Siemens 2.3 Service Manual PDF

Siemens Wind Power A/S
Borupvej 16 - Box 171

DK 7330 Brande - Denmark
Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
E-mail: windpower.pg@siemens.com
www.siemens.com/powergeneration
Service Manual
SWT - 2.3 - 82VS/93/101 INT. (US)
Document no.: ZSM1005840 Workgroup level:
Issued by: E R WP EN 212 Confidentiality class:
Approval no.: ECN50015 Language: US English
Revision. no.: R5. / edition 1 Country of installation: INT
Revision date: (dd-mm-yyyy) 01-11-2009 Applicable law: Country specific
SWT - 2.3 - 82VS/93/101 INT. (US) / ZSM1005840 / ECN50015
© Siemens Wind Power A/S 2009. All rights reserved.

Contents
Document no. Title Chapter
ZSM1005840_01 Technical specifications 1
ZSM1005840_02 Service safety 2
ZSM1005840_03 Inspection 3
ZSM1005840_04 Bolt tightening_general 4
ZSM1005840_05 Lubrication 5
ZSM1005840_06 Controls 6
ZSM1005840_07 Tower 7
ZSM1005840_08 Nacelle 8
ZSM1005840_09 Yaw system 9
ZSM1005840_10 Transmission system 10
ZSM1005840_11 Brake system 11
ZSM1005840_12 Pitch system 12
ZSM1005840_13 Components - diagrams 13
ZSM1005840_14 Blades 14
ZSM1005840_15 Crane 15
ZSM1005840_16 Brake 16
ZSM1005840_17 Tension 17
ZSM1005840_18 Paint repair 18
ZSM1005840_19 Turning gear 19
ZSM1005840_20 Fire detecting 20
ZSM1005840_21 Shadow detector 21
ZSM1005840_22 Ice dec equipment 22
ZSM1005840_23 Acoustic wind sensor 23
ZSM1005840_24 Visibility Meter 24
ZSM1005840_25 Aviation light 25
ZSM1005840_26 SALA fall protection system 26
ZSM1005840_27 SKY MAN servicelift TH250 27
ZSM1005840_28 Miscellanous tools 28

Document history
ECN no. Rev. no. Date Description for changes
ECN30446 R0 10-02-2009 Manual for SWT-2.3-82VS-93-101

created.
ECN30997 R1 24-07-2009 Chapter 26-27-28 added.
ECN32228 R2 14-08-2009 Chapter 2 - page 23 - Fig 2.5 - torque

changed to 400 Nm
ECN32453 R3 09-09-2009 General update for ZSM1005840

SWT-2.3-82VS-93-101.
ECN50015 R4 01-11-2009 Chapter 4 Bolt tightening_general

and check lists updated


INTRODUCTION .......................................................................................................................... 1
Document history ....................................................................................................................................................2
Introduction .............................................................................................................................................................3
Chapter 01 TECHNICAL SPECIFICATIONS .............................................................................. 7

Document history ....................................................................................................................................................8
Technical description ..............................................................................................................................................9
Components in the nacelle ...................................................................................................................................11
Technical specifications ........................................................................................................................................12
Weight List ............................................................................................................................................................14
Chapter 02 TURBINE SAFETY INSTUCTIONS ....................................................................... 17

Document history ..................................................................................................................................................18
Turbine safety instructions ....................................................................................................................................19
Opening and closing the nacelle hatches .............................................................................................................20
Pitch lock...............................................................................................................................................................23
Locking the rotor on the high-speed shaft.............................................................................................................24
Locking the rotor on the low-speed shaft ..............................................................................................................25
Locking the yaw system........................................................................................................................................27
Hand braking by use of hand pump and test hose ...............................................................................................28
Position of emergency stop...................................................................................................................................32
Access to area underneath yaw section ...............................................................................................................34
Mounting of manhole hatches in the hub ..............................................................................................................35
Measuring de-energized condition of frequency converter ...................................................................................37
Sikkerhed ved arbejde på transmission og nav / Safety when working on transmission and hub .......................59
Procedure for låsning og skiltning - HS rotorlås /

Lockout / Tag-out procedure - HS rotor lock ..............................................................................................................65
Chapter 03 INSPECTION AND MAINTENANCE...................................................................... 69

Inspection and Maintenance Schedule .................................................................................................................71
Precautionary measures in case of long periods of standstill for wind turbines....................................................73
Chapter 04 BOLT TIGHTENING ONSHORE............................................................................ 75

Maintenance Schedule .........................................................................................................................................77
Bolt tightening .......................................................................................................................................................79
Definitions .............................................................................................................................................................79
SWT - 2.3 - 82VS/93/101 INT. (US) // ECN50015 / / 14-08-2009 /

Contents
Bolt types ............................................................................................................................................................. 81
Calibration of tools ............................................................................................................................................... 83
Bolt inspection procedures................................................................................................................................... 83
Replacement of main components....................................................................................................................... 84
Tightening steps................................................................................................................................................... 84
Bolt tightening - Standard values ......................................................................................................................... 85
List of widths across flats ..................................................................................................................................... 86
Bolt Tightening - Specific Values ......................................................................................................................... 87
Bolts for lifting brackets ........................................................................................................................................ 92
Tightening torques for hydraulics and gearbox fittings......................................................................................... 93
Tightening torques in controller............................................................................................................................ 98
Position drawings for bolted joints........................................................................................................................ 99
Chapter 05 LUBRICATION..................................................................................................... 105

Document history ............................................................................................................................................... 106
Lubrication chart overview ................................................................................................................................. 107
General rules for lubrication ............................................................................................................................... 108
When should a gear oil sample be taken? ......................................................................................................... 109
Sampling of gear oil ........................................................................................................................................... 110
Replacement of gear oil ..................................................................................................................................... 111
When should a hydraulic oil sample be taken?.................................................................................................. 112
Sampling of hydraulic oil for pitch system .......................................................................................................... 113
Replacement of hydraulic oil .............................................................................................................................. 114
Changing yaw gear oil........................................................................................................................................ 115
Lubrication chart................................................................................................................................................. 116
Chapter 06 CONTROLS ......................................................................................................... 129

Controller and associated electrical installations ............................................................................................... 131
Electrical system ................................................................................................................................................ 132
Service and maintenance of the controller......................................................................................................... 137
Check after repair of controller switchboard....................................................................................................... 138
Service and maintenance of associated electrical installations ......................................................................... 139
Checking the frequency converter cooling system............................................................................................. 159
Chapter 07 TOWER ................................................................................................................ 165

2/8 SWT - 2.3 - 82VS/93/101 INT. (US) // ECN50015 / / 14-08-2009 /

Service and maintenance of tower......................................................................................................................167
Chapter 08 NACELLE ............................................................................................................. 173

Document history ................................................................................................................................................174
Nacelle ................................................................................................................................................................175
Check the liquid level of the tower damper in the nacelle (option)......................................................................178
Chapter 09 YAW SYSTEM...................................................................................................... 183

Yaw system.........................................................................................................................................................185
Service and maintenance of the yaw system......................................................................................................186
Chapter 10 TRANSMISSION SYSTEM................................................................................... 197

Service and maintenance of the transmission system........................................................................................199
Main bearing and main shaft...............................................................................................................................200
Gearbox ..............................................................................................................................................................203
Oil filter for gearbox.............................................................................................................................................208
Generator............................................................................................................................................................217
High speed centrifugal release unit.....................................................................................................................222
Testing the low speed monitoring unit ................................................................................................................223
Alignment of generator........................................................................................................................................225
Generator alignment with laser equipment .........................................................................................................232
Chapter 11 BRAKE SYSTEM ................................................................................................. 299

Brake / Hydraulic System....................................................................................................................................301
Function description............................................................................................................................................302
Service and Maintenance of the Hydraulic System ............................................................................................307
Service Procedures for Pumping Station ............................................................................................................308
Brake Service......................................................................................................................................................315
Chapter 12 PITCH SYSTEM ................................................................................................... 319

Pitch System .......................................................................................................................................................321
Service and Maintenance of the Mechanical Part of the Pitch System...............................................................323
Service / maintenance on the hydraulic part of pitch system..............................................................................333
Service procedures .............................................................................................................................................334
SWT - 2.3 - 82VS/93/101 INT. (US) // ECN50015 / / 14-08-2009 /

Contents
Chapter 13 COMPONENTS AND DIAGRAMS ...................................................................... 337

Components and diagrams ................................................................................................................................ 339
Components on the hydraulic block ................................................................................................................... 340
Components in the pitch system ........................................................................................................................ 348
Diagram for hydraulic system (nacelle) SWT-2.3-82VS, 93............................................................................... 350
Diagram for hydraulic system (nacelle) SWT-2.3-101 ....................................................................................... 351
Hydraulic diagram for pump station (standard) .................................................................................................. 352
Hydraulic diagram for pump station (arctic) ....................................................................................................... 353
Hydraulic diagram for pump station SWT-2.3-101 ............................................................................................. 354
Hydraulic diagram for blade block (light model) ................................................................................................. 355
Hydraulic diagram for blade block - SWT-2.3-82VS, 93 .................................................................................... 356
Hydraulic diagram for blade block - SWT-2.3-101 ............................................................................................. 357
Hydraulic diagram for pitch lock ......................................................................................................................... 358
Diagram for gear oil cooler................................................................................................................................. 359
Water cooling diagram ....................................................................................................................................... 360
Correction table for prepressure in accumulators .............................................................................................. 361
Chapter 14 BLADES............................................................................................................... 365

Blades ................................................................................................................................................................ 367
Servicing the Blades .......................................................................................................................................... 368
Service crane ..................................................................................................................................................... 371
Operating the service crane ............................................................................................................................... 372
Use of manual cheaters ..................................................................................................................................... 375
Service on service crane.................................................................................................................................... 377
Service on chain hoist ........................................................................................................................................ 378
Chapter 15 CRANE................................................................................................................. 379

Appendix - Installation and service manual for service crane ............................................................................ 381
Auxiliary tool....................................................................................................................................................... 383
Chapter 16 BRAKE................................................................................................................. 387

Appendix - Installation and service manual for brake ........................................................................................ 389
Installations- og servicemanual for bremse BSAJ 300....................................................................................... 391
4/8 SWT - 2.3 - 82VS/93/101 INT. (US) // ECN50015 / / 14-08-2009 /

Installations- og servicemanual for brake BSAK 300..........................................................................................409
Chapter 17 TENSION .............................................................................................................. 445

Appendix - Bolt tightening with tensions .............................................................................................................447
Chapter 18 PAINT REPAIR..................................................................................................... 473

Appendix - Paint repair procedure for tower and nacelle....................................................................................475
Repair painting, service & production .................................................................................................................477
Used by the service department: ........................................................................................................................478
Used by the Production Department:..................................................................................................................479
Nacelle damage ..................................................................................................................................................481
Damage on the fiberglass ...................................................................................................................................483
Damage on machine parts..................................................................................................................................484
Chapter 19 TURNING GEAR .................................................................................................. 485

Appendix - Turning gear (option) ........................................................................................................................487
Chapter 20 FIRE DETECTING ................................................................................................ 515

Appendix - Data sheet - fire / smoke detector (option) .......................................................................................517
Data sheet for series 600 (option).......................................................................................................................519
Data sheet for M600/M900 fire detection range (option) ....................................................................................529
Data sheet for M600/M900 low profile detector (option) .....................................................................................535
Smoke and heat detectors 65 series ..................................................................................................................539
Type: Honeywell (option) ...................................................................................................................................555
Data sheet for MXC panel (option) .....................................................................................................................565
Data sheet for H-series heat detectors (option) ..................................................................................................575
Chapter 21 SHADOW DETECTOR......................................................................................... 577

Appendix 10 - Data sheet - shadow detector (option).........................................................................................579
Data sheet - shadow detector .............................................................................................................................581
Chapter 22 ICE DEC EQUIPMENT ......................................................................................... 601

Appendix - Data sheet - ice detector (option) .....................................................................................................603
SWT - 2.3 - 82VS/93/101 INT. (US) // ECN50015 / / 14-08-2009 /

Contents
Ice detector / trouble shooting............................................................................................................................ 605
Ice detector / service guide ................................................................................................................................ 607
Data sheet - ice detector .................................................................................................................................... 609
Chapter 23 ACOUSTIC WIND SENSOR................................................................................ 635

Appendix - Data sheet - acoustic wind sensor (option)...................................................................................... 637
........................................................................................................................................................................... 639
Acoustic wind sensor ......................................................................................................................................... 640
Chapter 24 VISIBILITY METER.............................................................................................. 671

