.3 Emptying and clean the drip plate

Procedure:
1 Empty and clean the drip plates on the main bearing.
(1) Drip plate

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10.1.4 Removing discharge grease

Procedure:
1 Remove discharge grease by emptying or replacing the plastic cans.
(1) Grease discharge can
10.1.5 Lubricating the labyrinth seals

Important: The turbine must be idling before lubricating.
Procedure:
1 See "Lubrication chart" for correct grease type.
2 Lubricate the labyrinth seals.
3 Use a manual grease gun.
The grease must be distributed among all grease nipples.
4 Lubricate the front and the rear seals.
(1) Grease nipple for labyrinth seals

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10.1.6 Checking the central lubrication system for the main bearing
The check of the central lubrication system consist of a visual inspection for leaks and a functional test
of the central lubrication unit.
Procedure:
1 Visually check the couplings for leaks.
1.1 Check the couplings for leaks at the pump
1.2 Check the distributor block
1.3 Check the inlet of the central lubrication system
2 Check that the central lubrication system functions correctly.
2.1 Enter Menu 24 > Screen 14 in the hand terminal to start up the lubrication unit
2.2 Press . for Start
2.3 Press . for Stop
2.4 Read "grease total", when automatic lubrication is running, and check that it increases
when activated
2.5 Check the low level sensor by removing the plug from the lubrication system. After 10
min. the controller shall come up with a fault in the hand terminal.
2.6 The counter can be reset in the hand terminal Menu 24 > Screen 18

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10.2 Main gear
10.2.1 Inspection of the main gear

The check is performed in compliance with check list no. "CH547352". After the check list has been
filled in, send it to Siemens Wind Power A/S.

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10.2.2 Checking the oil level in the gearbox

Before you begin: The turbine must have been stopped for 10 minutes before checking the oil level.
(1) Oil level glass (Hansen gear)
(2) Oil level glass (Winergy gear).
Procedure:
1 Check the oil level at the level glass.
2 The oil level must be between MAX level and MIN level due to risk of leakages if above MAX.
3 If the level is below MIN but visible in the level glass, it is allowed to continue the operation of the
gearbox for maximum 5 days. Gear oil MUST be filled as soon as possible.
4 If no oil is visible in the level glass, do following:
4.1 stop all operations of the gearbox
only idling is allowed until the gearbox has been refilled with oil.
4.2 Refill with gear oil untill the oil level is between MIN and MAX level.
5 If oil level is over MAX, take out oil at drain valve until oil level is between MIN and MAX level.
6 Check for leakages.

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10.2.3 Checking oil level sensor for the gearbox

The oil level sensor is connected to the controller.
Procedure:
1 Disconnect plug (DI 8) in A3 - K2 cabinet.
2 Read the error message in the hand terminal.
3 Reconnect plug (DI 8) in A3 - K2 cabinet.
4 Check that the oil level sensor is connected correctly to the controller.
5 In case of malfunctioning, replace the oil level sensor. (Replace the entire unit as sensor and oil
container are calibrated as one unit).

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10.2.4 Checking the pressure transducer for gearbox oil pressure

Procedure:
1 Connect the hand terminal display to the turbine WTC and open Menu 2 > Screen 9.
2 Mount a manometer on the test nipple.
(1) Pressure transducer for gear oil

(2) Test nipple
(1) Pressure transducer for gear oil

(2) Test nipple
(3) Manometer
(4) Hand terminal
3 Start the oil pump.

3.1 Enter Menu 30 "Test switches"
3.2 Press 9 (Dahl 9 in zero position)
3.3 Press Esc (Escape).
3.4 Enter Menu 25 and go to "Output Control".
3.5 Find "gear oil pump Low-speed in WTC documentation
3.6 Use the arrow keys to find the required output
3.7 Press "." to start the pump
4 Read the pressure on the manometer.
5 Check the display of the hand terminal to ensure that the pressure is the same as on the
manometer.
6 Press "." to stop the pump after test.

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7 Reset WTC3 computer after test.
10.2.5 Checking the gear oil pump for leakage

Procedure:
1 Visually check pump housing for leakages. 2 different types of oil pumps are used.
Leakage may occur in the shaft seal between the pump and the motor.
(1) Pump for gear oil

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10.3 Service frequencies on idle pump system
10.3.1 Service frequencies on idle pump system
Service interval Task

Yearly Clean pipe strainer in idle pump system
10 years Replace idle valve and pump.

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10.3.2 Checking oil flow through idle pump and cleaning pipe strainer in Winergy
Gear
Procedure:
1 Check the oil flow through the idle pump.
Winergy Gear
(1) Idle valve
(2) Idle pump
(3) Pipe strainer
2 Dismount the pipe strainer
(1) Pipe strainer
3 Clean the pipe strainer.

4 Allow the turbine to idle.
Results: Now oil should come out of the pipe strainer.
5 Stop the turbine from idling.
6 Remove spilled oil with a cloth.
7 Refit the pipe strainer.

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10.3.3 Checking the oil flow through the idle pump in a Hansen Gear
Procedure:
1 Stop the turbine.
2 Dismount the pipe strainer.
3 Clean the pipe strainer.
4 Allow the turbine to idle.
Results: Now oil should come out of the pipe strainer.
5 Stop the turbine from idling.
6 Remove spilled oil with a cloth.
7 Refit the pipe strainer.
Hansen Gear type 1

(1) Pipe strainer
Hansen Gear type 2

(1) Pipe strainer

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10.3.4 Checking the magnetic rod (Hansen gear only)

Procedure:
1 Dismount the magnetic rod.
2 Estimate the degree of contamination of the magnetic rod, according to the photo.
2.1 Note the value of contamination in the check list
3 Refit the magnetic rod.

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10.3.5 Cleaning and checking gear and hydraulic oil cooler
NOTICE
Wear safety harness!
Procedure:
1 Remove the checker plate cover in order to get to the oil coolers.
(1) Cover
2 Clean the area if necessary.

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3 Clean the outside fins of the oil cooler and both sides of the hydraulic oil cooler.
(1) Hydraulic oil cooler

(2) Gear oil cooler
NOTICE
Wear eye protection
When working on the hydraulic system, safety glasses must be worn to protect the eyes
if a seal, hose or other pressurized hydraulic component should burst when under
pressure.
Wear safety gloves
Protective gloves must be worn as the hydraulic oil can cause skin irritation.
3.1 Use a powerful vacuum cleaner and cleaner brush attached to clean oil cooling and
hydraulic oil cooling coolers
A new bag and filter increase suction significantly
3.2 Point with a flash light through the cooling fins

Results: There should now be free air passage through the oil cooler fins
3.3 If the air passage is still not perfect, spray on Metal-clean or motor cleaner to remove any
dirt from the fins.
Important: If motor cleaner is used, always finish the cleaning procedure with Metal-
clean in order to make the fins completely dry. Dirt will otherwise quickly accumulate
again.
3.4 Start the cooling fan and let it run until the oil cooler is completely dry
3.5 Vacuum clean the fins again
Results: There should now be free air passage through the oil cooler radiator fins
3.7 If the air passage is still not perfect, use compressed air to clean the fins
Results: There should now be free air passage through the oil cooler fins
3.9 If the air passage is still not perfect, repeat step 3.3 to 3.8 until the oil cooler radiator fins
are clean and there is free air passage through the cooler fins

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4 Check the oil cooler for leakages.

The cooler fins must be dry and free of any oil
4.2 If the cooler leaks even the slightest amount of oil into the cooling fins it must be replaced
as dirt will otherwise quickly accumulate and reduce the cooling capacity
5 In case of any fluid is seen in the drip tray, clean the drip tray.
6 If the turbine is installed offshoreor in a salt-latent environmentapply anti-corrosion
compound to the hose fittings on both hydraulic oil and gear oil cooler. This should be done every
year.
(1) Fitting with rust protection

applied

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10.3.6 Replacing the air filter for the gearbox

Air filter for gearbox. 2 different gearboxes are used.
Procedure:
1 Unscrew the cover of the filter housing.
2 Replace the filter cartridge.
3 Refit the cover.
(1) Air filter for gearbox
(1) Air filter for gearbox

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10.3.7 Cleaning the ball valve filter for bleeding of the in-line filter
Procedure:
1 Make sure the ball valve is closed.
(1) Ball valve shown in open

position (Winergy gear)
(1) Ball valve shown in closed

position (Hansen gear)

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2 Unscrew the cap on the ball valve filter and clean the filter.
Ball valve filter shown disassembled
3 Reassemble the filter.

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10.3.8 Replacing the off-line filter for the gearbox

Before you begin: For service interval, see "Lubrication chart".
(1) Off-line filter for gearbox (Type: C. C.
Jensen)
Procedure:
1 Stop the pump for the filter.
2 Turn off the valve at the gearbox.
3 Drain the filter housing.
Important: Before replacing the filter element, the filter housing must be drained of oil.
(1) Valve at gearbox
(2) Hand pump
(3) Draining valve on filter
(4) Bleed plug
(5) Top nut
3.1 Connect the hand pump to the draining valve of the filter and open the draining valve
3.2 Pump air into the filter
Results: Air is pumped into the filter which presses the oil through the return hose to the
gearbox
3.3 When air is heard in the return hose, wait for minimum 5 minutes and pump again.
(Repeat this 3 times)
3.4 Loosen the bleed plug at the top of the filter housing to bleed the filter of air

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4 Replace the filter element.
(1) Wing nut

(2) Filter element
4.1 Remove the top nut on the filter housing and carefully remove the filter cap
4.2 Unscrew the wing nut and remove the spring and the spring guide
4.3 Remove the filter element and wrap it in a bag
4.4 Replace all the seals
4.5 Fit a new filter element in the filter housing
4.6 Check that the O-ring is placed correctly in the groove and press the spring and spring
guide into place
4.7 Loosely tighten the wing nut until it touches the top of the spring guide in order to ensure
everything is in place. Then turn it another 4 times approximately
4.8 Fit the filter cap and tighten the nut at the top of the housing
5 Remove the hand pump.
6 Close the draining valve and insert the plug (the valve may drip if not plugged).
7 Clean the filter housing and surrounding area of oil.
8 Open the valve at the gearbox, start the filter and let it run for a minimum of 15 minutes.
9 Check for leaks and check the pressure in the filter.
It is ok for the pressure to be in the red area if the oil is cold.
10 Bleed the filter of air. Loosen the bleed plug until oil comes out. Then tighten the bleed plug.
11 Check the oil level in the gearbox. Add oil if necessary.

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10.3.9 In-line oil filter for gearbox

(1) Fairey Arlon in-line filter

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10.3.10 Replacing the in-line oil filter for the gearbox

See "Lubrication chart".
The turbine uses 1 of 2 types of gearboxes.
Procedure:
1 Drain the filter using the WTC (Wind Turbine Controller).
1.1 Enter Menu 30"Test switches"
1.2 Press 9 (Dahl 9 in zero position)
1.3 Press Esc (Escape)
1.4 Enter Menu 25 and go to "Output Control"
1.5 Find "gear oil pump Low-speed" in the WTC documentation
1.6 Use the arrow keys to find the required output
2 Close the ball valve and the main valve on the gear.
(1) Ball valve (shown open)

(2) Main valve (shown open)
(1) Ball valve (shown open)

(2) Main valve (shown open)
3 Continue to drain the filter.