Appendix - Data sheet - visibility meter (option)................................................................................................. 673
Montage af sigtbarhedsmåler / Fitting of visibility meter .................................................................................... 675
Chapter 25 AVIATION LIGHT ................................................................................................ 683

Appendix - Data sheet - aviation light (option) ................................................................................................... 685
Type: ORGA CIP100 (option) ............................................................................................................................ 687
Type: ORGA CIP200 (option) .......................................................................................................................... 695
Type: ORGA GPS020 (option)......................................................................................................................... 707
Type: ORGA L303-865 Medium intensity flash head........................................................................................ 715
Type: BTI W-ROT (option) ............................................................................................................................... 729
Type: BTI low intensity (option)......................................................................................................................... 735
Chapter 26 SALA FALL PROTECTION SYSTEM ................................................................. 737

Appendix - Data sheet - SALA fall protection system (only US) ....................................................................... 739
SALA fall protection system - User manual........................................................................................................ 741
Chapter 27 SKY MAN TH250 SERVICELIFT (option) .......................................................... 777

Appendix - Data sheet - SKY MAN TH250 servicelift (option) ........................................................................... 779
Sky man TH250 service hoist ............................................................................................................................ 781
Introduction ........................................................................................................................................................ 782
Safety precautions ............................................................................................................................................. 783
Safety equipment ............................................................................................................................................... 784
6/8 SWT - 2.3 - 82VS/93/101 INT. (US) // ECN50015 / / 14-08-2009 /

1. Installation of service hoist..............................................................................................................................786
Lower service hoist into the tower in site (option) ..............................................................................................790
2. Roll-out of steel wire .......................................................................................................................................793
3. Feed-in of wire in the hoist..............................................................................................................................795
4. Bottom console for safety/driving wires ..........................................................................................................797
Offshore bottom console (option)........................................................................................................................799
5. Joining of power cables and operation boxes.................................................................................................802
Electricity diagram 1 G........................................................................................................................................804
Electricity diagram 2 G........................................................................................................................................805
6. Safety and driving wires in the service hoist ...................................................................................................806
7. Fitting of top & bottom power switch ...............................................................................................................809
8. Before use and operation of the service hoist.................................................................................................812
Emergency ascent/desent ..................................................................................................................................813
Maintenance of wires/gearbox and motor...........................................................................................................816
Replacement of wires/gearbox and motor ..........................................................................................................817
Standard check ...................................................................................................................................................820
External equipment (Standard check).................................................................................................................822
Troubleshooting ..................................................................................................................................................822
Chapter 28 MISCELLANEOUS TOOLS ................................................................................. 825

Appendix - Data sheet - Miscellaneous tools......................................................................................................827
Pressure tool for tower flanges (all middle flanges) for 2.3MW ..........................................................................837
Mounting and operating control box for use of crane, yaw and hydraulic pressure in hub (Old type) ................841
Mounting and operation of control box in A6 (Rotorlift).......................................................................................849
Mounting and operation of control box/pitch adjustment of older type (Option)..................................................855
SWT - 2.3 - 82VS/93/101 INT. (US) // ECN50015 / / 14-08-2009 /

Contents
8/8 SWT - 2.3 - 82VS/93/101 INT. (US) // ECN50015 / / 14-08-2009 /

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
INTRODUCTION
SWT - 2.3 - 82VS/93/101
Document no.: ZSM1005840 Workgroup level:
Revision date: (dd-mm- 10-02-2009 Applicable law: Country specific

yyyy)

INTRODUCTION
Document history
ECN30446 R0 10-02-2009 Added in ZSM1005840 for SWT-2.3-82VS/

93/101
2/6 SWT - 2.3 - 82VS/93/101 / ZSM1005840 / R0. / edition 1 /

INTRODUCTION
Introduction
Safety Note that the general safety instructions for service and installation work must al-
ways be followed. See SI 545781 - “General Health and Safety Rules for Working
in Turbines”.
Environmental consideration Protect the environment. Sort all waste in accordance with the guidelines given
by the local authorities.
About this service manual This service manual is for a SWT - 2.3 - 82VS/93/101 wind turbines.
The manual is compiled in order to:
• achieve a high safety level in and around the turbine, when operating the tur-
bine, climbing the tower and when working in the nacelle.
• achieve a high quality level when servicing the turbine or carrying out preven-
tative maintenance
• inform on any changes/updates made to the service and maintenance proce-
dures.
When receiving this updated copy of the service manual, all previous versions are
rendered invalid.
Chapter 3 contains an inspection and maintenance schedule for the turbine.
The torque settings and lubricating instructions are not given in each individual
chapter. This information is listed in separate chapters.
Bolt tightening torques are listed: Se: Kapitel 4, “Bolt tightening,” .
Lubrication instructions are shown in Chapter 5.
SWT - 2.3 - 82VS/93/101 / ZSM1005840 / R0. / edition 1 / 3/6

INTRODUCTION

INTRODUCTION
SWT - 2.3 - 82VS/93/101 / ZSM1005840 / R0. / edition 1 / 5/6

INTRODUCTION

- Chapter 01 TECHNICAL SPECIFICATIONS

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 01 TECHNICAL SPECIFICATIONS

SWT - 2.3 - 82VS/93/101
• Document history
• Technical Description
• Components in the nacelle
• Technical Specifications
• Weight List
Document no.: ZSM1005840_01 Workgroup level:
Revision. no.: R2 / edition 1 Country of installation: INT

yyyy)
SWT - 2.3 - 82VS/93/101 / ZSM1005840_01 / R2 / edition 1 / 7 / 16

Document history

93/101
ECN30997 R1 30-03-2009 Weight list - hub changed from 25 Ton to 28

Ton.
ECN32453 R2 11-09-2009 Weight list has been updated
8 / 16 SWT - 2.3 - 82VS/93/101 / ZSM1005840_01 / R2 / edition 1 /

Technical description
Rotor The rotor is a three blade self-contained construction mounted upwind of the tow-
er. The power limitation is by pitch regulation. The rotor speed is variable to max-
imize aerodynamic efficiency and to reduce loads on the gear system during
power regulation.
Blades The blades are mounted on pitch bearings and can be feathered 82° for shutdown
purposes. Each blade has its own independent fail-safe pitching mechanism ca-
pable of feathering 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 envi-
ronment for two service technicians during maintenance of blade roots and pitch
bearings from inside the structure.
Main shaft and main bearing The main shaft is made of constructional alloy steel. The shaft is hollow to allow
for activation of the blade pitching system.
The upwind main bearing absorbs the rotor thrust and reaction forces from gravity
and bending moments. It is a spherical roller bearing which is shrink fitted on the
main shaft. The bearing is grease lubricated, and the bearing seals are labyrinth
seals requiring no maintenance.
Gearbox 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 con-
struction. The intermediary and high-speed stages are helical providing the low-
est possible noise level.
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 vi-
bration sensors.
Generator The generator is a totally enclosed a-synchronous generator with squirrel cage
rotor and no slip rings. The generator is protected with thermal switches and an-
alogue temperature measurement.
The generator is fitted with a separate thermostat-controlled ventilation system.

The air is circulated internally in the generator via a heat exchanger which effi-
ciently keeps air temperature internally in the generator separate from the ambi-
ent temperature.
Mechanical brake The brake calliper and the brake discs are placed on the high speed shaft. The
brake is a positive acting brake, i.e. the brake is activated when the pressure in
the system is relieved from the calliper. The “braking force” on the brake pads is
applied by a heavy spring built in the calliper. When the brake is released, the hy-
draulic pressure in the system forces the spring back, away from the disc.

Yaw system The yaw bearing is an externally geared yaw plate sliding on grease lubricated
elements which functions as a yaw brake. 8 electric planetary gear motors drive
the yawing.
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 2.3MW MkII turbine can be adjusted for
all presently existing grid codes.
Remote monitoring The 2.3MW MkII turbine has WebWPS SCADA through which the turbine can be
monitored and controlled via a standard Internet browser.
In addition, the 2.3MW MkII turbine has WebCMS monitoring which measures vi-
brations 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 25m/s, feather-
ing of the blades shuts down the turbine. When the wind speed drops below the
re-starting limit, the safety systems are reset automatically.

Components in the nacelle
Fig. 1.0
6 7 9 10 11
1
14
4 16 15 21 23 22
2 8 17 12 13
3 5 18 19 20
1. Spinner / Spinner 14. Meterologiske sensorer / Meterological sensors

2. Rotornav / Rotor hub 15. Krøjering / Yaw ring
3. Vinge / Blade 16. Krøjetandhjul / Yaw gear wheel
4. Vingeleje / Blade bearing 17. Krøjegear / Yaw gear
5. Pitchsystem / Pitch system 18. Maskinramme / Bed plate
6. Hovedleje / Main bearing 19. Maskinkappe / Nacelle cover
7. Hovedaksel / Main shaft 20. Hydraulik med integreret opsamlingsbakke
8. Topboks for styring / Top control box / Hydraulics with integreted collecting tray
9. Hovedgear / Main gear 21. Gearolie opsamlingsbakke / Gear oil collecting tray
10. Bremseskive / Disc brake 22. Olie køler - gear med integreret opsamlingsbakke
11. Bremsekaliber / Brake / Oil cooler - gear box with integreted collecting tray
12. Kobling / Coupling 23. Olie køler - hydraulik med integreret opsamlingsbakke
13. Generator med integreret kølersystem / Oil cooler - hydraulic with integreted collecting tray
/ Generator with integreted cooling system

Technical specifications
Rotor Type ...........................................3-bladed, horizontal axis

Position ......................................Upwind
Diameter (82) .............................82,4m
Diameter (93) .............................93m
Diameter (101) ...........................101m
Swept area (82)..........................5300m²
Swept area (93)..........................6800m²
Swept area (101)........................8000m²
Synchronous rotor speed ...........6 - 16 rpm
Synchronous rotor speed (101)..6 - 18 rpm.
Power regulation ........................Pitch regulation with variable speed
Rotor tilt......................................6 degrees
Blades Type ...........................................Self-supporting

Blade length (82)........................40 m
Blade length (93)........................45 m
Blade length (101)......................49 m
Tip chord ....................................0.8 m
Root chord (82) ..........................3.1 m
Root chord (93) ..........................3.5 m
Root chord (101) ........................3.4 m
Aerodynamic profile ...................NACA 63xxx / FFxxx
Material ......................................GRE
Surface gloss .............................Semi-mat, < 30 / ISO2813
Surface colour ............................Light grey RAL 7035
Aerodynamic brakes Type ...........................................Full span pitching

Activation....................................Active, hydraulic
Load-supporting parts in the Hub.............................................Nodular cast-iron

nacelle Main bearing ..............................Spherical roller bearing
Main shaft...................................Alloy steel
Nacelle bed plate .......................Steel
Transmission system 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 l
Gearbox oil filtering ....................Inline and offline
Gearbox cooling .........................Separate oil cooler
Gearbox designation ..................PEAB 4456 (Winergy) or
EH851 (Hansen)
Coupling gear/generator ............Double flexible coupling
Brake (mechanical brake) Type ...........................................Hydraulic disc brake

Position ......................................High speed shaft
No. of callipers ...........................2

Generator Type ........................................... Asynchronous

Nominal power ........................... 2.3 MW
Synchronous speed ................... 1500 RPM
Protection................................... IP 54
Cooling.......................................Integrated heat exchanger
Insulation class ..........................F
Grid Terminals (LV) Nominal power ........................... 2,3MW

Voltage .......................................690 V
Frequency .................................. 50 Hz or 60 Hz
Canopy Type ........................................... Totally enclosed

Material ...................................... Steel
Surface gloss .............................Semi gloss, 30-50, ISO2813
Colour ........................................ Light grey, RAL 7035
Yaw system Type ........................................... Active

Yaw bearing ............................... Externally geared slewring
Yaw drive ................................... 8 electric gear motors with frequency converter.
Yaw brake .................................. Passive friction brake.
Controller Type ........................................... Microprocessor

Remote monitoring..................... WPS via modem
Controller designation ................KK WTC - 3.0
Controller manufacturer .............KK Electronic A/S
Tower Type ........................................... Cylindrical and/or tapered tubular

Hub height.................................. 80m or site specific
Corrosion protection................... Painted
Surface gloss .............................Semi gloss, 30-50 ISO2813
Surface colour............................ Light grey, RAL 7035
Operational Data Cut-in wind speed. ..................... 4 m/s

Cut-in wind speed (82)............... 3-5 m/s
Nominal power at approx. ......... 13 - 14 m/s
Nominal power at approx. (101).12 - 13 m/s
Cut-out wind speed ....................25 m/s
Max. 3 s gust..............................55 m/s (standard version)
Turbine (93-101) 59,5 m/s (IEC version)
Turbine (82) 70 m/s (IEC version)

Weight List
The weights given are approximate
Nacelle Nacelle ...................................... .................................. 82000 kg
Blades Blade B 40 m (3 pcs.) ................ .................................. 27600 kg

Blade B 45m (3 pcs.) ................. .................................. 34800 kg
Blade B 49m (3 pcs.) ................. .................................. 30600 kg
Hub Hub (with bolts) .......................... .................................. 28000 kg
Rotor Rotor including B 40m blades .... .................................. 54000 kg

Rotor including B 45m blades .... .................................. 59800 kg
Rotor including B 49m blades .... .................................. 59700 kg
Various parts Generator ................................... .................................... 7000 kg

Gear with disc and callipers ....... .................................. 23400 kg
Gear (Type: Flender) with disc and callipers................. 22500 kg
Gear (Type: Hansen) with disc and callipers................. 23500 kg
Main shaft with bearings ............ .................................. 16000 kg
B45 blade (1 blade) incl. thread rods ............................ 11400 kg
B45-01 blade (1 blade) incl. thread rods ....................... 10600 kg
B40 blade (1 blade) incl. thread rods .............................. 9500 kg
B49 blade (1 pcs.) incl. thread rods .............................. 10200 kg
Nacelle transportation frame ...... .................................... 5000 kg
Blade bolts (3 bolts) ................... .................................... 1000 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 ........................ .................................... 3000 kg

Frequency converter A12........... .................................... 1000 kg
Coil A14...................................... .................................... 1800 kg
Filter board A11 .......................... ...................................... 300 kg
Controller A2 .............................. ...................................... 400 kg
Controller / Wps ......................... ...................................... 800 kg
Total weight.......... 7300 kg



- Chapter 02 TURBINE SAFETY INSTUCTIONS

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 02 TURBINE SAFETY INSTUCTIONS

SWT - 2.3 - 82VS/93/101
• Turbine safety instructions
• Opening and closing the nacelle hatches
• Pitch lock
• Locking the rotor on the high-speed shaft
• Locking the rotor on the low-speed shaft
• Locking the yaw system
• Hand braking by use of hand pump and test hose
• Position of emergency stop
• Access to area underneath yaw section
• Mounting of the manhole hatches in the hub
• Sala fall protection system (only US)
Revision date: (dd-mm-yyyy) 14-08-2009 Applicable law: Country specific
SWT - 2.3 - 82VS/93/101 / ZSM1005840_02 / R1. / edition 2 / 17 / 36

Document history
ECN30446 R0 10-02-2009 Added in ZSM1005840 for SWT-2.3-82VS/93/101
ECN30997 R1 30-03-2009
18 / 36 SWT - 2.3 - 82VS/93/101 / ZSM1005840_02 / R1. / edition 2 /

Turbine safety instructions
Safety Please note that the general safety instructions for service and installation work
in wind turbines always apply. See SI 545781 “General Health and Safety Rules
for Working in Siemens Wind Power Turbines”.
IMPORTANT !! BEFORE ENTERING THE HUB, FILL IN “CH 579264” Lockout / Tag-out pro-
cedure - HS rotor lock
Positive HS brake The turbine is equipped with a positive brake and does not brake automatically at
normal stop, as the turbine is then set to idle.
Basic safety regulations for ALWAYS comply with the following regulations when working in the turbine!
work in the turbine
• Always wear hearing protection when working in the turbine during op-
eration.
• Always push MANUAL STOP before ascending the turbine
• Activate the “BLUE VALVE” (Service Brake) - (See also page 28)
• Operate the turbine through MENU 24
• The turbine can only be restarted after de-activating the “BLUE VALVE”
• ALWAYS engage the rotor lock when working in the hub and with the ro-
tor
• ALWAYS engage the yaw lock when working on the yaw system
• ALWAYS apply rotor lock and yaw lock during external crane work out-
side the turbine.
NOTE ! • Remember, before climbing up the tower, to... POSITION THE REMOTE
CONTROL SWITCH IN THE “LOCAL CONTROL” POSITION.
• Remember, after finishing work on the turbine, to....TURN THE SWITCH
BACK TO THE “REMOTE CONTROL” POSITION.
Locking the local/remote Locking the switch is required on some sites.

switch
• In these cases, the service technician must bring a pad lock to lock the
local/remote switch.
Verifying that the frequency “Measuring de-energized condition of frequency converter” on page 77
converter is de-energized

Opening and closing the nacelle hatches
WARNING ! BEFORE ENTERING THE HUB, MAKE SURE THAT THE HS ROTOR LOCK IS
ENGAGED.
DURING WORK ON THE TRANSMISSION, THE HS ROTOR LOCK MUST BE

ENGAGED.
VALVE (252) ON THE HYDRAULIC STATION MUST BE CLOSED “BLUE

BRAKE HANDLE”
Manual opening of hatches Fig. 2.0

without voltage in the turbine 1. Open the hook lock on the na-
celle hatches.
See “Operation of covers and crane without hydraulic pump pressure” on

page 43.

Operating handle for opening The nacelle hatches are opened by 2 hydraulic cylinders. The operating handles
and closing nacelle hatches are placed in the left-hand side of the nacelle. One handle (1) is used for opening
with voltage in the turbine hatch (1), the other (2) is used for opening hatch (2).
Fig. 2.1
The operating handles are
placed in the left-hand side of the
nacelle.
Fig. 2.2
In order to operate the handles,
activate button (1) - hatches
Fig. 2.3
Operating handles for opening
1 and closing the hatches.
2
Close
Open
NOTE ! • Opening the hatches: - Open hatch (1) first.

• Closing the hatches: - Close hatch (2) first.
Opening the nacelle hatches • Pull handle (1) away from the hatch until hatch (1) is fully opened.
• Pull handle (2) away from the hatch until hatch (2) is fully opened.
• IMPORTANT! - Lock the casement stays on both hatches.

Closing the nacelle hatches
WARNING ! Make sure that all persons are clear of the hatches when closing them.
• Remove the locks from the casement stays in both hatches.

• Push handle (2) towards the hatch until hatch (2) is fully closed.
• Push handle (1) towards the hatch until hatch (1) is fully closed.
• Relieve the cylinders by activating the handles without starting the
pump.
Close the hook locks on the hatch. Double check that they are locked correctly.
Casement stays Note! - Always use the casement stay in both hatches when working with the
hatches open.
Fig. 2.4
1. Casement stay lock

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.
Fig. 2.5
1. Pitch lock bracket. (Manual).
1 Bolt M24 x 160, 10.9
Pitch the blade until the pitch

lock holes fit the bolts.
Mount the pitch lock bolts, and

torque-tighten. Torque = 400 Nm
Fig. 2.6
1. Pitch lock (manual).
1
Position when not in use.
Pitch lock (hydraulic) Fig. 2.7

1. Pitch lock (hydraulic).
1
Activated in “MENU 24”

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.
WARNING ! Wind speed limit for the high-speed lock is 32 m/s.
NOTE ! Use the electric turning motor (see page 27) when pushing in the lock bolts. The
turbine motor must stay engaged until the lock bolts have been disengaged.
IMPORTANT !! Yaw the turbine out of the wind if the turning motor is unable to turn the rotor.
Fig. 2.8
1 Position of bolts when the ro-
tor is not locked.
2
2 Position of cotter pins when
the rotor is not locked.
1
Turn the rotor until the bolts can
engage. The rotor is turned using
the turning gear.
Fig. 2.9
To lock the rotor, bolts (1) must
2 be pressed fully home and the
cotter pins (2) inserted to lock the
bolts.

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 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 by using a screw spindle
WARNING ! Wind speed limit for the low-speed lock is 32 m/s.
Electric turning motor • Mount the plug (4) in the A9 cabinet for crane/hatches.
• Loosen the lock bolt and push the turning motor into contact with the
gearwheel (see the mark).
• Tighten the lock bolt and start the motor to make the rotor rotate in the
wanted direction.
Fig. 2.10
1. Electric turning motor.
1
2. Lock bolt.
3. Plug

Operating the rotor lock with • The rotor must be turned using the auxiliary motor until the rotor lock en-
screw spindle gages.
• Check between the hatch and the main bearing to see when the hole in
the flange is aligned with the rotor lock.
• Stop the turning motor.
• Remove the rotor lock cotter pin on both sides
Fig. 2.11
Rotor lock.
Fig. 2.12
Rotor lock NOT engaged.
1 1. Pull the safety lock pin slightly

outwards.
2 2. Screw in the screw spindle.
3. Indicator
Fig. 2.13
Rotor lock engaged.
1 1. Re-engage the safety lock pin
2. The screw spindle is fully in

2 and the rotor lock is engaged.
3. Indicator

Locking the yaw system
WARNING ! USE ROTOR LOCK WHEN WORKING ON:
• THE YAW SYSTEM - YAW CLAWS / TEETH

• REPAIRING THE OUTSIDE OF THE TURBINE
• EXTERNAL CRANING AT / ON THE TURBINE
WARNING ! Wind speed limit for the yaw lock is 32 m/s.
IMPORTANT !! To engage the yaw lock, use the buttons in the A18 cabinet. (A special box has
to be used during installation.)
Fig. 2.14
Yaw lock
Fig. 2.15
Yaw lock in the unlocked posi-
tion.
Locking the yaw system
• Pull out the lock pin.

• Push down the yaw brake
to lock the yaw ring.
Use MENU 2 - screen 1 - (manu-

al yawing) if the brake does not
engage.

Hand braking by use of hand pump and test hose
Service brake (Blue brake Fig. 2.16

handle) - Position of stop 1 Stop valve (252)
valve on hydraulic station
The label on the valve shows the
valve positions “Closed” and
“Open”.
Fig. 2.17
1. Valve in operating position.
“Service mode OFF”
Fig. 2.18
1. Valve in service position
“Service mode ON”

Fig. 2.19
Disconnect the hand pump hose
from block at the T piece.
Fig. 2.20
1. Hand pump.
1
2. Hose.
Prepare the hand pump hose

with fittings with a test nipple at
the end (article numbers 12103,
10150 and 26972)
Connect the test hose.
Fig. 2.21
Connect the test hose to 212 on
the block.
• Turn the ball plug valve to “Service mode ON” (tank closed off).

Fig. 2.22
Connect a manometer to test
nipple 227.
The brake can now be activated

1 by pumping pressure into the
brake circuit. 10 full strokes of
the hand pump will produce an
accumulator pressure on 220 of
app. 55 bar, whereas the operat-
ing pressure is 80 bar. This
means that the brake torque with
the hand pump is only 2/3 of the
brake torque when the pump is
operating.
• Relieve the brake again by turning the service valve to “Service mode
OFF”
• Reconnect the hoses in reversed order when the work is finished.

Position of stop valve in the Fig. 2.23

hub 1. The stop valve is placed on
the valve block under the check-
er plate. There is one stop valve
at each blade.
Fig. 2.24
1. Drain valve on the valve block.
The picture shows valve in

turned-off position.
1
Fig. 2.25
1. Drain valve on the valve block.
The picture shows valve in

turned-on position.
1
Fig. 2.26
1. Pull safety lock to activate the
drain valve.

Position of emergency stop
Position of emergency stop in Fig. 2.27

the nacelle Two emergency stops are found
in the nacelle hatches - one in
each side. They are activated by
pulling the wire.
Emergency stop in the left-hand

side.
Emergency
stop
Fig. 2.28
1. Reset button.
1 2. Emergency stop wire
Emergency stop in the right-

hand side.

the yaw section 1. Emergency stop.

Position of emergency stop Fig. 2.30

outside the yaw section 1. Emergency stop.

the controller 1. A2 controller
2. Emergency stop

Access to area underneath yaw section
Description of access for service and maintenance underneath yaw section, only to be done by autorized personel.
Adgangsvej til underside af krøjesektion:

Før adgang til nav -
1: Drej rotor således at lugedæksler "A" og "B" kan fjernes.
Før indgang i nav - følg sikkerhedsmanualens forskrifter vedr. adgang til

nav.
2: Gå ind i navet og fjern luge "C", der er nu adgang til at kravle ind under krøjesektionen
1 A
C 2 B
Access to area underneath yaw section:

Before entering the hub -
1: Turn the rotor so that manhole covers "A" and "B" can be removed.
Before entering the hub, make sure that the safety precautions are followed
in acc. with the safety manual
2: Enter the hub and remove manhole cover "C". It is now possible to
enter the area underneath the yaw section
18-06-2004
WARNING ! BEFORE ENTERING THE HUB, MAKE SURE THE HS ROTOR LOCK IS EN-
GAGED.