3.1 Press "." to start the pump

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3.2 Remove the screw on the pump immediately after the pump has started
(1) Screw on pump
3.3 Allow the pump to run for max. 1 min. at the time
3.4 Mount the screw on the oil pump again while the pump is still running
3.5 Stop the pump immediately after the screw on the oil pump is fitted.
3.6 Repeat the procedure 2-3 times at 10 -15 min. intervals.
Results: Now oil has been drained from the filter and the filter has been filled with air
4 Dismantle the hose on the filter cover.

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5 Remove the filter cover.
6 Fit the hook from the service crane in the lifting eye of the filter. Use the service crane for lifting
out the filter element carefully, and allow the oil to drip off.
(1) Lifting out the filter element

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7 Visually assess the degree of pollution on the filter magnets.

The degree of pollution on the magnets are estimated using following photos. The pollution
degree is in the range from 1 to 5 with number 1 as completely clean and 5 as very heavily
polluted.
7.1 Write down the corresponding number in the check list
(1) Magnets on filter element
(1) Completely clean

(2) Slightly polluted
(3) Medium polluted
(4) Heavily polluted
(5) Very heavily polluted
8 The filter element is taken apart by removing the nut at the bottom of the element.

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Do not take the filter element apart until it has crossed the edge of the filter housing (to avoid
accidentally dropping the nut into the filter house).
9 Remove the old filter element and pack it in a bag.
10 Clean the filter magnets.

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11 Insert a new filter.
12 Tighten the nut at the bottom of the filter element.
13 Carefully place the new filter in the housing. Assemble the filter housing and cross-tighten to 400
Nm.

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14 Mount the hose.
15 Open the main valve and the filter bleeding valve.

16 Enter Menu 3 and reset the computer.
Important: Check for leakages. Check that the seal / O-ring is intact.

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10.4 Generator
10.4.1 Generator
(1) Generator suspension
10.4.2 Checking the generator suspension

Before you begin: See "Bolt tightening".
Procedure:
1 Check that the Polyurethane (PUR rubber) in the generator suspension is intact.
(1) PUR rubber

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10.4.3 Checking the central lubrication of the generator bearings

Procedure:
1 Visually check joints for leaks at pump, distributor block and inlet.
2 Check the lubrication unit.
2.1 Enter Menu 24 > Screen 24 in the hand terminal
2.2 Press "." for start
2.3 Press "." for stop
2.4 Read "grease total" when automatic lubrication is running, and check that it increases
when activated
3 Check the "low level sensor" by removing the plug from the lubrication system.
3.1 After 10 min. the controller shall come up with a fault in the hand terminal.
4 The counter can be reset in the hand terminal Menu 24 > Screen 18.

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10.4.4 Refilling the lubrication system for the generator bearing

See "Lubrication chart".
Procedure:
1 Refill the lubrication system for the generator bearings with the easy grease pump.
Lubrication system for generator

bearings
The temperature of the grease must not be too low as this may result in difficulties for the
agitator in getting the air out of the product. The specific temperature depends on the type of
grease.
Dirt and impurities in the grease is not accepted as this will cause the pump element to
malfunction.
2 Check for correct grease type and screw the grease cartridge into the base of the easy grease
pump.
3 Flush the easy grease pump and hose with the correct grease type.
4 Connect the hose to the quick-acting coupling on the lubrication system.
4.1 Fill the grease container for the central lubrication system.
Do NOT overfill.
4.2 Disconnect the hose after refilling.

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(1) Quick coupling on the lubrication

system

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10.4.5 Emptying the drip plates on the generator

Procedure:
1 Empty the front generator drip plate and clean the grease drain.
(1) Drip plate

(2) Grease drain
2 Empty the rear generator drip plate and clean the grease drain.
(1) Grease drain

(2) Drip plate

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10.4.6 Cleaning the bearing insulation on the generator

Procedure:
2 Remove the cover on coupling.
3 Clean the carbons.
4 Clean the slip ring on the rotor.
5 Only use dry rags for cleaning. Do not use any cleaning agents.
6 Clean the bearing liner on both end shields.
6.1 Remove all dirt and grease with a rag that has been immersed in solvent SA-2000, part
No. 35096
6.2 Clean the area that is within 5 cm of the insulation, both on the inside and the outside
7 Replace the carbons if shorter than 19mm in lenght.
8 Mount the cover on coupling.

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10.4.7 Measuring resistance at D-end where carbons are mounted

Procedure:
1 Measure the resistance with a calibrated multimeter.
1.1 Hold one probe on slip ring and the other on chassis ground
1.2 Measure the resistance and make sure it is less than 1 Ohm
2 Write down the value in the check list.
(1) Carbons mounted

(2) Point of measurement (slip ring)
(3) Insulation
3 Point of measurement for chassis ground (place where no paint is present).
(1) Point of measurement for

chassis ground

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10.4.8 Measuring the bearing insulation at D-end where carbons are lifted
Before you begin: The bearings must be kept insulated. After any service work has been done to the
generator, check the insulation resistance. Special attention should be taken when reconnecting or
installing new grease pipes. A short circuit can happen if proper care is not exercised. The air through
the air channel at the ND-end must flow freely. Do not place anything on the machine that could fall
into the air channel.
Procedure:
1 Remove the carbons from the carbon holder, and place them on top of the carbon holder so that
they do not touch anything but the carbon holder.
2 Use a megger. The value must be above 1 giga-ohm.
(1) Carbons lifted

(2) Point of measurement (slip ring)
(3) Insulation
2.1 Place one probe on the slip ring of the rotor and the other probe on chassis ground
2.2 Measure the resistance for one minute
2.3 The value must be above 1 giga-ohm
2.4 Write down the value in the check list

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10.4.9 Checking the CENTA coupling

Procedure:
1 Check of CENTA coupling.
2 Remove any loose dirt from the coupling.

3 Inspect the coupling for cracks, chips or missing parts.
4 Replace faulty and missing parts.
5 Make a visual inspection of the links every 12 months
6 Exchange links in case of damage.
Links are packaged in sets. All links of a link set are the same weight. Only mount or replace
links in complete sets.

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10.4.10 Checking the generator alignment

The generator alignment is measured in terms of axial, angular and parallel deviation. If the deviations
are outside the specified tolerances the generator must be aligned.
Procedure:
1 Measure the axial deviation and adjust the alignment as needed using the procedure described in
the Work Instructions.
"ZWI1004240 Alignment and adjustment of generator with dial gauge".

"ZWI566637 Aligning and adjusting the generator with fixture laser".
Max. wind limit for alignment is 12 m/s.

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Axial deviation
A is measured at top and bottom
A = 635mm 1 mm
Angular deviation
B is measured 10 - 15 mm inside
the edge of the flange.
Vertical parallel deviation

(1) Gearbox
(2) Generator - Generator deviation
above the gearbox is not permitted.
(C) Generator deviation below the
gearbox is allowed with max. 1 mm.

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Horizontal alignment
(1) Gearbox
(2) Generator - Generator deviation
to the right of the gearbox is not
permitted. Generator deviation to
the left of the gearbox is allowed
with max. 1 mm.

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10.4.11 Checking the HCU manually

Important: The turbine must be stopped during check.
WARNING
Caution - this is live work.
Secure the work area according to live work regulations and local instructions (LOTO/AWP).
Procedure:
1 Engage HS rotor lock.
2 Check that an HCU error message occurs in hand terminal when the pin is removed from the pin
holder.
3 The unit looks as it should, which means no corrosion and so on.
The weight levers on the HCU can be moved without resistance.
The bolts for the HCU halves are tightened in accordance with "Bolt tightening".
4 Check that the pin holder holds the pin tightly.

5 Check that the weight levers will knock out the pin when activated.
(1) Weight lever

(2) Pin
(1) Weight lever

(2) Pin

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11 Brakes and hydraulic system in nacelle

11.1 Safety..............................................................................................................................................................................11-2
11.1.1 Safety precautions working with hydraulics.............................................................................................................. 11-2
11.2 Service procedures for nacelle.................................................................................................................................... 11-3
11.2.1 General service procedures......................................................................................................................................11-3
11.3 Function descriptions................................................................................................................................................... 11-4
11.3.1 Brake and pitch hydraulic system stop types............................................................................................................11-4
11.3.2 Turbine idling.............................................................................................................................................................11-6
11.3.3 Over speed safety system.........................................................................................................................................11-8
11.4 Hydraulics, oil and filters..............................................................................................................................................11-9
11.4.1 Checking oil level in hydraulic system.......................................................................................................................11-9
11.4.2 Replacing and refilling oil in hydraulic system.........................................................................................................11-10
11.4.3 Testing oil level sensor in pumping station............................................................................................................. 11-11
11.4.4 Replacing the filter element in the pressure filter (11).............................................................................................11-12
11.4.5 Replacing the filter element in the return filter (30)................................................................................................. 11-13
11.5 Pressure transducers..................................................................................................................................................11-17
11.5.1 Testing the pressure transducer (17)......................................................................................................................11-17
11.5.2 Testing the pressure transducer (218)....................................................................................................................11-17
11.5.3 Testing the pressure transducer (228)....................................................................................................................11-17
11.5.4 Testing the relief valve (10).....................................................................................................................................11-18
11.6 Valves........................................................................................................................................................................... 11-19
11.6.1 Testing and adjusting relief valve (210).................................................................................................................. 11-19
11.6.2 Testing brake valves (215) and (216)..................................................................................................................... 11-19
11.6.3 Testing brake valve (211)........................................................................................................................................11-19
11.7 Accumulators...............................................................................................................................................................11-21
11.7.1 Testing pressure and refilling accumulators (82) (220) (230)................................................................................. 11-21
11.8 Brake system............................................................................................................................................................... 11-23
11.8.1 Checking and adjusting brake pads........................................................................................................................11-23
11.8.2 Inspecting the brake pads.......................................................................................................................................11-25
11.8.3 Bedding in new brake pads.....................................................................................................................................11-25
11.8.4 Checking for leakage and tightening brake calipers............................................................................................... 11-25
11.8.5 Checking brake disc................................................................................................................................................11-25

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11.1 Safety
11.1.1 Safety precautions working with hydraulics

For working in the turbine, the "Basic Health and Safety Rules" must be followed.
Important: With some service procedures and during repair of the hydraulic system, the brake system
will be out of operation. Therefore, the rotor must be locked using the low speed lock for the hub and
brake disc locking bolts on the high speed shaft.