ENGAGED.
“THE BLUE HANDLE” - VALVE (252) ON THE HYDRAULIC STATION - MUST

BE IN “SERVICE MODE ON”
IMPORTANT !! Se: Kapitel , “Chapter 02 TURBINE SAFETY INSTUCTIONS,”
Please note that the “Basic Health and Safety Rules for Service Technicians
Working in Siemens Wind Power’s Turbines” SI 545781 always apply.

Mounting of manhole hatches in the hub
WARNING! Make sure that the hydraulic hoses in the hub are not pinched by the clos-
ing device of the manhole hatches.
Fig. 2.32
The hydraulic hoses for pitching
the blades are fitted immediately
inside the manhole in the hub.
Nødstop
Fig. 2.33
Because of the design of the
closing device on the hinges of
the manhole hatches there is a
risk that one of the closing devic-
es may catch the hydraulic hose
as illustrated in this photo.
Both safety and environmental

problems may arise if the hose is
chafed or pinched.
Nødstop
Fig. 2.34
Check when the hatch is closed
that no hydraulic hoses are
caught.
This is easily ascertained when

the three hand screws are tight-
ened.
Also, it is easily observed if one

of the three bolts/catches are fur-
Nødstop ther in than the other two.


Measuring de-energized condition of frequency converter

Materials
• Measuring device
• Main switch locking device (SWP no. 30573)
• Personal padlock (SWP no. 1003020)
• Lock system for MS325 (SWP no. 20768)
Info
The cut-in of the main switch (circuit breaker) is monitored by the controller and
must not be performed manually.
It is mandatory to follow the 3 safety rules in correct order to avoid the risk of
an electric shock.
The 3 safety rules

1. De-energize These 3 safety rules must be fol-
lowed prior to performing any
2. Secure against reconnection work on the circuit.
3. Confirm the de-energized condition
Fig. 3.1
Hearing protection must be worn
during start-up and operating of
the turbine.
Tools required:
Fig. 3.2
L-AUS bag contains all the ne-
cessary equipment.
Caution:
“Measuring de-energized condition of frequency converter” 77 / 82

Rev: 15.01.2007 / ECN 22999

If more than one person are 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.
A PRACTICAL EXAMPLE:
Fig. 3.3
Remove cover to get into main
switch.
Fig. 3.4
Main switch with a cut-out in the
shielding.
Disconnect
Fig. 3.5
Disconnecting the turbine is, as
usual, conducted by switching off
the main switch by means of the
corresponding red push-button
"OFF".
(Prior to this, the turbine must be

stopped via the display.)
78 / 82 “Measuring de-energized condition of frequency converter”

Rev: 15.01.2007 / ECN 22999

Fig. 3.6
1 Main switch for locking de-
vice
2 Personal padlock
To assure each individual techni-

cian's working safety, the locking
1 device shown must be used on
the main switch.
2
Fig. 3.7
Everybody working in the turbine
must mount a personal padlock
1
in the lock system.
1 Post a warning sign
Fig. 3.8
1 The charging resistors in the
1 DC link for the frequency
converter are connected in
parallel with the main switch.
They must also be discon-
nected by switching off the
circuit breaker +A1 -
000F1.1.
Secure against reconnection:

Rev: 15.01.2007 / ECN 22999

Fig. 3.9
As the WTC3 controller can re-
connect the main switch inde-
pendently, the latter must be
secured against reconnection by
the above-mentioned means.
See Fig. 3.10
Fig. 3.10
The circuit breaker +A1 -
1 000.F1.1 or +A1 -000.F4.1 is
protected against reclosing by
means of the yellow locking de-
vice.
Also use the personal padlock.
Assure de-energized condition:
Prior to the actual measurement of the de-energized condition, it must be

checked that the measuring device used is actually functional. For this purpose,
one measurement in the AC section and one in the DC section must be conducted
on live measuring points.
Fig. 3.11
Measuring device
A Fluke tester can be used for

the voltage measurement.
All measurements in the turbine

voltage section must be condu-
cted with the extra secured test
prods.

Rev: 15.01.2007 / ECN 22999

Fig. 3.12
Ensure that the measuring de-
vice is intact, use the switch
mode by the power supply.
Check both AC and DC.
As all measurements are to be conducted in the AC section and the DC section

and it is necessary to measure the frequency converter thoroughly on the grid
side and the generator side and in the so-called DC link section, a total of 30
measurements are to be conducted on the frequency converter.
Measurement 1: Grid side: 1. U - V, 2. U - W, 3. V - W, 4. U - ground, 5. V - ground,

6. W - ground
Measurement 2: Generator side: 7. U - V, 8. U - W, 9. V - W, 10. U - ground, 11.

V - ground, 12. W - ground
Measurement 3: Dc link: 13. DC+ - DC-, 14. DC+ - ground, 15. DC- - ground

Rev: 15.01.2007 / ECN 22999

The measurements must be conducted in the AC section and the DC section re-
spectively.
A12 Cabinet (frequency converter) Fig. 3.14
Fig. 3.13 1
Check measurement 1.
Fig. 3.15
3
Fig. 3.16
1
3

Rev: 15.01.2007 / ECN 22999

SIEMENS
Aktivitet/Operation: Betjening af luger og kran ved man- ZWI1004273
glende hydraulisk pumpetryk
Designer: SPE
Operation of covers and crane without
hydraulic pump pressure Designer dato/date: 21-10-08
Mølle type / Turbine: SWT-2.3-82 / SWT-2.3-93 ECN nr./no.: 29388
Dokument ref. / Document ref.: ECN Dato/date: 24-10-08
Klassificering / Rating: 3
DK- Vigtigt:
Brug altid nødvendigt sikkerhedsudstyr, når der arbejdes med kemikalier, elværktøj og luftværktøj.
Der henvises iøvrigt til sikkerhedsdatabladene.
Hold altid arbejdsområdet rent. Fjern spåner og snavs, når disse findes.
Alle mål er angivet i SI enheder.
INT- Note:
Always use the necessary personal protective equipment when working with chemicals, electrical
tools and pneumatic tools. Also check the safety data sheets.
Always keep the work area clean. Clean away any swarf and dirt.
All measurements are given in SI units.
DK- Stop møllen. Husk at bære høreværn

under drift og opstart af møllen.
INT- Stop the turbine. Remember: Hearing

protection is mandatory during turbine
operation and startup.
Fig 1
Siemens Wind Power A/S Side / Page 43 / 52 Conveyed confidentially as trade secret
© All Rights Reserved 2007 ZWI1004273 - 29388
DK- Flyt blåt håndtag til “Service mode ON” .
INT- Shift the blue lever to “Service mode ON”
Fig 2
DK- Håndtag for manuel pumpe er placeret i

polypper på siden af generatorstol
mellem generator og servicekran.
INT- The lever for the manual pump is placed

in clips on the side of the generator sup-
port between the generator and the ser-
vice crane.
Fig 3
DK- Monter håndtaget i pumpen og pump

tryk på.
INT- Fit the lever in the pump and build pres-

sure.
Fig 4
DK- Håndtag for lugeåbning aktiveres imens
der pumpes. Åbn lugerne.
INT- Activate the lever for operating the cov-

ers during pumping. Open the covers.
Fig 5
DK- Vigtigt: Når lugerne er åbnet SKAL de

sikres og splitten SKAL monteres
INT- Important: When the covers are open

ALWAYS secure them and ALWAYS
use the split pin.
Fig 6
DK- Træk nødstop for at sikre mod at hydrau-

likmotor kan starte.
INT- Activate the emergency stop to prevent

the hydraulic motor from starting.
Fig 7
DK- Drej afbryder 609.Q1 i A3 skabet om på
“OFF” og hæng “Må ikke betjenes” skilt
på.
INT- Turn switch 609.Q1 in the A3 box to

“OFF” and post the sign “Do not oper-
ate”.
Fig 8
DK- Åbn hane Pos. 14 for at gøre hoved-

Pos. 27 kreds trykløst.
Luk hane Pos. 31 for at lukke for tryk-
siden til pitchkreds.
Åbn hane Pos. 27 for at gøre pitchkreds
Pos. 14 trykløst.
INT- Open valve Pos. 14 to depressurize the

main circuit.
Close valve Pos. 31 to close off the pitch
circuit pressure side.
Pos. 31
Open valve Pos. 27 to depressurize the
pitch circuit.
Fig 9
DK- Kontroller med manometer på testnippel

Pos. 18 Pos. 18 at systemet er trykløst.
Afmonter trykslange for kran på Pos. P
crane. Bemærk under selve arbejdet
med hydraulikslanger skal der beny-
ttes handsker.
INT- Check that the system is depressurized-

with a manometer on test nipple Pos. 18.
Disconnect the pressure hose for the
crane at Pos. P. crane. Note: Use
gloves when working with hydraulic
Pos. hoses.
P crane
Fig 10
DK- Afmonter trykslange for luge på den
manuelle pumpe.
INT- Disconnect the pressure hose for the

cover on the manual pump.
Fig 11
DK- Slange for luger monteres midlertidigt på

Pos. P crane på hydraulikstation så
oliespild minimeres.
INT- Temporarily connect the hose for the

covers to Pos. P crane on the hydraulic
station to minimise oil waste.
Fig 12
DK- Monter trykslange for kran på manuel

pumpe. Bemærk under selve arbejdet
med hydraulikslanger skal der beny-
ttes handsker.
INT- Connect the pressure hose for the crane

to the manual pump.
Note: Use gloves when working with
hydraulic hoses.
Fig 13
DK- Pump tryk med manuel pumpe.
INT- Build pressure with the manual pump.
Fig 14
DK- Betjen kranen med håndtagene imens

der pumpes tryk med manuel pumpe.
INT- Operate the crane with the levers while

building pressure with the manual pump.
Fig 15
DK- Efter endt brug af kran, afmonter tryk-

slange for kran på manuel pumpe.
Bemærk under selve arbejdet med
hydraulikslanger skal der benyttes
handsker.
INT- When the work with the crane is com-

peted, disconnect the pressure hose for
the crane on the manual pump.
Note: Use gloves when working with
hydraulic hoses.
Fig 16
DK- Afmonter slange for luger på Pos. P
crane.
INT- Disconnect the hose for the covers at

Pos. P crane.
Fig 17
DK- Monter slange for luger på manuel

pumpe.
INT- Connect the hose for the covers to the

manual pump.
Fig 18
DK- Monter trykslange for kran på Pos. P

crane.
INT- Connect the pressure hose for the crane

to Pos. P. crane.
Pos.
P crane
Fig 19
DK- Luk hane Pos. 14 for at sætte tryk på
Pos. 27 hovedkreds.
Åbn hane Pos. 31 for at åbne for tryk-
siden til pitchkreds.
Luk hane Pos. 27 for at sætte tryk på
Pos. 14 pitchkreds.
INT- Close valve Pos. 14 to build pressure in

the main circuit.
Open valve Pos. 31 to open the pitch cir-
cuit pressure side.
Pos. 31
Close valve Pos. 27 to build pressure in
the pitch circuit.
Fig 20
DK- Fjern “Må ikke betjenes” skilt og drej

afbryder 609.Q1 om i “ON” i A3 skabet.
INT- Remove the “Do not operate” sign and

turn switch 609.Q1 to “ON” in the A3
box.
Fig 21
DK- Aktiver nødstop igen.
INT- Re-activate the emergency stop.
Fig 22
DK- Fjern lugesikring.
INT- Remove the cover lock.
Fig 23
DK- Monter håndtaget i pumpen og pump

tryk på.
INT- Fit the lever in the pump and build pres-

sure.
Fig 24
DK- Håndtag for lugeåbning aktiveres imens

der pumpes. Luk lugerne.
INT- Activate the cover operating lever during

pumping. Close the covers.
Fig 25
DK- Placer håndtag for manuel pumpe i
polypper på siden af generatorstol
mellem generator og servicekran.
INT- Place the handle for the manual pump in

the clips on the side of the generator
support between the generator and the
service crane.
Fig 26
DK- Flyt blåt håndtag til “Service mode OFF”
INT- Shift the blue lever to “Service mode

OFF”
Fig 27


Fig 1
SIEMENS
Aktivitet/Operation: Adgang til vinge ZWI 1001712
Access to blade Designer: AML
Designer dato/date: 12-03-08
Mølle type / Turbine: SWT-2.0-76, SWT-2.3-82, SWT-2.3-82 VS, ECN nr./no.: 29412
SWT-2.3-93
Dokument ref. / Document ref.: ZWI579823, ZWI1004219 ECN Dato/date: 28-10-08
DK- Vigtigt:
INT- Note:

INT- Stop the turbine. Remember to wear ear

muff during operation and start-up of the
turbine.
Fig 1
© All Rights Reserved 2008 ZWI 1001712 - 29412
DK- Placer et digital vaterpas på navet ( som
vist på billedet). Navet drejes med turner
gearet med uret iht. ZWI579823, indtil at
vaterpasset viser ca. 39 grader.
Vigtigt: Der må ikke være montører i
navet mens navet drejes.
INT- Place a digital level on the hub ( as

shown on the picture) Turn the hub
clockwise with the turner gear according
to ZWI579823 until the level shows
approx 39 degrees.
Important: Service technicians must
not be in the hub while rotating the
hub.
Fig 2
DK- Vigtigt: Det er altid vingen til højre der

skal arbejdes i.
INT- Important: It is always the blade to the

right, that must be worked on.
Fig 3
DK- Monter HS rotor låse.
INT- Fit HS rotor locks.
Fig 4
DK- Luk for sikkerhedshaner på alle tre
vinger.
INT- Close the safety valves on all three

blades.
Fig 5
DK- Afmonter oileabsorbere som sidder ved

siden af huller til mekanisk pitchlås.
INT- Dismantle the oil absorbers which are

placed next to the holes for the mechani-
cal pitch lock.
Fig 6
DK- Afmonter røde propper fra huller til

mekanisk pitchlås.
INT- Dismantle red plugs from holes to

mechanical pitch lock.
Fig 7
DK- Tryk på den blå knap, for at deaktivere
nødstop.
INT- Press on the blue button to deactivate

emergency stop.
Fig 8
DK- Gå i menu 2. Efter aktivering af nødstop

vil status være 1003. Tryk på punktom
tasten, hvorefter status vil være 1001
igen.
INT- Go in menu 2. After activating the emer-

gency stop, the status will be 1003.
Press the “period key”, and then the sta-
tus will be 1001 again.
Fig 9
DK- Åben sikkerhedshane på vingen der skal

arbejdes på.
INT- Open the safety valve on the blade that

is going to be worked on.
Fig 10
DK- Pitch 1-2 grader med vingen iht.
ZWI1004219 indtil boltene fra den meka-
niske pitchlås passer ned i hullerne.
Spænd boltene moment iht. servicema-
nualen.
INT- Pitch 1-2 degrees with the blade accor-

ding to ZWI1004219 until the bolts from
the mechanical pitch lock fit down in the
holes.
Tighten the bolts to torque according to
service manual.
Fig 11
DK- Luk sikkerhedshane igen.
INT- Close the safety valve again.
Fig 12
DK- Afmonter dæksel ud til vingen, der skal

arbejdes på.
Når arbejdet i vingen er lavet, monteres
dækslet ud til vingen igen.
INT- Dismantle the cover to the blade that is

going to be worked on.
When the work in the blade is done, fit
the cover to the blade again.
Fig 13
DK- Afmonter pitchlås.
INT- Dismantle pitch lock.
Fig 14
DK- Monter olieabsorberne.
INT- Fit the oil absorbers
Fig 15
DK- Åben forsigtigt sikkerhedshanerne, og

forlad nav iht. ZWI579823.
INT- Open carefully the safety valves, and

leave the hub according to ZWI579823.
Fig 16
Sikkerhed ved arbejde på transmission og nav / Safety
when working on transmission and hub
Godkend- Sign.: Dato: CHECK LIST ZCH 576186

else: Sign.: Date:
Approval:
Designer: VS 27.08.07 Beskrivelse: Sikkerhed ved arbejde på transmission og nav

Description: Safety when working on transmission and hub
Prod. / Serv- _______ _______ Operation: Service

ice: Operation: Service
Quality Dept.: _______ _______ Vare nr. / Part No.:
ECN 31957 CSL 01.07.09 Mølletype / Turbine type: CombiStall og VS / CombiStall and VS
Kunde / Mølleejer - Customer / Owner:
Mølle Nr. / Turbine No.: Site No. / Project No.:
Denne checkliste er et supplement til Opstillingsmanual, Servicemanual og Generelle sikkerhedsregler for

montørarbejde og anvendes ved arbejde på transmission og Nav. - Ved andre opgaver henvises til
gældende regler i manualerne.
This checklist is a supplement to Assembly Instruction, Service Manual and General Health and Safety
Rules for technicians working on transmission and hub. - For other tasks - see valid rules in the manuals.
Generel beskrivelse:
Checklisten skal anvendes til alle CombiStall og Pitch møller.
Under arbejde på transmission og nav, skal der være min. 2 montører tilstede.
Checklisten skal kontrolleres og signeres af begge montører. (En aktivitet afsluttes og kontrolleres før næste påb-
egyndes).
Hvis rotor lås skal anvendes flere gange i forbindelse med et job, udfyldes hver gang en ny checkliste.
General description:
The check list must be used for all CombiStall and Pitch turbines.
When working on transmission and hub, at least 2 technicians must be present.
The check list must be checked and signed by both service technicians. (An activity must be finished and checked
before starting a new activity)
In case of multiple engagements of the rotor lock in connection with a job, a new check list must be filled in for each
engagement.
Siemens Wind Power A/S - Sikkerhed ved arbejde på nacelle og nav / Safety when working on Nacelle and hub 59 / 64
ECN 31957

1. - Aktion i tårnbund inden opstigning i tårnet. Dato: / Udført af: / Kontrolleret af: /
Date: Made by: Checked by:
Activities in bottom section before climbing the tower.
• Indstil omskifter for fjernovervågning til “LOKALBETJENING”

på styreskabet og isæt hængelås.
• Set the remote control switch to the “Local” position on the

controller and mount the padlock.
• Tryk “Manuel Stop” på håndterminal
• Push “Manual Stop” on the hand terminal
• Indtast service kode - MENU 12 i håndterminalen
• Enter service code - MENU 12 in hand terminal
2. - Aktion i nacellen før der arbejdes på transmission og Dato: / Udført af: / Kontrolleret af: /
nav. Date: Made by: Checked by:
Activities in the nacelle before working on transmission and

hub.
• Drej servicebremse hane (“Blå hane”) i position: Service

mode “ON” - (kun på møller med positiv bremse)
• Turn service brake valve (“Blue valve”) to position: Service

mode “ON” - (only on turbines with positive brakes)
• Åben lugerne i nacellen og montér lugesikringer (må udføres

/ kontrolleres af én montør) - gælder ikke for 3.6MW.
• Open the nacelle covers and mount casement stay locks (can
be performed / checked by one service technician) - N/A for
3.6MW.
60 / 64 Siemens Wind Power A/S - Sikkerhed ved arbejde på nacelle og nav / Safety when working on Nacelle and hub
ECN 31957

3. - Aktion: Montering af rotorlås før der arbejdes på trans- Dato: / Udført af: / Kontrolleret af: /
mission og nav Date: Made by: Checked by:
Activities: Mounting of rotor lock before working on trans-

mission and hub
• Positionér rotor så den ene vinge peger nedad, ved anven-

delse af MENU 24 og elektrisk tørnemotor (hvis monteret)
• Position the rotor in such a way that one blade points down-
wards by using MENU 24 and electric turning gear (if mount-
ed)
• Montér begge HS rotorlåse og isæt låsesplitter (2.3MW)

• Monter HS rotorlås og isæt låsebolt (3.6MW)
• Fit both HS rotor locks, and insert cotter pins (2.3MW)

• Fit HS rotor lock, and insert lock bolt (3.6MW)
• Aktivér bremsen i MENU 24
• Apply the brake in MENU 24
• Aktivér “NØDSTOP” - for at sikre adgang til navet
• Activate “EMERGENCY STOP” - to secure entrance to hub
4. - Aktion i nav før der arbejdes i nav. Dato: / Udført af: / Kontrolleret af: /
Activities in hub before working in hub interior .
• Montøren kravler ind i navet og drejer alle 3 (tre) vinge sikker-

hedshaner (108) i position “LUKKET”
• The technician climbs into the hub and turns all 3 (three)
blade safety valves (108) to position “CLOSED”
• Reset NØDSTOP
• Reset EMERGENCY STOP
ECN 31957

5. - Aktion inde i nav efter arbejdet i nav er afsluttet. Dato: / Udført af: / Kontrolleret af: /
Activities in hub when the work is finished
• Pitch kun ÉN vinge ad gangen (én af de to vinger der peger

opad).
• Efter endt arbejde pitches vingerne, en af gangen, i stop po-
sition.
Dog findes følgende undtagelser:
• Tilspænding / efterspænding af vingebolte. Der kan pitches
med vinge, som peger lodret nedad.
• Skift af vingecylinder. Der kan pitches med vinge, som peger
lodret nedad
• Pitch offset justering på 1MW, 1,3MW og 2MW møller med
WTC 2.0 styring. Anvend hydraulik haner for at pitche alle 3
vinger til driftsposition én af gangen.
• Only pitch ONE SINGLE blade at a time (one of the two

blades pointing upwards)
• When the work is finished the blades are pitched back to stop
position, one at the time.
There are, however, the following exceptions:
• Tightening/retightening of blade bolts. Blade pointing straight
downwards can be pitched.
• Replacement of blade cylinder. Blade pointing straight down-
wards can be pitched.
• Pitch offset adjustment on 1 MW, 1.3 MW and 2 MW wind tur-
bines with WTC 2.0 controller. Use the hydraulic valves to
pitch all three blades to operating position, one at the time.
• Når navet forlades, SKAL alle 3 (tre) vinger stå i stopposition
• When leaving the hub, all 3 (three) blades MUST be in stop

position
• De 3 (tre) vinge sikkerhedshaner (108) stilles i “ÅBEN” posi-

tion
• The 3 (three) blade safety valves (108) are set to “OPEN” po-
sition
ECN 31957

6. - Aktion i nacelle efter arbejdet i nav er afsluttet. Dato: / Udført af: / Kontrolleret af: /
Activities in nacelle when the work is finished in hub.
• Nedfiring af værktøj
• Lowering the tools
• Aktivér NØDSTOP
• Activate EMERGENCY STOP
• Reset NØDSTOP
• Reset EMERGENCY STOP
• Kontrollér visuelt at alle vinger er i stopposition
• Visually ensure that all blades are in stop position
• Gå i MENU 24 og sikre at bremse-hydraulik pumpe er ak-

tiveret (kun på møller med positiv bremse)
• Go to MENU 24 and make sure that the brake hydraulic pump

is activated (only on turbines with positive brake)
• Bremse løsnes i MENU 24
• Release brake in MENU 24
• Afmontér begge HS rotorlåse (vinger SKAL være i stopposi-

tion)
• Remove both HS rotor locks (blades MUST be in stop posi-

tion)
• Bremse aktiveres i MENU 24
• Apply brake in MENU 24
• Tørnermotor tages ud af indgreb (kun møller med tørnemo-

tor)
• Disengage turning gear (only turbines with turning gear)
7. - Aktion i nacelle før nacelle forlades (må udføres / kon- Dato: / Udført af: / Kontrolleret af: /
trolleres af én montør). Date: Made by: Checked by:
Activities in nacelle before leaving the nacelle - (can be per-

formed / checked by one service technician)
• Afmontér lugesikring og luger lukkes
• Remove the locks from the casement stays and close the
covers
• Drej servicebremse hane (“Blå hane”) i position: Service

mode “OFF” - (kun på møller med positiv bremse)
• Turn service brake valve (“Blue valve”) to position: Service

mode “OFF” - (only on turbines with positive brake)
ECN 31957

8. - Aktion i tårnbund efter udført arbejde i møllen og før Dato: / Udført af: / Kontrolleret af: /
møllen forlades. Date: Made by: Checked by:
Activities in bottom of tower when the work is finished in the

wind turbine and before leaving the wind turbine.
• Opstart af mølle i tårnbund
• Start-up of turbine in bottom of tower
• Indstil omskifter for fjernovervågning til “FJERNBETJENING”

på styreskabet
• Set the remote control switch to the “REMOTE” position on

the controller
ECN 31957

Procedure for låsning og skiltning - HS rotorlås /
Lockout / Tag-out procedure - HS rotor lock
Godkendelse: Sign: Dato: CHECK LIST CH 579264

Approval: Sign: Date:
Designer: VS 09.10.07 Beskrivelse: Låsning og skiltning - HS rotorlås

Description: Lockout / Tag-out procedure - HS rotor lock
Prod. / Serv- _______ _______ Operation: Spændningsatte møller

ice: _ _ Operation: (Net/Nødgenerator)
Energized turbines
(Grid/Auxiliary generator)
Quality dep.: _______ _______ Vare nr / Part no:

_ _
ECN 31957 CSL 01.07.09 Mølle type/Turbine type: CombiStall og VS / CombiStall and VS
Kunde / Mølleejer - customer / owner:
Mølle Nr. / Turbine no: Site Nr/ No:
Generel beskrivelse:
Checklisten skal signeres af Lead technician.
Hvis rotorlås skal anvendes flere gange i forbindelse med et job, udfyldes en ny checkliste hvergang.
General description:
The check list must be signed by Lead technician.
By multiple use of rotor lock in connection with a job, a new checklist must be filled in, at each use.
Fig. 0.1
Låsning og skiltning - HS rotorlås
(kun 2.3MW)
Lockout/Tag-out - HS rotor lock.

(only 2.3MW)
Sikkerhed ved arbejde på nacelle og nav - LOTO procedure / Safety when working on Nacelle and hub - LOTO procedure 65 / 68
ECN 31957 / Rev: 01.07.2009

Fig. 0.2
Kun 3.6MW
1. Placering af HS-låsen i ven-

stre side.
Rotoren skal tørnes med tørne-

motoren, til HS-låsen kan kom-
me i indgreb.
Only 3.6MW
1
1. Position of the HS-lock on the
left side.
Turn the rotor by using the turn-

ing motor until the HS-lock is
able to be engaged.
Fig. 0.3
Kun 3.6MW
Placering af HS-låsen i venstre

side.
Isæt Rotorlås.
Isæt låsebolt.
Only 3.6MW
Position of the HS-lock on the left

side.
Insert rotor lock.
Insert the lock bolt
Låsning og skiltning - HS rotorlås Dato: / Udført af: / Made by

Lockout / Tag-out procedure - HS rotor lock. Date:
• Tryk “Manuelt stop”
• Push “Manual stop”
• Drej servicebremse hane (“Blå hane”) i position: Service Mode “ON" -

og anbring skilt på servicegreb (kun på vindmøller med positiv brem-
se)
• Turn service brake valve (“Blue valve”) in position: Service Mode “ON"
and mount tag at service handle. (Only for turbines with positiv brake)
66 / 68 Sikkerhed ved arbejde på nacelle og nav - LOTO procedure / Safety when working on Nacelle and hub - LOTO procedure
ECN 31957 / Rev: 01.07.2009

Låsning og skiltning - HS rotorlås Dato: / Udført af: / Made by
Lockout / Tag-out procedure - HS rotor lock. Date:
• Montér HS rotorlås.
Montér hængelås og skilt.
• Engage HS rotor lock.

Mount padlock and tag.
Bemærk: Det er vigtigt at sikkerhedsventilerne (108) anvendes, når der arbejdes i navet.
Please note: It is important to use the blade safety valves (108) when working inside the hub.
Demontere HS rotorlås Dato: / Date: Udført af: / Made by
Disengage HS rotor lock
• Pitch vingerne til 60 grader og tilbage til stopposition.
• Pitch the blades to 60 degrees and back to stop position.
• Demontér hængelås og skilt.
• Demontér HS rotorlås.
• Remove padlock and tag.
• Disengage HS rotor lock device.
• Når al servicearbejde i møllen er færdigt - fjern skilt på servicebremse

hane (“Blå hane”) og drej hanen til position "Service Mode OFF".
• When all other service work in turbine is completed - remove tag on

service brake valve (“Blue valve”) and turn valve to position "Service
Mode OFF"
Sikkerhed ved arbejde på nacelle og nav - LOTO procedure / Safety when working on Nacelle and hub - LOTO procedure 67 / 68
ECN 31957 / Rev: 01.07.2009

68 / 68 Sikkerhed ved arbejde på nacelle og nav - LOTO procedure / Safety when working on Nacelle and hub - LOTO procedure
ECN 31957 / Rev: 01.07.2009

- Chapter 03 INSPECTION AND MAINTENANCE

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 03 INSPECTION AND MAINTENANCE

SWT - 2.3 - 82VS/93/101
• Inspection and maintenance schedule

yyyy)

Document history

93/101
ECN30997 R1 30-03-2009 CH545772 added as a link
ECN32453 R2 09-09-2009 Precautionary measures, yaw gearwheel -

Cogs are lubricated at assembly deleted.
Check lists are deleted and notification to

the check lists are made.

Inspection and Maintenance Schedule
See: Chapter , “Precautionary measures in case of long periods of standstill for

wind turbines,”
ZCH 1009380 - Bolt inspection module, 500 hours service.
ZCH 1009384 - Service module, 500 hours service.
ZCH 1009381 - Bolt inspection module, 12 months service.
ZCH 1009386 - Service module, 12 months service.
ZCH 1009382 - Bolt inspection module, annual service.
ZCH 1009387 - Service module, annual service.
ZCH 1009383 - Bolt inspection module, 5 -10 -15... years service
ZCH 1009388 - Service module, 5 -10 -15... years service.
CH 545791 (SI)
CH 537783 - Annual inspection of the crane (HMF)
CH 545772 - Annual inspection of chain hoist. (ABB)
CH 547352 - Gearbox inspection.


Precautionary measures in case of long periods of standstill for wind turbines
Precautionary measures in case of long periods of stand-

still for wind turbines
General A wind turbine is a machine which is constantly affected by wind and climatic
changes. Like all machines the wind turbine is designed to run. It is, therefore, im-
portant that all periods of standstill are as short as possible. A period of standstill
may occur at installation but may also occur after commissioning.
Free idling If the turbine is not started immediately after final assembly, the rotor must be set
to idling. The blades are pitched to stop position, the tip angle is adjusted to allow
the pitch lock to be fitted. The rotor is then idling freely but at a very low rpm.
Note! If there are at least 3 functional hydraulic or mechanical pitch pawls on the turbine,
it is not necessary to mount the manual pitch locks. Make sure that all 3 pitch
pawls are able to engage before idling the turbine.
Rotation of the transmission The turbine must not be stopped for more than 3 days, then it must idle. If the tur-
system bine is not powered, all 3 manual pitch locks must be mounted on the blade bea-
rings and torqued, thereby securing the blades in the stop position.
Note! If there are at least 3 functional hydraulic or mechanical pitch pawls on the turbine,
it is not necessary to mount the manual pitch locks. Make sure that all 3 pitch
pawls are able to engage before idling the turbine.
Blade bearings Blade bearings must be motioned 85° at installation and then once every 1.5
months.
Piston rods in the hub The rods are rubbed with hydraulic oil at installation and then once every 1.5
months.
Gears Gears with mechanical pumps: OK
Rotating union No requirements
Lubricants The lubrication intervals and volumes applying to a turbine in operation also apply
in case of standstills. (Must, however, be lubricated at biannual intervals.)
Immediately before start-up, lubricate with the volume corresponding to the

amount of time the turbine has been standing still. This volume is calculated in
proportion to the lubricant volume for a whole year, i.e. if the turbine has been
standing still for 3 months, it must be lubricated with a lubricant volume correspon-
ding to three twelfths of the total yearly volume.
If a standstill lasts for more than 3 months, an oil sample must be taken from the
gear oil and the hydraulic oil respectively.The gear oil sample is taken at the off-
line filter. The hydraulic oil sample is taken at the test nipple at the pumping sta-
tion.
The oil must be analyzed for any water content.
The off-line filter for the gear must run for 24 hours before the start of the turbine.
The off-line filter is functional at oil sump temperatures above -10 degrees C.
Operating parameters for the off-line pump may be temporarily changed at the
controller.
Precautionary measures in case of long periods of standstill for wind turbines 73 / 74

Rev: 09.09.2009 / ECN 32453

Precautionary measures in case of long periods of standstill for wind turbines
Yaw gearwheels - Yaw motors SWT-1.0-54 - SWT-2.3-101. The yaw lock is disengaged.
SWT-3.6-107-120. If the yaw brake pressure is dropping below the normal brake
pressure, the hand pump must be used in order to pump in pressure until a normal
brake pressure is reached.
Generator If the turbines are stopped for more than 3 days, the generator must be connected
to heat in the generator for 24 hours before start-up.
Electrical boxes - electrical If the turbines are stopped for more than 3 to 14 days, apply corrosion protection
parts to the cabinets and cover the air holes with tape.
At shutdowns exceeding 3 months (or a shorter period if the turbine is placed in

an aggressive environment – contact SWP service dept.), the cabinets must be
applied with corrosion protection Zeerust (no. 206070) and air holes must be co-
vered with tape.
At restart, cabinets must be reheated and ventilated for 24 hours.
Before connecting voltage, the terminal boards must be inspected for moisture
and tape removed from the ventilation holes.
SWT-2.3-82 VS - SWT-3.6-120. If there is a risk of moisture in or inadequate air-

conditioning of the reactor, the air fan must be started approx. 3 hours before re-
start in order for the reactor to be aired and any possible big differences of tem-
perature and/or moisture to be eliminated.
UPS batteries must be charged for at least 4 hours before starting a new turbine.
If a turbine is standing still for more than 3 months, the UPS must be charged for
an additional 4 hours.
Nacelle In order to make allowance for possible site-specific conditions, the turbine must
be visually inspected every 3 months.
The inspection covers e.g. corrosion of/in controller cabinets, pointer in the hub,
gears, yaw gearwheels and hydraulic piston rods in the hub.
If the turbine is going to be out of service for more than 6 months, the Service De-
partment at Siemens Wind Power must be contacted for an assessment of future
actions in order to protect the turbine from standstill damage.
Warning light Project-specific.
Dehumidification If the turbines are stopped for more than 1.5 months, they must be inspected for
humidity before start-up.
74 / 74 Precautionary measures in case of long periods of standstill for wind turbines

Rev: 09.09.2009 / ECN 32453

- Chapter 04 BOLT TIGHTENING ONSHORE

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 04 BOLT TIGHTENING ONSHORE

SWT - 2.3 - 82VS/93/101
• Inspection and maintenance schedule

yyyy)

Document history

93/101
ECN30997 R1 15-06-2009 Torques wrench settings_onshore added

as a link from Foto 2
ECN32453 R2 09-09-2009
ECN50015 R3 01-11-2009

Maintenance Schedule
See “Bolt tightening”


Bolt tightening
Introduction The bolts in wind turbines are tightened to specific values. Overtightening will
cause the bolts to break during tightening or operation of the turbine. Undertight-
ening will cause the bolts to break during operation of the turbine.
If the procedures described in this chapter are followed, it is safe to operate the
tools and the 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 start breaking after several years of operation.
Service intervals The turbines are serviced according to specific service check lists defined for
each of the service intervals listed below:
• 500 hrs service

• 12 months service
• Annual service
• 5, 10, 15 years service (same service procedure)
Installation
12 months
10 years
15 years
500 hrs
5 years
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Annual
Year 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Definitions
Bolted Joint Two or more parts clamped together with bolts.
Loose bolt A bolt is loose if the nut can be rotated relative to the bolt by performing a tight-
ening procedure.
If the bolt is mounted in a blind 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 tightened.
Nut standoff The length of thread from the nut to the end of the bolt. When using tension tools
the nut standoff must be at least 1 x the bolt diameter.
SWT-2.3-82 VS, SWT-2.3-93, SWT-2.3-101 / Bolt tightening / 11-02-2009 79 / 104

Rev: 01-11-2009 / ECN 50015

Fig. 0.1
Torque Tension
P = Pitch of thread d = bolt diameter
Torque tool A calibrated tool that can tighten a bolt by applying a torque.
• Manual torque tool:

A manually operated torque wrench.
• Hydraulic torque tool:

A hydraulic powered torque wrench
Tension tool: A calibrated tool that can tighten a bolt by applying a force.
Fig. 0.2
Torque (Nm) Tension (kN)
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 nut.
When tightening procedures are being preformed it is important to observe if

there is relative movement between the bolt and the nut.
If the bolt is mounted in a blind hole, movement between bolt head and surface
must be observed.
If movement is observed, the bolt is loose and the whole joint must be tightened.
80 / 104 SWT-2.3-82 VS, SWT-2.3-93, SWT-2.3-101 / Bolt tightening / 11-02-2009

Rev: 01-11-2009 / ECN 50015

Bolt types
Bolt specification table
Type Normal HV Stainless
Property class 8.8 10.9 12.9 10.9 70 80
Marking Bolt 8.8 10.9 12.9 10.9 HV 70 80
Nut 8 10 12 10 HV 70 80
Washer No marking HV
Standard Bolt ISO4014 EN14399-4

ISO4017
Nut ISO4032 EN14399-4
Washer ISO7090 EN14399-6
Width across flats Normal Large Normal
Lubrication Yes on friction surfaces No Yes, on friction surfac-

es
Threadlocker If specified in work instruction No If specified in work in-

struction
Assembly 8.8: Washer on friction surfaces Always two washers.