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11.2 Service procedures for nacelle
11.2.1 General service procedures

Numbers in brackets refer to the position numbers in the diagrams for the hydraulic system and the
numbers on the units in the turbine. All pressure values are shown in the hydraulic diagram. All
hydraulic hoses in the pitch system must be replaced every 10 years.
Important: When working in hubs, where pitch cylinders are mounted with maintenance free joint
bearings, lubrication must under NO CIRCUMSTANCES come in contact with the joint bearings. It will
reduce life time of bearings drastically. If any lubrication is observed on or at joint bearings, the
bearings MUST be de-greased with ethyl alcohol.
Procedure:
1 Check for leakages and check the oil level at each service visit. If a leakage has occurred, clean
up thoroughly after repairing the fault.
2 Before disconnecting any valves, rotating union and so on thoroughly clean the spot where the
defective part is connected to the system.
When dealing with the hydraulic system, be extremely careful not to get dirt into the system.
3 When service has been performed, and if the brake and hydraulic system has been interfered
with, the brake system must be tested thoroughly before the turbine is returned to automatic
operation.

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11.3 Function descriptions
11.3.1 Brake and pitch hydraulic system stop types

The turbine has a hydraulic brake system mounted on the high-speed shaft in the gearbox, which is
located in the nacelle. The brake system is referred to as the positive HS brake.
The brake system consists of a hydraulic unit and 2 positive brake calipers on one brake disc.
The calipers and brake discs are placed on the high-speed shaft in the gearbox. The brake is a
positive-acting brake, which means that, when the brake is activated, hydraulic pressure is built up in
the caliper. The pressure for the brake pads is applied by a piston inside the caliper. When the brake
is released, the hydraulic pressure is relieved from the caliper. Only one hydraulic operating pressure
is used, and braking is therefore always done at full brake torque. The pressure increase will
nevertheless be generated more slowly when the idle brake is applied than when the service brake is
applied.
The brake system can be activated in the following ways:
Automatically by the High Speed Centrifugal Unit (HCU) where the controller uses 4 different
stop types: S10, S20, S30, and S50.
Manually activating stop type S40 in the WTC by using a hand terminal.
The 5 different stop types in the controller depend on the fault register:
S10: Emergency stop. CAN (Controller-area network) error.
S20: The WTC has registered over speed. Pitch error.
S30: The WTC has registered brake error, grid drop or over speed.
S40: Manual stop.
S50: Normal stop sequence.

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Figure 11.1 Stop types

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11.3.2 Turbine idling

When the turbine idles the rotor turns slowly with the generator cut out and with the blades in stop
position. Idle mode is used to reduce the load on the main bearing and gear in case of long periods of
stand still. The turbine has 3 idle modes or idle types. Numbers in brackets refer to the diagrams for
the hydraulic system.
Controlled idling
During controlled idling the blades are pitched to +85 . In addition to this the turbine hydraulic
system functions as during normal operation.
Free idling
The turbine enters free idling mode in case of grid failure. Before entering free idling mode, a
positive feedback must be received from minimum 2 pitch pawls. The following occurs when free
idling is followed by grid failure.
When the grid fails an error is registered and followed by stop type S30.
The WTC registers that the three blades are locked in stop position. The automatic pitch lock is
important for the safety during free idling. For that reason it is important to check that all three
pitch locks have been engaged before the turbine is ready to idle.
The brake callipers are emptied of oil and the turbine starts to idle.
After approx. 24 hours the WTC's battery backup, UPS (Uninterruptible Power Supply), has run
out, but the turbine continues to idle.
When the rotor is fully stopped and the blades are in stop position, the rotor is released for free idling,
also in case of grid failure. However, idling is not allowed in all types of stop positions, for example
manual stop and emergency stop.
The 3 idle types are shown in the following figure:
Idle type 10 (no idling)
Idle type 20 (free idling)
Idle type 30 (controlled idling)

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Figure 11.2 Idle types
Start up after idling

The supply for valves (253) and (254) is stopped and valves (215) and (216) are supplied after a
delay of 1 s in order to build up brake pressure. The following occurs:
The blades pitch to operating position.
Then the normal start procedure is followed.
The pressure in the callipers is checked through the pressure transducer (228).
Start up after grid drop
To prevent the use of hard brake in case of power failure, a UPS (Uninterruptible Power Supply). If
a power failure occurs, the UPS takes over and supplies power for up to 1 min, allowing the turbine
to be stopped using soft braking.

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11.3.3 Over speed safety system

3 independent safety systems are installed to prevent over speed.
Over speed monitoring: If an error situation occurs where the generator speed exceeds 1800 rpm, a
sensor in the generator and main shaft registers over speed. The WTC activates the disc brake and
the blades are pitched to stop position so the turbine stops (stop type S30).
High speed centrifugal release unit (HCU): The HCU is a mechanical safety feature that prevents
over speed. If an over speed situation occurs, the HCU is activated when the rotation speed exceeds
1820 rpm. The HCU is placed on the high speed shaft by the gear and is activated by centrifugal
force. On activation, an arm swings out and knocks a fuse out of place. This cuts off the power supply
to the brake and pitch system, which, in turn, pitches the blades in stop position and apply the disc
brake (stop type S20).
Low speed monitoring unit (LMU): As an extra precaution measure, the low speed shaft is also
monitored independently of WTC3 through the monitoring module LMU.
Feedback is received when the following condition is met:
LMU is not active during test and the digital input is low for more than 100 ms.
Feedback if the difference in speed between LMU and main shaft exceeds max. rpm deviation.
LMU is stopped, if test signal is set at 0. This function is removed as soon as the LMU has been
upgraded in all turbines, with hardware profiles supporting LMU.

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11.4 Hydraulics, oil and filters
11.4.1 Checking oil level in hydraulic system

Turn the service valve on the pumping station to maintenance position.
Procedure:
1 Check the oil level when the turbine is stopped (normal stop), and the system in the hub is filled.
2 Read the oil level on the inspection glass.
(1) Oil level inspection glass
3 Oil level must be between minimum and maximum indications. Otherwise refill oil to correct level.
(1) Oil level when turbine is stopped

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11.4.2 Replacing and refilling oil in hydraulic system

Procedure:
1 Check the oil level in the inspection glass.
Read the level when the system is not pressurized.
2 Remove the plug on the return filter.

3 Refill oil.
Use a clean funnel when refiling oil.
(1) Refill new oil
4 Read the inspection glass to check the hydraulic oil level.
(1) Oil level sensor

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11.4.3 Testing oil level sensor in pumping station

Procedure:
1 Dismount the sensor.
2 Lift the sensor above the oil level until an error is registered in the hand terminal.
(1) Oil level sensor
3 Refit the sensor and reset error in hand terminal.

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11.4.4 Replacing the filter element in the pressure filter (11)

Numbers in brackets refer to the diagrams for the hydraulic system and the numbers on the units in
the turbine.
(1) Pressure filter
Procedure:
2 Open valve (14).
3 Mount manometer on test nipple (32) and check that the pressure is 0 bar.
4 Remove the bowl and take out the filter element.
5 Empty the bowl of oil and clean it inside with a clean cloth.
6 Insert a new filter element in the bowl.
7 Carefully push the bowl onto the O-ring.
DO NOT jam the O-ring.
8 Screw the bowl onto the filter housing by hand.

9 Tighten the bowl.
10 De-activate the emergency stop.
11 Close valve (14).
12 Run the pump and check for leaks.
13 Check the oil level.

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11.4.5 Replacing the filter element in the return filter (30)

the turbine.
Procedure:
2 Open valve (14).
3 Loosen / dismount the nuts and carefully remove the lid on the return filter.
(1) Return filter
4 Remove the spring.
(1) Spring

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5 Lift filter up and let it drip off.
6 Unscrew the nut / spring. The nut in the opposite end must remain tightened.
(1) Filter nut / spring unscrewed
(1) Filter housing

(2) Magnet
(3) Nut / spring

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7 Replace the filter element.
(1) Filter element
8 Clean the magnets. If dirt is found on the magnets, this must be written in the service check list.
(1) Magnets
9 Re-assemble the return filter. The nuts must be tightened to 30 Nm.

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11 De-activate the emergency stop.

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11.5 Pressure transducers
11.5.1 Testing the pressure transducer (17)

the turbine.
Procedure:
1 Connect a manometer to the test nipple (18).
2 Start the hydraulic pump.
3 Go to Menu 24 > Screen 10 in the hand terminal.
4 Compare the pressure of the manometer with the pressure indicated in the hand terminal. The
tolerance is 2 bar.
5 If the tolerance is exceeded the pressure transducer must be replaced.

the turbine. The pressure sensor monitors the pressure in the accumulator bank. When the pressure
drops to a certain level the pressure transducer opens valve (35). This means that pressure is added
to the system. The software makes sure that the valve is closed again, when the necessary pressure
for normal operation is reached.
Procedure:
1 Lock the rotor with the HS rotor lock.
4 Compare the pressure on the manometer with the pressure indicated by the hand terminal.
5 If the tolerance of 2 bar is exceeded the pressure transducer must be replaced.

the turbine. The pressure transducer monitors the pressure in the brake caliber. 0 bar when operating,
90 bar when stopped.
Procedure:
4 Compare the pressure of the manometer with the pressure indicated in the hand terminal in
Menu 2 > Screen 8. The tolerance is 2 bar.
5 If the tolerance is exceeded the pressure transducer must be replaced.

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11.5.4 Testing the relief valve (10)

the turbine.
Procedure:
2 Close the valve (31).
3 Start the pump. Be ready to open the valve (14) in case the pressure becomes too high.
4 Disconnect the plug on the transducer (17).
5 Read the manometer when the pressure is constant even with the pump running. The
measurement is the opening pressure of relief valve (10).
6 Adjust relief valve (10) if the read pressure is not identical to the one indicated in the hydraulic
diagram.
7 Re-connect the plug on the transducer (17).
8 Open the valve (31).

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11.6 Valves
11.6.1 Testing and adjusting relief valve (210)

the turbine. The relief valve is installed for safety reasons. If valve (35) does not close when it is
expected to close, pressure will build up in the system. Relief valve (210) prevents the over pressure.
Procedure:
3 Stand by to open valve (14) if the pressure exceeds 230 bar.
4 Disconnect the plug on the pressure transducer (218).
Results: Valve (35) opens. The pressure will build up until the relief valve (210) opens. Then the
pressure will remain constant also when valve (35) is open.
5 Read the pressure when the pressure is constant.
6 Replace relief valve (210) if the pressure is not the same as indicated in the hydraulic diagram.
90 bar +/- 5 bar.
11.6.2 Testing brake valves (215) and (216)

the turbine.
Procedure:
1 Lock the rotor lock with the HS rotor lock.
2 Attach a manometer to the test nipple (227).
3 Release the brake in Menu 24 (manometer pressure is 0 bar).
4 Disconnect the plug on the solenoid valve (215).
5 Check that the pressure build up.
6 Connect the plug to solenoid valve (215) and check that the pressure is 0 bar.
7 Repeat the procedure for valve (216).
11.6.3 Testing brake valve (211)

the turbine.
Procedure:
1 Lock the rotor lock with the HS rotor lock and put the turbine in manual stop UF1001.
3 Release the brake (make sure service valve (252) is in service.
Results: Pressure drops to 0+.
4 Put service valve (252)(blue valve) in operation
5 Disconnect the plug on valve (211) and check that the pressure rises to 50+ bar in less than 10
seconds.