10.9: Always two washers. Chamfer shall face out-
Nut marking visible. wards.
Nut marking visible
Reuse Yes, but relubricate No, replace nut if disas- Yes, but relubricate.
sembled
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.
Stainless steel bolts are of property class 70 / 80.
70 is the weakest.
Marking The property class is stamped into the bolt head and nut. Most bolts also have
information of manufacturer and batch number stamped into the bolt head and
nut.
Standard Relevant standard for the individual bolt types - see bolt specification table above.
Width across flats HV bolts and nuts have large width across flats. Always use HV nuts and washers
with HV bolts.

Rev: 01-11-2009 / ECN 50015

HV nuts are prelubricated - see lubrication for more information.
Lubrication The purpose of lubricating is to achieve 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 to prevent corro-
sion.
The different bolt types shall be lubricated in the following way:
• Hot dip galvanized bolts shall be lubricated with Never-Seez.

• Stainless bolts shall be lubricated with Anti Bloc.
• Bolts tightened into aluminium shall be lubricated with oil.
• HV bolts have prelubricated nuts, and shall not be lubricated further.
The different types of lubricant must under no circumstances be mixed. E.g. never
lubricate an HV nut with Never-Seez.
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 rotation of the nut and therefore
also lubricated under the nut.
If a bolt is mounted into a blind hole or if tightening on the nut is impossible, the
bolt must be lubricated under the bolt head and tightened on the bolt head.
Threadlocker Some times threadlocker is applied to the bolts before assembly. This is normally
only done in the production. If threadlocker is used, lubrication is not allowed.
Assembly The chamfered side of the washer must face towards the bolt head and the nut
respectively .
For M22 bolts or larger, HV washers shall be used.
Reuse If a normal bolt has been tightened with a torque tool and then loosened, it can be
tightened again if it is re-lubricated on the thread and under the moving part.
Bolts, nuts and washers with visible damage must be discarded and replaced with
new ones.

Rev: 01-11-2009 / ECN 50015

Calibration of tools
Calibration of tools and hy- Torque tools and pumps must be calibrated according to calibration department
draulic pumps 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 max-
imum number of cycles varies from 2000 - 8000 depending on the tool and is writ-
ten on the counter on the tool. Check that the cycle count is working and below
the maximum number of cycles before use.
Check of hoses on tools Hydraulic hoses must, according to calibration department specifications, be
checked a least every six months. The equipment is marked with the check due
date and the date must be checked before use. If the check date is overdue or the
label is missing, do not use the equipment.
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 X bolts. E.g. tighten every 5 bolts.

The 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.
Visual inspection Visual inspection is performed by grasping the number of bolts defined in the
check list to ensure that the bolts are not broken.
Fig. 0.3
Visual inspection

Rev: 01-11-2009 / ECN 50015

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 check list for 500
hours service after main component replacement: ZCH 1009329. Thereafter the
component will follow the standard service intervals matching the rest of the tur-
bine.
Tightening steps
The following steps are only meant as a guide. For a more thorough explanation
of how the individual tools work and how they are adjusted, please consult rele-
vant work Instructions on the subject.
Hydraulic tightening tools 1 Find the joint in the specific tightening values table
2 If in doubt check the joint ID number and drawings
3 Find the bolt size, type and class of the bolt in the turbine and check that it is
the same in the table
4 Find the tension or torque value for the tool and decide which tool to use
5 Find the calibration certificate for the tool and check that the tool ID matches
6 Read the pressure and adjust the hydraulic pump
7 Tighten the bolts
8 Check regularly throughout tightening that the pressure is correct
Manually operated torque 1 Find the joint in the specific tightening values table
wrench 2 If in doubt check the joint ID number and drawings
3 Find the bolt size, type and class of the bolt in the turbine and check that it is
the same in the table
4 Find the torque value for the tool and decide which tool to use
5 Adjust the calibrated torque wrench to the correct value
6 Tighten the bolts
7 After use, reset the tool

Rev: 01-11-2009 / ECN 50015

Bolt tightening - Standard values
Bolt torque When tightening with the torque tool, use the values below.
In special cases, other values are used. If this is the case, these will be stated in
the table: “Bolt Tightening - Specific Values”.
Bolt type Hot dip galvanized Stainless and bolts tightened

into aluminium.
Property class 8.8 10.9 All property classes
Size Nm Nm Nm
M8 21 30 14
M10 42 60 29
M12 75 100 52
M16 175 250 125
M20 350 450 250
M24 600 800 425
M30 1150 1650 800
M33 1550 2200
M36 2000 2800
M42 3200 4500
M48 4700 6500
Bolt tensioning When tightening with the tension tool, use the values below.
In special cases, other values are used. If this is the case, these will be stated in
the table: “Bolt Tightening - Specific Values”.
Quality class 8.8 Quality class 10.9
Size kN kN
M30 340 480
M36 500 700
M42 680 960
M48 900 1260

Rev: 01-11-2009 / ECN 50015

List of widths across flats
Bolt Bolt type ISO 4014 Bolt type DIN 6914

(Large width across
flats)
Size Width across flats: Width across flats:
M 10 16 mm
M 12 18 mm
M 14 21 mm
M 16 24 mm 27 mm
M 18 27 mm
M 20 30 mm 32 mm
M 22 34 mm
M 24 36 mm 41 mm
M 27 41 mm
M 30 46 mm 50 mm
M 33 *50 mm
M 36 55 mm 60 mm
M 42 65 mm 70 mm
M 48 75 mm 80 mm

Rev: 01-11-2009 / ECN 50015

Bolt Tightening - Specific Values
Note: X = tigtening / V = visual inspection
Lube at mount-
500 hrs service
Annual service
5 year service
WIdth across
Tension (kN)
Torque (Nm)
12 months
Bolt type
Position
flats
ing
1. HUB
H10 Blade - Blade bearing M36, 10.9 Hot YES 425 kN 55 mm X X X X

SWT-2.3-82 VS, SWT-2.3-93, SWT-2.3-101 galv.
SWT-2.3-82 VS: If the threading (nut standoff)

is not long enough for tension tools, the whole
joint must be tightened with torque tool 2000
Nm.
H20 Blade bearing - Hub M36, 10.9 hot NO 670 kN 60 mm X X X X

SWT-2.3-82 VS, SWT-2.3-93, SWT-2.3-101 galv. HV
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.
SWT-2.3-82 VS: If the threading (nut standoff)

is not long enough for tension tools, the whole
joint must be tightened with torque tool 2800
Nm.
H30 Hub - Spinner plate M30, 10.9 hot YES 1650 Nm 46 mm X V V X

galv.
H31 Spinner bracket - Reinforce- M24, 8.8, hot YES 600 Nm 36 mm X X V X

ment plate galv.
H32 Spinner plate - Nose cone (spin- M12, 8.8, hot YES 75 Nm 19 mm - - - -
nerbeslag - spinnernæse) galv.
M16, 8.8, hot 175 Nm 24 mm
galv.
- Lifting bracket cover M12, 8.8, hot YES 75 Nm 19 mm

galv.
H40 Distance block for pitch cylinder M30, 8.8 hot YES 1150 Nm 46 mm X X V X
- Hub galv.
H41 Plate for pitch cylinder - Blade M36, 8.8 hot YES 2000 Nm 60 mm X X V X
bearing. galv.
H42 Mounting plate - Root bracket- M20, 8.8 hot YES 40 Nm 30 mm X X X X

long (PUR bushings) galv.
H43 Mounting plate - Root bracket M20, 10.9 hot YES 475 Nm 30 mm X X X X
short (mounted rigidly) galv.
M24, 10.9 hot YES 800 Nm 36 mm
galv.

Rev: 01-11-2009 / ECN 50015

500 hrs service
Lube at mount-
Annual service
5 year service
WIdth across
Tension (kN)
Torque (Nm)
12 months
Bolt type
Position
flats
ing
H44 Accumulator brackets M12, 8.8 stain- YES 66 Nm 19 mm X V V X
less.
H45 Blade block for hyd pitch M12, 8.8 hot YES 75 Nm 19 mm X X V X
galv.
M12, 80 stain- 66 Nm
less
H33 Hub box (A6) - Spinner plate/ M12, 8.8 hot YES 75 Nm 19 mm X X V X
Console galv.
M24, 8.8 hot YES 600 Nm 36 mm
galv.
H50 Pitch lock M30, 10.9 hot YES 1650 Nm 46 mm X X V X

galv.
M30, 8.8 hot YES 1150 Nm 46 mm
galv.
M12, 8.8 hot YES 75 Nm 19 mm
galv.
2. NACELLE
N20 Main bearing housing - Bed M30, 8.8, hot YES 1150 Nm 46 mm X X V X
frame galv.
N30 Gear support - Bed frame M33, 8.8, hot YES 1550 Nm 50 mm X X V X
galv.
N31 Plate - Gearbox M24, 10.9 hot YES 800 Nm 36 mm X X V X

galv.
N50 Bed frame - Canopy brackets M30, 8.8, hot YES 1150 Nm 46 mm X X V X
front galv.
N51 Bed frame - Canopy brackets M30, 10.9, hot YES 1650 Nm 46 mm X X V X
rear galv.
N52 Canopy brackets - Canopy M24, 8.8, hot YES 600 Nm 36 mm X X V X

(front) galv.
M30, 8.8, hot 1150 Nm 46 mm
galv.
N53 Canopy brackets - Canopy M30, 8.8, hot YES 1150 Nm 46 mm X X V X

(rear) galv.
Nacelle suspension cover M10, 8.8, hot YES 60 Nm 17 mm

galv.

Rev: 01-11-2009 / ECN 50015

500 hrs service
Lube at mount-
Annual service
5 year service
WIdth across
Tension (kN)
Torque (Nm)
12 months
Bolt type
Position
flats
ing
N80 Hydraulic stand M8, stainless YES 20 Nm 13 mm X V V V
N55 Hatch - Canopy hinges M16, stainless YES 165 Nm X V V V
N58 Cylinder bracket - Hatch M16, stainless YES 165 Nm 24 mm X V V V
A10 Canopy - Maintenance crane M16, 8.8, hot YES 175 Nm 24mm X X V X
galv.
A11 Warning lights - Canopy top cov- M12, cl80 YES 52 Nm 19 mm X V V X

er stainless
M12, cl70 YES 66 Nm
stainless
A12 Wind vane and anemometer M12, 8.8 hot YES 45 Nm 19 mm X V V X

galv.
A13 Wind vane stand M10, 8.8 hot YES 42 Nm 17 mm X V V X

galv.
4. YAW SECTION
N40 Yaw clamp - Bed frame M30, 8.8 hot YES 1150 Nm 46 mm X X V X
galv.
N41 Yaw clamp adjusting bolts (verti- M30, 8.8 hot YES 150 Nm 46 mm X X X X
cal) galv.
N42 Yaw clamp adjusting bolts(hori- M16, 8.8 hot YES 10 Nm 24 mm X X X X

zontal) galv.
N60 Yaw gear - Bed frame M16, 10.9 hot YES 250 Nm 24 mm X X V X
galv.
M16, 12.9 hot 300 Nm
galv.
5. MAIN SHAFT
N10 Hub - Main shaft M36, 10.9 hot NO 2800 Nm 60 mm X X V X

galv. HV
6. MAIN BEARING
N20 Main bearing housing - Bed M30, 8.8, hot YES 1150 Nm 46 mm X X V X
frame galv.
N21 Main bearing housing - Bearing M24, 8.8, hot YES 300 Nm 36 mm X X V X
cover (front) galv.
N22 Main bearing housing - Bearing M24, 8.8, hot YES 600 Nm 36 mm X X V X
cover (rear) galv.