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the turbine.
Procedure:
2 Turn the service valve (252) into service position.
4 Set the brake in Menu 24 in the hand terminal, and make sure that there is sufficient brake
pressure on the system and that it is stable, that is 80 5 bar.
5 Loosen the brake in Menu 24 and check that the turbine loosens the brake and the manometer
shows 0 bar.

the turbine.
Procedure:
2 Turn service valve (252) into operating position.
The turbine must be stopped manually (1001).
4 Make sure that there is sufficient brake pressure on the system and that it is stable, that is 80 5
bar.
5 Press start and check that the brake loosens and the manometer shows 0 bar.
6 Turn service valve (252) back into service position.

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11.7 Accumulators
11.7.1 Testing pressure and refilling accumulators (82) (220) (230)

the turbine. The hydraulic hoses must be replaced every 10 years.
(1) Accumulator (82)
Before you begin: Replace accumulator (82) if measured pressure is below 130 bar.
Replace accumulator (220) if measured pressure is below 30 bar.
Replace accumulator (230) if measured pressure is below 5 bar.
The pressure of the accumulators is measured with a manometer and adjusted by using an Olaer kit
shown below.
Preload equipment with:
(1) Manometer
(2) Test hose
(3) Hose for nitrogen bottle
Procedure:
1 Lock the rotor with the HS-rotor lock.
2 Turn the service valve (252) into operation position.
3 Open valve (14).
4 Switch off the power (690 V) to the hydraulic pump.
5 Remove the plug on valve (253).

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6 Check that the accumulators are without pressure.

6.1 Mount a manometer on test nipple (18) and check that the pressure is 0 bar
7 Wait for 5 minutes to allow the gas in the accumulator to reach the same temperature as the
accumulator housing.
8 Check the temperature in the accumulator housing (82), (220) and (230) and correct the pre-
pressure.
9 Connect a manometer to the accumulators one at a time and read the nitrogen pressure.
10 Refill the accumulator with nitrogen if the pressure is too low as follows:
10.1 Fit the test hose between Olaer kit and accumulator or fit the Olaer kit directly to the
accumulator.
10.2 During filling, open the tap on the nitrogen bottle very carefully.
10.3 When the required pressure has been reached, close the tap on the nitrogen bottle.
11 Replace the accumulator if the pressure is below the minimum limit.
Important:
Valve (27) on the pumping station must be closed during operation in order to avoid damage to
the rotating union.
Valve (14) must be closed during operation in order to build system pressure.
Valve (31) must be open during operation in order to build system pressure in the hub.

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11.8 Brake system
11.8.1 Checking and adjusting brake pads

The adjustment of brake pads are described for BSAK 300-MS30S-200 brake pads and BSAJ 300-
MSXXS-102 brake pads. The procedure is the same for each type of brake pads. Removing the brake
pad covers is slightly different and is therefore shown for both types in the procedure.
Procedure:
1 Visually check brake disc and lining for wear and discoloration.
If the brake disc wears on the brake lining, adjust the calliper travel by adjusting the positioning
screw.
2 Visually check the air gap between the brake disc and the brake pads and listen for noise.
The air gap must be between 1 mm and 1.5 mm on both sides of the disc. If not the brake pads
must be adjusted as described below.
2.1 Lock the rotor with the HS rotor lock.

2.2 Remove the covers.
(1) BSAK 300-MS30S-200
(1) BSAJ 300-MSXXS-102

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2.3 Adjust the rear brake pads with the positioning screw.
(1) Positioning screws
2.4 Adjust the brake pads with the positioning screw.
(1) Positioning screws

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11.8.2 Inspecting the brake pads

Procedure:
2 Remove covers.
3 Measure thickness of the brake pads plus the backing plate.
If this distance is 19 mm or less, then replace the brake pads.
Important: The brake pads must be replaced, at the very latest, when the thickness of the brake
lining plus the back plate is 19 mm or less. See "ZWI1017103 Replacement of brake pads on HS
brake".
11.8.3 Bedding in new brake pads

Procedure:
1 Start up the turbine and let it run at operational speed for a short time.
2 Stop the turbine by pressing the emergency stop button.
3 Repeat step 1 and 2 twice with 15 min interval.
4 Release the turbine into automatic operation.
11.8.4 Checking for leakage and tightening brake calipers

Procedure:
1 Check that no oil is coming out from the lower drain port (plastic hose).
If the caliper is leaking it must be replaced.
2 Tighten the brake caliper bolts, see "Bolt tightening".
11.8.5 Checking brake disc

Procedure:
1 Inspect the brake disc for signs of cracks and discoloration.

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12 Pitch and hydraulic system in hub

12.1 Safety..............................................................................................................................................................................12-2
12.1.1 Safety precautions working in the hub...................................................................................................................... 12-2
12.2 Service procedures for hub..........................................................................................................................................12-3
12.2.1 General service procedures......................................................................................................................................12-3
12.2.2 Entering the hub........................................................................................................................................................12-4
12.2.3 Leaving the hub.........................................................................................................................................................12-4
12.2.4 Hydraulic pitch lock................................................................................................................................................... 12-5
12.3 Maintenance of mechanical parts of pitch system.....................................................................................................12-6
12.3.1 Testing the hydraulic pitch locks............................................................................................................................... 12-6
12.3.2 Checking the hydraulic pitch lock..............................................................................................................................12-6
12.3.3 Cleaning oil spillage in the hub................................................................................................................................. 12-7
12.3.4 Checking ventilation fan in the hub........................................................................................................................... 12-8
12.3.5 Checking central lubrication system for blade bearings............................................................................................12-9
12.3.6 Refilling lubrication system for blade bearings........................................................................................................12-10
12.3.7 Checking seal ring of blade bearings......................................................................................................................12-12
12.3.8 Replacing excess grease cups............................................................................................................................... 12-13
12.3.9 Checking pitch angle...............................................................................................................................................12-14
12.3.10 Calibrating sliding valve signal..............................................................................................................................12-14
12.3.11 Offset adjusting pitch angle...................................................................................................................................12-15
12.4 Service of mechanical parts of pitch system............................................................................................................12-17
12.4.1 Checking pre-pressure on accumulators (106A to 106D)....................................................................................... 12-17
12.4.2 Refilling accumulators.............................................................................................................................................12-20
12.4.3 Checking valve (103) and (120)..............................................................................................................................12-21
12.4.4 Checking valve (109).............................................................................................................................................. 12-21
12.4.5 Checking valve (119).............................................................................................................................................. 12-22
12.4.6 Checking valve (116).............................................................................................................................................. 12-23
12.4.7 Checking non-return valve (26)...............................................................................................................................12-24
12.4.8 Checking pressure transducer (107).......................................................................................................................12-24
12.4.9 Replacement of valve 13.........................................................................................................................................12-25
12.4.10 Replacement of valve 101.....................................................................................................................................12-29

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12.1 Safety
12.1.1 Safety precautions working in the hub

For working in the turbine the "Basic Health and Safety Rules" must be followed.
Important: With some service procedures and during repair of the hydraulic system, the brake system
will be out of operation. Therefore, the rotor must be locked using the low speed lock for the hub and
the brake disc locking bolts on the high speed shaft.
Before you begin:
WARNING
Before entering the hub, make sure that the high-speed rotor lock is engaged
During work on the transmission, the high-speed rotor lock must be engaged.
Service valve (252) on the hydraulic station must be set to "Service Mode On".
WARNING
Read the safety regulations for working in the hub before entering the hub (see safety
instructions, SI545781, 'Basic Health and Safety Rules for Technicians Working in
Siemens Wind Turbines').
Wear H-harness when in the spinner.
When accessing or working in the hub while the 108 valves are not set to Service mode or in
case of grid power loss, there are risks associated with rotating machinery and entrapment. In
these situations, always ensure that you are standing on top of the checker plates; this is
particularly important when performing tasks that require blade pitching.
NOTICE
Wear eye protection
When working on the hydraulic system, safety glasses must be worn to protect the eyes if a
seal, hose or other pressurized hydraulic component should burst when under pressure.
Wear safety gloves
Protective gloves must be worn as the hydraulic oil can cause skin irritation.
Before entering the hub, fill out "CH 579264" Lockout / Tag-out procedure - HS rotor lock.

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12.2 Service procedures for hub
12.2.1 General service procedures

Numbers in brackets refer to the position numbers in the diagrams for the hydraulic system and the
numbers on the units in the turbine. All pressure values are shown in the hydraulic diagram. All
hydraulic hoses in the pitch system must be replaced every 10 years.
Important: When working in hubs, where pitch cylinders are mounted with maintenance free joint
bearings, lubrication must under NO CIRCUMSTANCES come in contact with the joint bearings. It will
reduce life time of bearings drastically. If any lubrication is observed on or at joint bearings, the
bearings MUST be de-greased with ethyl alcohol.
Procedure:
1 Check for leakages and check the oil level at each service visit. If a leakage has occurred, clean
up thoroughly after repairing the fault.
2 Before disconnecting any valves, rotating union and so on thoroughly clean the spot where the
defective part is connected to the system.
When dealing with the hydraulic system, be extremely careful not to get dirt into the system.
3 When service has been performed, and if the brake and hydraulic system has been interfered
with, the brake system must be tested thoroughly before the turbine is returned to automatic
operation.

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12.2.2 Entering the hub

Before you begin: Fill out the "CH579264: Lockout / Tag-out procedure - HS rotor lock".
Procedure:
1 Enter the hub by opening the hatch at the front of the nacelle.
The rotor is positioned so that one of the hub hatches is aligned with the front hatch in the
nacelle.
2 Engage the HS rotor lock before removing the hatch.

3 Remove the hatch.
(1) Hatch
12.2.3 Leaving the hub

Procedure:
1 Remove any loose objects from the hub and controller box.
2 Check that the cover on the controller box is locked.

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12.2.4 Hydraulic pitch lock

The pitch lock is designed as an additional safety device. In extreme winds it will prevent the blade
from pitching into operating position as a result of aerodynamic influence. During normal operation the
pitch lock will be kept open by the hydraulic pressure. This means that the lock is passive.
(1) Hydraulic pitch lock
60 seconds after a normal stop the valve is activated, the pressure is relieved and the lock is
activated.
If the emergency stop is activated, the pressure is also relieved and the lock is activated.
Consequently, the blade is not able to pitch into operating position until the pressure is rebuilt.

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12.3 Maintenance of mechanical parts of pitch system
12.3.1 Testing the hydraulic pitch locks

Procedure:
2 Start hydraulic pump. The hydraulic pitch locks must disengage.
3 Press Esc. in the hand terminal and the hydraulic pitch locks must engage.
12.3.2 Checking the hydraulic pitch lock

Procedure:
1 Tighten bolts according to "Bolt tightening".
(1) Hydraulic pitch lock
2 Lubricate sliding surface with Optipit grease.

3 Check that the lock is able to engage.
(1) Pitch ramp with lubrication

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12.3.3 Cleaning oil spillage in the hub

Procedure:
1 Clean the inside of the blade bearing.
1.1 Clean up oil and grease
1.2 Replace oil-absorbers in hub
1.3 Remove all drain cups
2 Clean the outside of the blade bearing.
2.1 Clean gaskets, blade and spinner as much as possible
2.2 Turn the blade 1/4
2.3 Turn the rotor 1/3 and repeat the procedure above
2.4 Turn the rotor 1/3 again and repeat the procedure above
Results: This way the gasket can be cleaned all around
The blade bearings are lubricated according to "AI-WI573524 Flushing and replacing blade
bearing grease". Bolts are re-tightened according to bolt tightening values, see "Bolt tightening".
3 Clean 3 times at 1 week intervals.

4 Check the drain cups when cleaning and replace them if required.
Drain cups containing grease must be replaced with new cups. Drain cups change position when
the turbine is stopped.

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12.3.4 Checking ventilation fan in the hub

Menu 24 >
Before you begin: Make sure that the valves in the hub are energized.
Procedure:
1 Enter Menu 24 > Screen 7 in the hand terminal.
2 Press the right arrow to start the hydraulic pump in order to energize the valves.
3 Check the fan visually and replace it if there are any strange sounds.
(1) Ventilation fan
4 Check the filter.
(1) Filter

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12.3.5 Checking central lubrication system for blade bearings

Procedure:
1 Visually check joints for leaks at the pump, distributor block and inlet.
2 Start the lubrication system.
2.1 Use Menu 24 > Screen 7 in the hand terminal
2.2 Press the right arrow to start the pump
2.3 Use Menu 24 > Screen 13 in the hand terminal
2.4 Press: "." for Start
2.5 Press "." for Stop
2.6 Read "grease total" and check that it increases when the automatic lubrication system is
started
2.7 The pulse counter can be reset in Menu 24 > Screen 18 in the hand terminal
2.8 Check the "low level sensor" by removing the plug from the lubrication system. Then
insert a jumper between pin 1 and 3 in the plug, to indicate a fault in the hand terminal
(1) "Low level sensor" plug

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12.3.6 Refilling lubrication system for blade bearings

Before you begin: For correct grease type, see "Lubrication chart".
(1) Blade bearing lubrication system -
SWT-2.3-82VS/93
(1) Blade bearing lubrication system -

SWT-2.3-101/108
Dirt and impurities in the grease is not accepted as this will cause operational failure of the pump unit.
Temperature of grease must not be too low as this may cause difficulties for the stirrer in getting the
air out of the product. The temperature depends on the type of grease.
Procedure:
1 Check for correct grease type and screw the grease cartridge into the base of the easy grease
pump.

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2 Flush the pump and hose with the correct grease type.
3 Connect the hose to the quick acting coupling on the lubrication system.
4 Fill the grease container for the lubrication system.
Do not overfill.
5 Disconnect hose after refilling.
(1) Filling hose connected to the

lubrication system

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12.3.7 Checking seal ring of blade bearings

Procedure:
1 Check that the seal ring of blade bearings is intact.
(1)Seal ring of blade bearing
2 Wipe off the area around the bearings and the seal ring.

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12.3.8 Replacing excess grease cups

Procedure:
1 Remove the hatch to the blade in order to access the excess grease cups.
CAUTION: Do not open the hatch on the blade pointing downwards.
(1) Blade hatch
2 Empty or replace the excess grease cups.
Excess grease cups

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12.3.9 Checking pitch angle

Procedure:
1 Turn the blade to 0 .
2 Check that the arrow on the blade bearing and the mark on the blade are aligned.
(1) Alignment of pitch angle
3 Perform "Offset adjustment of blades" if necessary.

4 Note any deviation in the check list.
12.3.10 Calibrating sliding valve signal

Proportional valves with feedback system for the movement of the valves are used in the hub. These
must be calibrated.
It is very important that the calibration is completed without errors before the blades are calibrated.
Procedure:
2 Select blade A, B or C with the arrow keys and start the calibration by pressing Enter. The
following screen appears.
PITCH CALIBRATION
Choose blade with </> Blade A
E = Start calibration (1. pos.)
3 When the calibration is completed one of the following screen appears.

PITCH CALIBRATION
Calibration completed: Blade A
PITCH CALIBRATION
Calibration error: Blade A

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12.3.11 Offset adjusting pitch angle

The offset adjustment is performed using the small metal arrows on the bar at 0 on the blade bearing
and a position mark on the blade plate, see "Checking pitch angle". The blade is also calibrated at 60
, where the pitch encoder is used as angle meter.
The offset adjustment is made on one blade at a time.
(1) Arrow for check of pitch angle
Procedure:
2 Select blade A, B or C with arrow keys and start the calibration by pressing Enter. The following
screen appears.
PITCH CALIBRATION Blade A 0 9/29
Value A: 88 B: 87.9 C: 89.8 AE: 84.9
Choose blade with </>
3 Use the right and left arrows to move the blade until it is at exactly 0 . The size of steps can be
adjusted with the up and down arrows.
Value A: 0.0 B: 80.3 C: 80.9 AE: - 2.6
Step size with ^/v
4 When the blade is at exactly 0 press Enter.

Value A: 0.0 B: 80.3 C: 80.9 AE: - 2.7
5 Press Enter again.

Results: Now the pitch encoder is reset to 0
6 Turn the blade towards 60 . Adjust the blade until the pitch angle shows 60.0 .
Value A: 60.4 B: 80.3 C: 80.9 AE: 59.3
Wait, auto calibration in progress...
Abort: (ESC) / (E)

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7 When the blade is adjusted to 60 press Enter and the calibration of the next blade can begin.
Value A: 87.8 B: 87.9 C: 89.8 AE: 84.9
Choose blade with </>
8 Reset the hand terminal and check the pitch angle of all 3 blades visually in Menu 24 > Screen 7
in the hand terminal (check one blade at a time).

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12.4 Service of mechanical parts of pitch system
12.4.1 Checking pre-pressure on accumulators (106A to 106D)

One blade is checked at a time.
Accumulator
The cover plug on the accumulator
(1) Manometer
(2) Accumulator

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Thermometer
Procedure:
1 Measure the temperature on the accumulator housings.
3 Connect the manometer to test nipple (111).
4 Activate valve (117). Check that the pressure drops to 0 bar in the hand terminal and on the
manometer. Menu 24 > Screen 10.
Results: The accumulators are de-pressurized.
5 Wait 15 minutes for the gas in the accumulators to reach the same temperature as the
accumulator housing.
6 Measure pre-pressure of the accumulators with a manometer.
7 Measure the temperature on the accumulator housing and correct pre-pressure according to the
correction table.
8 Refill with nitrogen if necessary using the pre-load equipment.
9 Check that the test nipple is tight using leak detecting spray.
The cover plug is removed.

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The test hose is fitted.
Replace accumulator if pressure is lower than 70 bar.

What to do next: After checking start hydraulic pump Menu 24 > Screen 10 and refill the
accumulators on the blade just checked.
Remember to tighten the accumulator cover plugs.

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12.4.2 Refilling accumulators

Procedure:
1 Fit the test hose between the pre-load kit and the accumulator or fit the pre-load kit directly to the
accumulator.
The pre-load kit consist of:

Manometer
Test hose
Hose for nitrogen bottle
2 During fitting, open the tap on the nitrogen bottle very carefully.
3 When the required pressure has been reached, close the tap on the nitrogen bottle.
4 Check for leakages using leak detecting spray.
What to do next: Remember to tighten the accumulator cover plug after refilling.
Tightening cover plugs

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12.4.3 Checking valve (103) and (120)

The procedure is done for one blade at a time. The numbers in brackets refer to elements in the
hydraulic diagrams for blade block.
Open safety valve (108) on the blade being tested
CAUTION: Blades will pitch during test
Pitch speed can vary from blade to blade, when the valves are disconnected. This is OK.
Procedure:
1 Go to Menu 24 > Screen 6 on the hand terminal.
2 Pitch the blade into operating position and wait until the pump has stopped refilling.
3 Disconnect the plugs on valve (119) and valve (109). Then disconnect the plug on valve (103)
Results: The blade must pitch into stop position immediately.
4 Set the pitch reference to 90 . When the pitch reference reaches 90, refit the plugs on the 3
valves.
5 Pitch the blade into operating position and wait until the pump has stopped refilling.
6 Remove the plugs on valve (109) and valve (119). Then disconnect the plug on valve 120.
Results: The blade must pitch into stop position.
7 Set the pitch reference to 90 . When the pitch reference reaches 90, refit the plugs on the 3
valves.
8 Repeat the procedure for the remaining blades.
12.4.4 Checking valve (109)

Procedure:
1 Loosen the screw on the plug on valve (109) .
2 Switch on the hydraulic pump Menu 24 > Screen 6.
3 Open safety valve (108).
4 Set pitch reference to 0 Menu 24 > Screen 6.
After the blade has started pitching dismount the plug on valve (109) and the blade must stop
pitching.
5 Mount the plug on valve (109) and the blade must continue pitching towards 0 .
6 When the blade is positioned in 0 set the pitch reference to 90 and the blade must return to
stop position.
7 Stop the hydraulic pump.
8 Close the safety valve (108).
9 Tighten the screw in the plug after testing.

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The purpose of valve (119) is to act as seals for proportional valve (102). Proportional valve (102) is a
valve type which is not quite tight in closed position.
Procedure:
1 Loosen the plug screw on the valve(119).
2 Switch on the hydraulic pump. Menu 24 > Screen 6
3 Open safety valve (108).
4 Set the pitch reference to 0 Menu 24 > Screen 6.
5 After the blade has started to pitch, dismantle plug on the valve (119).
Results: The blade must stop pitching.
6 Mount the plug on the valve (119) again.
Results: The blade must continue towards 0 .
7 When the blade is in 0 position, set the pitch reference to 90 .
Results: The blade must return to stop position.
8 Stop the pump.
9 Close safety valve (108).
10 Tighten the screw in the plug after testing.

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The procedure is done for one blade at a time.
Procedure:
1 Mount the manometer on test nipple (112) or (114) on pitch cylinder.
Mounting on pitch cylinder

3 Set the pitch reference to 0 , and pitch the blade to operation mode.
4 The read out on the manometer must approx. 230 bar.
5 Stop the hydraulic pitch pump.
6 Dismount the plug on valve (116).
7 The read out on the manometer must be between 0 and 10 bar.
8 Refit the plug on valve (116).
9 Pitch the blade into stop position.

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12.4.7 Checking non-return valve (26)

The numbers in brackets refer to elements in the hydraulic diagrams for blade block.
Procedure:
1 Connect the manometer to test nipple (T) on the distributer block.
3 Start the hydraulic pump.
4 Read the pressure (2.5 - 5 bar) when the hydraulic pump is running.
12.4.8 Checking pressure transducer (107)

Procedure:
2 Connect a manometer to test nipple (111).
3 Start the pump.
5 Compare the pressure on the manometer with the pressure read in the hand terminal ( 2 bar).

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12.4.9 Replacement of valve 13
WARNING
Hydraulic system
WARNING
WARNING
Procedure:
1 Set rotor lock.
2 Shift the service lever to Service mode ON.

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3 Lock the switch for the hydraulic pump with a yellow locking device and a padlock as per the
control diagram.
4 Open the ball plug valve pos. 14 and the ball plug valve pos. 27 in order to relieve pressure in the
hydraulic system.
5 Check that the hydraulic system is depressurized. Measure with a manometer on test nipple 18.

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6 Remove valve 13. Fit a new valve. Torque as per the Service Manual. NOTE: Fit a new O-ring on
the new valve.
7 Close the ball plug valve pos. 14 and ball plug valve pos. 27.

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8 Remove the padlock and the yellow locking device. Switch on breaker.
9 Shift the service lever to Service mode off.
10 Release rotor lock.

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12.4.10 Replacement of valve 101
WARNING
Hydraulic system
WARNING
WARNING
Procedure:
1 Shift the service lever to Service mode ON.

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2 Mount the HS rotor locks.
3 Lock the switch for the hydraulic pump with a yellow locking device and a padlock as per the
control diagram.
4 Open the ball plug valve pos. 14 and the ball plug valve pos. 27 to relieve hydraulic pressure in
the hydraulic system.

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5 Close the ball plug valve pos. 31 for hydraulic pressure to the hub.
6 Close the safety valves on all (3x) blades in the hub.
7 Relieve the accumulators by actuating valve 117 on the blade block. NOTE: Only empty the
accumulator from one blade at a time, since the hydraulic tank can only contain the hydraulic
liquid from the accumulators of one blade.

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8 Check that the hydraulic system is depressurized by connecting a manometer to test nipple 111.
9 Remove valve 101. Fit a new valve. Torque as per the Service Manual. NOTE: Fit a new O-ring
on the new valve. NOTE: If you need to replace the valves on more than one blade, perform step
11 and step 13, start the hydraulic pump in menu 24 to fill the accumulators with hydraulic oil.
Then go to step 3. Repeat this procedure until the required number of valves have been
replaced.

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10 Open all (3x) safety valves in the hub.
11 Close the ball plug valve pos. 14 and ball plug valve pos. 27.
12 Open the ball plug valve pos. 31.

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13 Remove the padlock and the yellow locking device. Switch on breaker.
14 Remove the HS rotor locks.

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15 Shift the service lever to Service mode off.

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13 Cooling system
13 Cooling system
13.1 Servicing frequency converter cooling system..........................................................................................................13-2
13.1.1 Frequency converter cooling system overview......................................................................................................... 13-2
13.1.2 Visually inspect converter cooling system.................................................................................................................13-4
13.1.3 Replacing cooler hoses.............................................................................................................................................13-5
13.1.4 Changing coolant...................................................................................................................................................... 13-5
13.1.5 Servicing the cooling system.....................................................................................................................................13-6
13.1.6 Checking and cleaning the cooler for the cooling system.........................................................................................13-9
13.2 Generator cooling........................................................................................................................................................13-12
13.2.1 Checking the generator cooling system..................................................................................................................13-12
13.2.2 Cleaning cooler fins in cooler for hydraulic oil.........................................................................................................13-13

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13 Cooling system
13.1 Servicing frequency converter cooling system
13.1.1 Frequency converter cooling system overview
Number Description Number Description

1 Hose clips 11 Manometer
2 Temperature sensor PT100 12 Pressure sensor
3 Thermometer 13 Pump
4 Pressure relief valve 3.5 bar 14 Automatic ventilation
5 Thermostat valve or 3-way 15 Outlet

actuator valve
6 Expansion tank 16 Inlet
7 Ball valve 17 Ball valve
8 Filling / draining valve 18 Pump bleed screw
9 Filter 19 End of hose placed in 25 liter container
10 Test nipple (bleeding)

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13 Cooling system
Number Description
20 3-way valve
21 Motor valve

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13 Cooling system
13.1.2 Visually inspect converter cooling system

All of the hoses and connections in the frequency converter cooling system (shown in Frequency
converter cooling system overview (on page 13-2)), as well as those associated with the cooling fans,
must be inspected to ensure that there is no damage or leaks that compromise the integrity of the
system. Any damaged components must be replaced.
Procedure:
1 Inspect all hoses and connection joints in the system for leaks or visible damage. Any damaged
components must be replaced
2 Inspect all hose clips and replace any that appear to be corroded, loose or damaged. Do not re-
tighten clips.
Example of a damaged hose clip
(1) Older hose clamp, marked with

blue paint.
(2) Newer hose clamp, pre-
lubricated, with spring disks, and
marked with orange/red paint.
3 Check the air vent/test nipple for leakage.

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13 Cooling system
4 Inspect the converter cabinet for any evidence of leaks.
13.1.3 Replacing cooler hoses

Before you begin: Remove the coolant from the cooling system. See Changing coolant (on page 13-
5).
Procedure:
1 Remove the existing cooling hoses.
2 Lubricate the hose connections with clean water (oil or grease dissolve the hose!)
3 Push the hose ends onto the hose connections and tighten the hose clamps to 20 Nm using a
torque wrench.
4 Refill the cooling system with coolant. See Changing coolant (on page 13-5).
13.1.4 Changing coolant

The procedure describes how to change the coolant in the frequency converter cooling system.
Before you begin: The antifreeze coolant used is BASF Glysantine G30
Ratio of mixture: 33 % (1 part coolant to 2 parts water).
Ratio mixture for cold climate: 50 % (1 part coolant to 1 part water).
Procedure:
1 Turn of the circulating pump and heating element in converter. In accordance with controller
diagram.
2 Open the bleed valves at the top of the frequency converter modules.
3 Drain off coolant at filling / draining valve (8).
4 Close the bleed valves at the top of the frequency converter modules .
5 Add new coolant at filing / draining valve (8).

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13 Cooling system
13.1.5 Servicing the cooling system

Procedure:
1 Close the ball valves (1) and (2).
(1) Ball valve

(2) Ball valve
(3) Filling valve
2 Turn of the circulating pump and heating element in converter. In accordance with controller
diagram.
3 Drain off coolant at filling/draining valve (3).
Do not use the relief valve as bleed valve as it will easily begin to leak.
4 When the system is without pressure. Measure the air pressure on the expansion tank. The
pressure must be adjusted to 0.5 0.1 bar, no matter whatever the pressure might be measured
to.
If the pressure is too low add pressure to 0.5 0.1 bar, with an air pump.
If the pressure is too high adjust the pressure to 0.5 0.1 bar, with the valve on the expansion
tank.
If the pressure is lower than 0.3 bar, replace the expansion tank.
Otherwise refill the expansion tank up to 0.5 0.1 bar.

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13 Cooling system
5 When the system is without pressure, check that the pressure transducer read-out in the hand
terminal Menu 2 > screen 13 is: 0 0.1 bar.
(1) Ball valve

(2) Ball valve
(3) Pipe strainer
6 Dismount and clean the pipe strainer (pos.3) see graphic above.
6.1 Refit the pipe strainer
(1) Pipe strainer

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13 Cooling system
7 Add coolant at the filling / draining valve using a pump until the pressure is 1.5 bar in the hand
terminal.
(1)Hose for water bleeding valve

(2) Power drill pump
(1)Pump for refilling of system
8 Open both ball valves (1) and (2).

9 Turn on the circulating pump and the heating element.
10 Bleed off the system using the bleed valves at the top of the delta modules.
11 Check the pressure at the system 1.8-2.0 bar. Add more coolant if necessary.
Power unit fitted with ABB converter is fitted with automatic bleeding valve. Bleeding will be
performed automatically. Check the coolant pressure after 30 min. of operation, add more
coolant if the pressure is too low.

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13 Cooling system
13.1.6 Checking and cleaning the cooler for the cooling system
The outside cooler under the staircase must be cleaned at the service visit. Four different cooler
configurations shown.
Procedure:
1 Check that the cooler blows upward at low speed and high speed fan operation. Menu 24 >
screen 27, except if cooling system has thermostat valve
2 Check the water cooler for leaks, cracks and corrosion of cooler fins.
3 Lattice (optional) to be removed to gain access to cooler. If necessary, clean the outside cooler
from beneath by using a powerful vacuum cleaner with brush. (new bag and filters increase the
suction significantly).
1. Cooling fins which needs

cleaning
2. Cooling fins which do not need
cleaning
4 Point the beam of a flash light through the fins. If the air passage is still not free, spray with Metal
Clean.
If motor cleaner is used, always end by using oil-soluble fluid to dry the fins completely as dirt
otherwise build up again very quickly.
5 Start the fan until the cooler is completely dry.

6 If the air passage is still not fully open, use compressed air.
7 If the cooler leaks the slightest amount of fluid into the cooling fins, it must be replaced as dirt will
otherwise build up quickly and reduce the cooling effect
8 Lattice (optional) to be mounted again

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13 Cooling system
9 Four different cooling configurations shown below

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13 Cooling system

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13 Cooling system
13.2 Generator cooling
13.2.1 Checking the generator cooling system

Procedure:
1 Check that the flexible hoses on the generator are tight and intact.
(1) Flexible hose
(1) Flexible hoses

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13 Cooling system
2 Check that the cooling system and the generator fan are bolted tightly together.
(1) Generator cooling system
13.2.2 Cleaning cooler fins in cooler for hydraulic oil

Procedure:
1 Clean the cooler fins.
(1) Cooler for hydraulic oil

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13 Cooling system

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14 Components and diagrams

14.1 Components in hydraulic block................................................................................................................................... 14-2
14.1.1 Pumping station........................................................................................................................................................ 14-2
14.1.2 Component list for pumping station for pitch system................................................................................................ 14-4
14.1.3 Component list for brake system...............................................................................................................................14-5
14.1.4 Rotating union...........................................................................................................................................................14-5
14.1.5 Hydraulic oil cooler....................................................................................................................................................14-6
14.2 Components in pitch system........................................................................................................................................14-7
14.2.1 The pitch system in the blades..................................................................................................................................14-7
14.2.2 Component list for hydraulic system in one blade.....................................................................................................14-7
14.3 Hydraulic diagrams....................................................................................................................................................... 14-8
14.3.1 Nacelle SWT-2.3-82VS/93........................................................................................................................................14-8
14.3.2 Nacelle SWT-2.3-101/108.........................................................................................................................................14-9
14.3.3 Pump station (standard)..........................................................................................................................................14-10
14.3.4 Pump station (arctic)............................................................................................................................................... 14-11
14.3.5 Pump station SWT-2.3-101/108..............................................................................................................................14-12
14.3.6 Blade block (light model).........................................................................................................................................14-13
14.3.7 Blade block - SWT-2.3-82VS/93............................................................................................................................. 14-14
14.3.8 Blade block - SWT-2.3-108 - SWT-2.3-101 - SWT-2.5-108 SWT-2.3-101/108...................................................... 14-15
14.3.9 Pitch lock.................................................................................................................................................................14-16
14.3.10 Diagram for gear oil cooler....................................................................................................................................14-17
14.3.11 Water cooling diagram.......................................................................................................................................... 14-18
14.3.12 Correction table for pressure in accumulators...................................................................................................... 14-22

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14.1 Components in hydraulic block
14.1.1 Pumping station

Numbers in brackets are the numbers punched into the hydraulic block / pos. numbers in hydraulic
diagram.
(1) Motor (4)
(2) Air filter (20)
(3) Return filter (30)
(4) Oil filling hole
(5) Oil tank
(1) Motor (4)

(2) Air filter (20)
(3) Return filter (30)
(4) Oil filling hole
(5) Temperature monitor (21)
(1) Hydraulic block (9)

(2) Hydraulic block - brake (55)
(3) Oil level glass (22)
(4) Oil tank (23)
(5) Level monitor (21)

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(1) High-pressure filter (11)

(2) Oil level glass (22)
(3) Level- and temperature monitor (21)
(4) Accumulator (82) for hydraulic system
(1) High-pressure filter (11)

(2) Accumulator for brake (230)
(1) PT 100 sensor

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(1) PT 100 sensor
(1) (Option) Heating element for HY tank

(arctic).
14.1.2 Component list for pumping station for pitch system
Position Component Position Component

4 Motor 27 Valve - return pressure
9 Hydraulic block 28 Solenoid valve
10 Relief valve 30 Return filter
11 Pressure filter 31 Valve - hub
13 Relief valve 32 Test nipple
14 Valve - system pressure 33 Solenoid valve
17 Pressure transducer 34 Relief valve
18 Test nipple 35 Solenoid valve
20 Air filter 55 Hydraulic block - brake
21 Level- and temperature sensor 82 Accumulator for hydraulic system
22 Oil level glass 220 Accumulator for hydraulic system
23 Oil tank 230 Accumulator for brake
25 Solenoid valve (bypass)

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14.1.3 Component list for brake system

227 Test nipple 55 Hydraulic block
228 Pressure transducer 210 Relief valve
230 Accumulator 212 Test nipple
240 Brake calipers 215 Solenoid valve
252 Valve 216 Solenoid valve
253 Solenoid valve 218 Pressure transducer
254 Solenoid valve 220 Accumulator
222 Relief valve
14.1.4 Rotating union

(1) Return hoses from the systems in the
hub (blades)
(2) Pressure hoses for the systems in the
hub (blades)
(3) Drain hose from the rotating union
(4) Rotating union
(5) Slip ring

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14.1.5 Hydraulic oil cooler

(1) Cooler for hydraulic oil
Clean the cooling fins.

(1) Valve block for cooler
(2) Block "C"

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14.2 Components in pitch system
14.2.1 The pitch system in the blades

Numbers in brackets are the numbers punched into the hydraulic block.
The pitch system shown for one blade.
(1) Hydraulic block
(2) Accumulators (106A, 106B, 106C,
106D)
(3) Hydraulic cylinders (109 and 110)
(4) Automatic pitch lock
14.2.2 Component list for hydraulic system in one blade

100 Hydraulic block 109 Solenoid valve
101 Relief valve 109A Solenoid valve
102 Proportional valve 109B Hydraulic cylinder
103 Solenoid valve 110 Non-return valve
104 Non-return valve 111 Test nipple
106A Accumulator 112 Test nipple (pitch cyl.)
106.1A Orifice valve 113 Test nipple (pitch cyl.)
106B Accumulator 114 Test nipple (pitch cyl.)
106.1B Orifice valve 115 Test nipple (pitch cyl.)
106C Accumulator 116 Solenoid valve
106.1C Orifice valve 117 Manual on / off valve
106D Accumulator 118 Non-return valve
106.1D Orifice valve 119 Solenoid valve
107 Pressure transducer 120 Solenoid valve
108 Safety valves 130 Solenoid valve

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14.3 Hydraulic diagrams
14.3.1 Nacelle SWT-2.3-82VS/93

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14.3.2 Nacelle SWT-2.3-101/108

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14.3.3 Pump station (standard)

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14.3.4 Pump station (arctic)

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14.3.5 Pump station SWT-2.3-101/108
Figure 14.17 SWT-2.3-108 - SWT-2.3-101 - SWT-2.5-108

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14.3.6 Blade block (light model)

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14.3.7 Blade block - SWT-2.3-82VS/93
Figure 14.19 SWT-2.3-93 - SWT-2.3-82VS

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14.3.8 Blade block - SWT-2.3-108 - SWT-2.3-101 - SWT-2.5-108 SWT-2.3-101/108

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14.3.9 Pitch lock

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14.3.10 Diagram for gear oil cooler

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14.3.11 Water cooling diagram

Water cooling frequency converter diagram for SWT-2.3 MW turbines.
Position No. Description

1 Frequency inverter modules with manual air bleeders in cabinet
2 Manifold heating cartridges
3 Hose 2", EPDM rubber
4 Hose clamp
5 Water cooler, 2 speed fan, 1.8 kW
6 Thermo valve 25 C - 38 C or turbine controlled 3-way valve
7 PT 100 temperature sensor
8 Temperature gauge
9 Safety valve 1", 3.5 bar
10 Ball valve 2"
11 Filling valve "
12 Dirt filter 2"
13 Test nipple 3/8" (Manual bleeding and pressure measurement)
14 Pressure gauge
15 Pressure transducer, 0 - 6 bar
16 Accumulator 18 litre, 0.5 bar
17 Hose 3/4"
18 Pipe 2" metalized

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19 Circulator pump canned rotor type with air bleeding valve / screw. Grundfos 50 Hz UPS 40-180F or
Grundfos 60 Hz UPS 40-160
20 Automatic air bleeder 3/8" or test nipple
21 Union nut. Cone lubricated with grease

1 Frequency inverter modules
2 Automatic air bleeder 3/8" or test nipple
6 Hose clamp
8 Water cooler, 2 fans each 2.2 kW
9 Turbine controlled 3-way valve
10 Ball valve 2"
11 Dirt filter 2"
12 Temperature gauge
13 Pressure gauge
15 Filling dirt filter
16 Filling valve
17 Hose 3/4"

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19 Pipe 2" stainless steel
20 Circulation pump with no shaft sealing and with air bleeding valve / screw. 50 Hz CRN 10-3 or 60 Hz CRN
10-2. DN40 flange.
21 Heating element, 4.5 kW

1 Frequency inverter modules
5 Hose clamp
7 Water cooler, 2 fans each 2.2 kW
8 Ball valve
10 Filling dirt filter
11 Filling valve
12 Hose 3/4"

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14 Heating element, 4.5 kW
15 Turbine controlled 3-way valve
16 Circulation pump with no shaft sealing and with air bleeding valve / screw. 50 Hz CRN 10-3 or 60 Hz CRN
10-2. DN50 flange.

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14.3.12 Correction table for pressure in accumulators
Pressure Accumulator
bar bar
173 183 186 193 200 207 214 221 227 200
164 171 177 184 190 197 203 210 216 190
155 162 168 174 180 186 192 198 205 180
147 153 158 164 170 176 182 187 193 170
142 148 153 159 165 171 176 181 187 165
138 144 149 155 160 166 171 176 182 160
130 135 140 145 150 155 160 165 171 150
121 126 130 135 140 145 150 154 159 140
112 117 121 126 130 134 139 143 148 130
104 108 112 116 120 124 128 132 136 120
99 103 107 111 115 119 123 126 130 115
95 99 103 106 110 114 118 121 125 110
91 94 98 101 105 109 112 116 119 105
86 90 93 97 100 103 107 110 114 100
82 85 89 92 95 98 102 105 108 95
78 81 84 87 90 93 96 99 102 90
73 76 79 82 85 88 91 94 97 85
69 72 75 77 80 83 86 88 91 80
65 67 70 72 75 78 80 83 85 75
60 63 65 68 70 72 75 77 80 70
56 58 61 63 65 67 69 72 74 65
52 54 56 58 60 62 64 66 68 60
48 49 51 53 55 57 59 61 63 55
43 45 47 48 50 52 53 55 57 50
39 40 42 43 45 47 48 50 51 45
35 36 37 39 40 41 43 44 45 40
30 31 33 34 35 36 37 39 40 35
26 27 28 29 30 31 32 33 34 30
22 22 23 24 25 26 27 28 28 25
17 18 19 19 20 21 21 22 23 20
13 14 14 15 15 16 16 17 17 15
8.6 9 9.3 9.7 10 10 11 11 11 10
4.3 4.5 4.7 4.8 5 5.2 5.3 5.5 5.7 5
-20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C 60 C
Find 100 bar in the column to the right.

Find 10 C in the column in bottom row.
Move up in the 10 C column and stop when you reach 100 bar in the right column.
Read the pressure.
The pressure must be 97 bar when the preloading gas is at 10 C.

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15 Blades
15 Blades
15.1 Safety..............................................................................................................................................................................15-2
15.1.1 Safety precautions before entering hub and working with blades.............................................................................15-2
15.2 Servicing and maintaining blades................................................................................................................................15-3
15.2.1 Noise caused by the blades......................................................................................................................................15-3
15.2.2 Scratches / cracks in the blades............................................................................................................................... 15-3
15.2.3 Blade bearings.......................................................................................................................................................... 15-3
15.2.4 Bolt tightening........................................................................................................................................................... 15-3
15.2.5 Adjusting the blades..................................................................................................................................................15-3
15.2.6 Checking the blades..................................................................................................................................................15-3
15.2.7 Checking Stall-lists....................................................................................................................................................15-4
15.2.8 Checking Vortex generators......................................................................................................................................15-4
15.2.9 Checking Dino tails (Option)..................................................................................................................................... 15-4
15.2.10 Checking Dino shells (Option).................................................................................................................................15-5
15.2.11 Checking Gurney flaps............................................................................................................................................15-5
15.2.12 Checking lightning protectors..................................................................................................................................15-6
15.3 De-icing system............................................................................................................................................................. 15-7
15.3.1 Inspecting the de-icing system boxes....................................................................................................................... 15-7
15.3.2 Inspecting the de-icing power slip ring....................................................................................................................15-11

ZSM1005840 / 16
15 Blades
15.1 Safety
15.1.1 Safety precautions before entering hub and working with blades
WARNING
Read the safety regulations for working in the hub before entering the hub (see safety
instructions, SI545781, 'Basic Health and Safety Rules for Technicians Working in
Siemens Wind Turbines').
Wear H-harness when in the spinner.
When accessing or working in the hub while the 108 valves are not set to Service mode or in
case of grid power loss, there are risks associated with rotating machinery and entrapment. In
these situations, always ensure that you are standing on top of the checker plates; this is
particularly important when performing tasks that require blade pitching.
Before entering the hub, fill out "CH 579264" Lockout / Tag-out procedure - HS rotor lock.
CAUTION: When working on the blades:
Always close the double valve (108) when working on the blades and no pitching needs to be
carried out.
Only open the double valve (108) after having checked that there are no persons who may get
caught in the pitch cylinder, and so on.
No person is allowed to climb into the blade until the technician inside the hub has verbally
confirmed that the manual pitch lock has been mounted or the hydraulic pitch lock is engaged
and the plug on valve (130) is removed, and the double valve (108) closed. See "ZWI1001712
Access to blade"
Check before leaving the hub that all 3 blades have been pitched into the "STOP" position, and
check that all 3 double valves (108) are "OPEN" and the plug on valve (130) is refitted.
Remove any loose objects from the hub before turning it.
Valve handle illustrated in closed position
(1) Double valve (108) on valve blade
block
(2) Check that the locking pin has been
inserted

ZSM1005840 / 16
15 Blades
15.2 Servicing and maintaining blades
15.2.1 Noise caused by the blades

It is important to listen carefully to the noise created by the rotor blades. Any unusual noise may
indicate a fault and an immediate check must be made of the blades.
15.2.2 Scratches / cracks in the blades

The Service Department at Siemens Wind Power A/S must be informed about all types of damage
and cracks in the rotor blades, whether it is a giving cause for concern or just a surface scratch.
Cracks are usually not critical unless they are "propagating". To monitor a crack, mark its length and
direction with a water-resistant marker and sign with your initials and date.
Check following:
Listen for noise coming from the rotor blades.
Visually check the blades, blade roots and tips from the sky lift or crane basket, from the ground
and from the nacelle.
Look for cracks and other abnormalities.
15.2.3 Blade bearings

Wipe grease off the blade bearings. Check that the seal is mounted correctly. If the seal is pinched, it
must be adjusted.
15.2.4 Bolt tightening

The following bolted connections must be re-tightened, see "Bolt tightening".
Blade / bearing
Bearing / hub
15.2.5 Adjusting the blades

Blade tip angle: Standard 0 and 60 .
15.2.6 Checking the blades

Check for cracks or dissonance during operation.
Check the area surrounding the lightning detectors on the blades. Use powerful binoculars. Typical
damage may be black stripes on the fiberglass. If the blades are damaged, the turbine must not be
started before it has been thoroughly examined.

ZSM1005840 / 16
15 Blades
15.2.7 Checking Stall-lists

If damaged / missing parts, estimate amount
Stall list
15.2.8 Checking Vortex generators

Vortex generators
15.2.9 Checking Dino tails (Option)

Dino tails

ZSM1005840 / 16
15 Blades
15.2.10 Checking Dino shells (Option)

Dino shells
15.2.11 Checking Gurney flaps

In case of damage or missing parts, estimate amount.
Gurney flaps

ZSM1005840 / 16
15 Blades
15.2.12 Checking lightning protectors

Procedure:
1 Check the lightning protection visually.
(1) Vortex Generator

(2) Centre of gravity
(3) Receptor / Lightning pos. 27 m
(4) Receptor / Lightning pos. 36 m
(5) Receptor tip / Lightning tip
(6) Web

ZSM1005840 / 16
15 Blades
15.3 De-icing system
15.3.1 Inspecting the de-icing system boxes

Before you begin: Before entering the hub, engage the high-speed rotor lock (with lockout/tagout
procedures); see Locking the rotor on the high-speed shaft (on page 1-61). Comply with all
instructions in Electrical work (on page 1-39), Safety precautions when working with electrical
installations (on page 1-69) and Safety precautions before entering hub and working with blades (on
page 15-2).
These are the components of the optional de-icing system that must be inspected.
(1) DE-ICE fuse box
(2) DE-ICE hub box
(3) DE-ICE lightning boxes (1 at the root
of each blade)
(4) Blade DE-ICE terminal boxes (2 in
each blade)
Figure 15.3.1.209 De-icing system components
For more information about the optional de-icing system, see Operation and Maintenance Manual:
Gen-1 SWT 2.3-101/108 De-Icing system (ZOM1025154) and the de-icing system electrical diagrams.
During the inspection, anything abnormal that is observed, such as loose connections or any sign of
arcing must be corrected.
WARNING
Procedure:
1 Go to the DE-ICE fuse box in the nacelle.

ZSM1005840 / 16
15 Blades
2 Open breaker Q102 in the DE-ICE fuse box in the nacelle to deactivate the deicing system in
nacelle, hub, and blades. Place a padlock and tag on the breaker and comply with all local
lockout/tagout procedures.
3 Using the turbine electrical diagrams as a reference, test and prove that the de-icing circuits from
the DE-ICE fuse box have a zero energy state.
4 Visually inspect the DE-ICE fuse box for discoloration and spark marks. Replace any
components that show evidence of damage.
5 Go to the DE-ICE hub box.

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15 Blades
6 Open the DE-ICE hub box and visually inspect for discoloration and spark marks. Replace any
components that show evidence of damage. Close the box when the inspection is completed.
7 Enter each blade (it will be necessary to leave the hub, disengage the high-speed rotor lock and
rotate the hub to gain access to at least one of the blades) through the access hatch and:
7.1 Open and visually inspect the DE-ICE lightning box (attached to the blade-bearing
reinforcement plate) for evidence of a lightning strike. If the indicator is green, no lightning
strike has occurred. If the indicator is red, a lightning strike has occurred and the
DEHNguard hardware unit in the box must be replaced. Make a lightning strike report
(noting the turbine ID, blade number and date) and return any red units to the site office
so that they can be sent to Siemens Wind Power, A/S ATT: E S SR WP GTL DC DM MC,
Fabriksvej 4, 7330 Brande, Denmark.
7.2 Close the DE-ICE lightning box when the inspection is completed.

ZSM1005840 / 16
15 Blades
7.3 Open and visually inspect the two blade DE-ICE terminal boxes for discoloration and
spark marks. Replace any components that show evidence of damage.
7.4 If required by the checklist, re-torque the bolt in each terminal box in accordance with Bolt
tightening - standard values (on page 4-13).
7.5 Close the DE-ICE terminal boxes.

8 Once the inspection is complete, go to the DE-ICE fuse box in the nacelle and close breaker
Q102 to re-activate the de-icing system. The high-speed rotor lock can also be disengaged.

ZSM1005840 / 16
15 Blades
15.3.2 Inspecting the de-icing power slip ring

Before you begin: Engage the high-speed rotor lock (with lockout/tagout procedures); see Locking
the rotor on the high-speed shaft (on page 1-61). Comply with all instructions in Electrical work (on
page 1-39) and Safety precautions when working with electrical installations (on page 1-69).
The de-icing power slip ring can be found behind the gearbox in the nacelle.
(1) De-icing power slip ring
Figure 15.3.2.217 De-icing power slip ring
For more information about the optional de-icing system, see Operation and Maintenance Manual:
Gen-1 SWT 2.3-101/108 De-Icing system (ZOM1025154) and the de-icing system electrical diagrams.
During the inspection, anything abnormal that is observed, such as loose connections or any sign of
arcing must be corrected.
WARNING
Procedure:
1 Go to the DE-ICE fuse box in the nacelle.

ZSM1005840 / 16
15 Blades
2 Open breaker Q102 in the DE-ICE fuse box in the nacelle to deactivate the deicing system in
nacelle, hub, and blades. Place a padlock and tag on the breaker and comply with all local
lockout/tagout procedures.
3 Using the turbine electrical diagrams as a reference, test and prove that the de-icing circuits from
the DE-ICE fuse box have a zero energy state.
4 Go to the de-icing power slip ring.

ZSM1005840 / 16
15 Blades
5 Remove the de-icing power slip ring covers.
6 Inspect the four cables (grey, brown, black and yellow-green) and connectors in the de-icing
power slip ring for any sign of arcing, spark marks or heat damage. Replace any damage
components and indicate this on the checklist. If necessary, use an adjustable inspection mirror
and a flashlight to check cables and connectors that are difficult to see.
7 Replace the de-icing power slip ring covers.

ZSM1005840 / 16
15 Blades
8 Once the inspection is complete, go to the DE-ICE fuse box in the nacelle and close breaker
Q102 to re-activate the de-icing system. The high-speed rotor lock can also be disengaged.

ZSM1005840 / 16

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Service Manual

Document no: ZSM1005840 Revision no.: 16

Issued by: E W EN OEN DES DOC Confidentiality class: Restricted

Approval no.: 105375 Language: EN-US, original

Revision date: 2013-12-18 Applicable law: Country Specific

Siemens Wind Power A/S. All rights reserved.

Siemens Wind Power A/S. All rights reserved.

Disclaimer of liability and conditions of use

Siemens Wind Power A/S. All rights reserved.

Siemens Wind Power A/S. All rights reserved.

1 Safety instructions for the wind turbine

Siemens Wind Power A/S. All rights reserved. 1-1 of 70

1.3.15 Position of emergency stop.......................................................................................................................................1-67

1-2 of 70 Siemens Wind Power A/S. All rights reserved.

1.1.1 Preface and revisions

Siemens Wind Power A/S. All rights reserved. 1-3 of 70

1.1.2 Visitors and access

1-4 of 70 Siemens Wind Power A/S. All rights reserved.

Smoking is not allowed in Siemens owned or leased buildings and vehicles.

Siemens Wind Power A/S. All rights reserved. 1-5 of 70

No open fire is permitted outside the designated work areas on site.

Leaving the site

1.1.3 Disciplinary rules

1-6 of 70 Siemens Wind Power A/S. All rights reserved.

Siemens Wind Power A/S. All rights reserved. 1-7 of 70

1.1.6 Fire prevention

Use of open fire

No open fire is permitted on site outside the designated work areas.

Smoking is not allowed in Siemens owned or leased buildings and vehicles.

Heating, lighting, and cooking

1-8 of 70 Siemens Wind Power A/S. All rights reserved.

Be familiar with the location and use of fire extinguishers on site.

Siemens Wind Power A/S. All rights reserved. 1-9 of 70

First aid equipment

First aid kit (dressings, thermal blankets, bandage, and so on)

Fire risk/fire extinguisher

Dry powder extinguisher (4 -6 kg)

1-10 of 70 Siemens Wind Power A/S. All rights reserved.

Siemens endorse a reverse or drive-through parking policy.

Siemens Wind Power A/S. All rights reserved. 1-11 of 70

Effective and reliable communication is vital when working in wind turbines.

Cell phone and radio

1-12 of 70 Siemens Wind Power A/S. All rights reserved.

1.1.9 Weather forecast

Siemens Wind Power A/S. All rights reserved. 1-13 of 70

1-14 of 70 Siemens Wind Power A/S. All rights reserved.

Figure 1.1.10. Safety areas in the turbine

Siemens Wind Power A/S. All rights reserved. 1-15 of 70

1.1.11 Extreme wind

1.1.12 Wind during installation

1-16 of 70 Siemens Wind Power A/S. All rights reserved.

1.1.13 Wind during service work

Wind speed limits for work on 300 - 600 kW

Up to 12 m/s (23 kn) / No restrictions

Above 18 m/s (35 kn) / Do not work in the nacelle

Up to 12 m/s (23 kn) / No restrictions

Do not work in the hub.

Siemens Wind Power A/S. All rights reserved. 1-17 of 70

Wind speed limits for work on the early prototypes of SWT-2.3-113DD

Turning of rotor and inserting of rotor locks is not allowed.

Do not work in the hub.

1.1.14 Wind force

Beaufort Description term Wind speeds Wave height (m)

1 Light air Ripples 1-3 0.3 - 1.5 0.1 0.1