Rev: 01-11-2009 / ECN 50015

500 hrs service
Lube at mount-
Annual service
5 year service
WIdth across
Tension (kN)
Torque (Nm)
12 months
Bolt type
Position
flats
ing
N23 Clamping ring - Main shaft M24, insex, YES 800 Nm 19 mm X X V X
black
N24 Bearing cover - seal ring (front/ M12, 8.8, black YES 75 Nm 19 mm X X V X
rear) M8, 8.8 hot 21 Nm 13 mm
galv.
N25 Labyrinth ring M10, 8.8, hot YES 42 Nm 17 mm X X V X

galv.
7. GEARBOX
N32 Shrink disc - low speed M33, 12.9, YES 2650 Nm 50 mm X X V X

black
N30 Gear support - Bed frame M33, 8.8, hot YES 1550 Nm 50 mm X X V X
galv.
8. BRAKE
N33 Shrink disc - high speed M20, 10.9, YES 475 Nm 30 mm - - - -

black
N73 Brake caliper - Gearbox plate M20, 8.8, black YES 350 Nm 30 mm X X V X
N74 HCU M8, cl80, stain- YES 21 Nm 5 mm X V V X

less, insex
9. COUPLING
N72 Coupling - Generator to gearbox M20, 10.9, NO 490 Nm 30 mm X X V X

black
10. GENERATOR
N71 Generator feet - Generator M24, 8.8, hot YES 600 Nm 36 mm X V V X

(PUR rubber) galv.
N71 Generator feet - Generator M24, 8.8, hot YES 600 Nm 36 mm X V V X

(ESM damper) galv.
ESM damper - Frame M20, 8.8, hot YES 350 Nm 30 mm X V V X

galv.
N71 Generator suspension M30, 8.8, hot YES 1150 Nm X V V X

galv.
N75 Generator beam (Reinforce- M16, 8.8, hot YES 175 Nm 24 mm X V V X

ment bar) galv.
Terminals on generator (ABB) M16 NO 190 Nm 30 mm X X X X

(large
(After a generator replacement, termi-
retightening must be carried out nal)
at the subsequent service visit)
N76 Cable bracket for generator ca- M12, 8.8 hot YES 75 Nm 19 mm V V V V
bles generator galv.

Rev: 01-11-2009 / ECN 50015

500 hrs service
Lube at mount-
Annual service
5 year service
WIdth across
Tension (kN)
Torque (Nm)
12 months
Bolt type
Position
flats
ing
N77 Generator spacing plate M30 8.8 Hot 1150 Nm X V V X
galv.
11. HYDRAULICS
Bracket for rotating union M24, 8.8 hot YES 600 Nm 36 mm X X X X

galv.
13. TOWER
T30 Tower top flange - Yaw ring M30, 10.9, hot YES 1600 Nm 46 mm X X V X
galv.
T40 Ladder brackets M12, 8.8, hot NO 75 Nm X V V X

galv.
M16, 8.8, hot NO 75 Nm
galv.
T60 Platforms M10, 8.8, hot NO 42 Nm X V V X

galv.
M16, 8.8, hot NO 110 Nm
galv.
Tower / Tower M36, 10.9, hot NO 2800 Nm 60 mm X X V X

galv.

galv.

galv.
Foundation bolts M42, 8.8, black YES 400 kN 65 mm X X V X
Foundation bolts (Germany) M42, 8.8, black YES 460 kN 65 / 70 X X V X

mm
Foundation bolts M48 8.8, black YES 550 kN 75 mm X X V X
Foundation bolts (Rockadapter) M48 8.8, black YES 610 kN 75 mm X X V X
Transition piece (Monopile) M48, 10.9, hot NO 1260 80 mm X X V X

galv kN

Rev: 01-11-2009 / ECN 50015

Bolts for lifting brackets
Position Bolt type Lube at Nm Comments

mounting
Lifting brackets for tower top section, top M30, 10.9, black. NO 400 width across flats 46
mm
Lifting brackets for tower bottom section and M42, 10.9, hot galv. NO 400 width across flats 70
middle section, top mm
Lifting bracket for hub without blades M48, 10.9 hot galv. NO 400 Impact socket 75 mm
(single blade mounting) 1" reduced to 100 mm
outside diameter.
Lifting bracket for rotor M48, 10.9 hot galv. NO 400 Impact socket 75 mm
1" reduced to 100 mm
outside diameter.
NOTE! It must be stressed that only shackles and wires specified by Siemens Wind Power A/S may be used. More-
over it must be ensured for each lifting procedure that the wire angles (relative to the brackets) comply with the
requirements specified by Siemens Wind Power A/S.
Lifting brackets for nacelle M42, 10.9, hot galv. dry 4500 width across flats 70
Round thimble (not to be dismounted) mm
Bracket at generator M36, 8.8, hot galv. dry 40 To be hand tightened
Checking bolts for lifting At sites where the erection of the turbines spans a longer period of time, the bolts
bracket in the lifting brackets must be checked at each lift.
The bolts must be checked for:
• Marks
• Dents or notches in the shank/head of the bolt
• Breaks
• Bends
IMPORTANT! Bolt and nuts must be replaced with new ones if the check reveals damage,
play or wear. If there is any doubt about the integrity of the bolts, replace
the bolts and nuts.

Rev: 01-11-2009 / ECN 50015

Tightening torques for hydraulics and gearbox fittings
When working with hydraulic fittings: Lubricate threads and torque tighten accord-
ing to specifications.
General note: Always remember when working with hydraulics and gearboxes that dirt is ex-
tremely harmful to hydraulic components and gearbox bearings.
IMPORTANT! Make sure to use the necessary safety equipment when working with gear/hy-
draulic oil. Always 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
Torques for gear oil flanges, fittings and cooler
Gear oil flanges - cooler Gear oil flanges - steel Water cooler clips
- aluminum
65 Nm 75 Nm 20 Nm
Torques for valves
Torques for valves
Position SWT-2.3-82 VS SWT-2.3-93 SWT-2.3-101
Pos. 101 80Nm 80Nm 80Nm
Pos. 102 15.5Nm (M6x40) 15.5Nm (M6x40) 15.5Nm (M6x40)
Pos. 103 40Nm 40Nm 50Nm
Pos. 107 35Nm 35Nm 35Nm
Pos. 108 22Nm (M8x60) 22Nm (M8x60) 22Nm (M8x60)
Pos. 109 10Nm (M6x90) 50Nm 50Nm
Pos. 116 9.3Nm (M6x65) 40Nm 40Nm
Pos. 117 10Nm (M6x30) 10Nm (M6x30) 10Nm (M6x30)
Pos. 119 10Nm (M6x90) 50Nm 50Nm
Pos. 120 9.3Nm (M6x70) 60Nm 90Nm
Pos. 130 - 5.4Nm (M5x45) 5.4Nm (M5x45)
Accumulator bleed valve: 25 - 30 Nm.

Rev: 01-11-2009 / ECN 50015

Torques for fittings Always clean and lubricate the fittings before assembly with the same type
of oil that 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).
Fig. 0.4
The torques apply to electro-
galvanized fittings.
Tightening torques for fittings

with RG/BSP thread.
BSP
Torques for RG/BSP fittings in blocks
Thread size of fittings. Outside diameter of the Tightening torque in Tightening torque in alu-
RG/BSP thread in mm steel (Nm) minum (Nm)
1/8” 9.7 18 14.4
1/4” 13.1 35 28
3/8” 16.6 70 56
1/2” 20.9 90 72
3/4” 26.4 180 144
1” 33.2 310 248
1 1/4” 41.9 450 360
1 1/2” 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 alu-
RG/BSP thread in mm steel (Nm) minum (Nm)
1/8” 9.7 13 13
1/4” 13.1 30 28
3/8” 16.6 60 56
1/2” 20.9 80 72
3/4” 26.4 140 140

Rev: 01-11-2009 / ECN 50015

Torques for bolts (metric thread) in blocks
Bolts 8.8 and stainless Tightening torque in Tightening torque in aluminum (Nm)
steel (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
Torques for BSP unions on hoses and fittings
Thread size of fittings. Outside diameter of the Wrench openings for Tightening torque in alu-
BSP thread in mm unions in mm minum (Nm)
1/4” 13.1 19 25
3/8” 16.6 22 50
1/2” 20.9 27 70
3/4” 26.4 32 110
1” 33.2 41 140
1 1/4” 41.9 50 200
1 1/2” 48 57 300
Fig. 0.5
Tightening torques for
O-lock
O-lock

Rev: 01-11-2009 / ECN 50015

Fig. 0.6
Tightening torques for
JIC union.
JIC
Torques for JIC unions on hoses, fittings and pipes
Thread size" Outside diameter of the Wrench openings for Tightening torque (Nm)
thread in mm unions in mm
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 7/8”JIC 47.6 55 - 60 340
2 1/4”JIC 57.1 65 380
2 1/2”JIC 63.5 75 450
Torques for O-lock unions on hoses, fittings and pipes
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

Rev: 01-11-2009 / ECN 50015

Torques for stainless JIC unions
3/4”JIC 19 22 - 24 60
7/8”JIC 22.2 25.4 - 27 100
1 1/16”JIC 27 32 150

Rev: 01-11-2009 / ECN 50015

Tightening torques in controller
IMPORTANT! See SI 545781 - “Basic Health and Safety Rules for Service Technicians
Working in Siemens Wind Power Turbines”.
Pull test: To avoid overtightening the terminal screws, pull at the individual wires to check that they are properly fixed.
100% check after 500 hours of operation. Thereafter visual check for blue discoloration of bolts, cable lugs and bus bars - annually.
Work instruction for bolt tightening in controller

This work instruction describes the tightening torques for different types of bolts and screws in the controller.
These torques must be applied unless otherwise specified in the work instruction.
Components Thread Torque Nm Relay Nm

Bolt M5 5
Bolt / Insulator M6 8
Bolt M14 86
Bolt M16 129
Insulator M16 80
Mounting Plate bolt - Eldon/Häva M8 12
Cubic busbar nut piece M10 40
Cubic busbar holder -bolt M8 20
KG18 (alu terminal) M10 40
Bolt/bolt terminal 95mm2 M10 15
Bolt/bolt - 150/185/240mm2 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 6
ABB SACE S5N 400 (fishplate) M10 18 6
ABB SACE S3N 630/800 (fishplate) M6 6 6
ABB SACE S7S 1250/1600 (fishplate) M10 32 6
ABB SACE S7S 1250/1600 (fishplate) M12 56 6
Varistor V15 M6 4
Varistor DEHNGUARD M6 7
Fuse base OFAX M5 5
ABB A300 - 30 contactor 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
ABB A95, A110 Contactor M10 18
Ferraz-Shawmut Fuse holder 2P (J211056) XX 2,5
Ferraz-Shawmut Fuse holder 3P (Z216682) XX 2,5
Schneider Compact NS100 XX 10
This torque table for electrical

connections is placed in the fre-
quency converter.

Rev: 01-11-2009 / ECN 50015

Position drawings for bolted joints
Drawings The check lists and bolt tightening tables refer to drawing position numbers.
The numbers are found in the following drawings:
Hub drawings: All position numbers starting with H:
• H-ZDG
Nacelle drawings: All position numbers starting with N:
• N1-ZDG
• N2-ZDG
• N3-ZDG

Rev: 01-11-2009 / ECN 50015

Fig. 0.7
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
L L
A
A
B
B
# H43
K K
# H42
C
J J
C D
D
I I
# H50 # H10
# H20
H
# H45 H
# H44
G G
F
# H41 F
# H40
# H32 # H31
E E
# H30
D D
C C
B B
Vægt ca.: Matr.:

Weight app.: 18591,6 kg Matr.:
Emne: Tegn. format:

Part: Draw. format: ISO
A0
Dette dokument må ikke kopieres eller gøres tilgængeligt Tegn. skala/Draw. scale:
A for trediemand uden vor skriftelig tilladelse. A
Indholdet må kun benyttes som aftalt med os.
Overtrædelse af dette vil medføre retsforfølgelse.
1:10
This document must not be copied or made available to any Tegn. nr./Draw. no.:
third party without our written permission. Siemens Wind Power A/S
The contents must be used only as agreed with us.
Dato:
Date:
ECN nr.: Init:
ECN no.: Init:
Breach of the above will cause legal action.
Borupvej 16 DK-7330 Brande
Tel. +45 9942 2222 H-ZDG
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Rev: 01-11-2009 / ECN 50015

Fig. 0.8

/ $ /
1 1
. .
$
- -
,
1 ,
' 1
+ +
1
* *
1
1 '
) )
% &
&
( (
(

)
' '
%
1
)
(
& &
% %
1 1
9 JWFD
:HLJKWDSS
NJ 0DWU
0DWU

(PQH 7HJQIRUPDW
3DUW 'UDZIRUPDW ,62

$
$ 'HWWHGRNXPHQWPnLNNHNRSLHUHVHOOHUJ¡UHVWLOJ QJHOLJW 7HJQVNDOD'UDZVFDOH
$
IRUWUHGLHPDQGXGHQYRUVNULIWHOLJWLOODGHOVH

,QGKROGHWPnNXQEHQ\WWHVVRPDIWDOWPHGRV
1
2YHUWU GHOVHDIGHWWHYLOPHGI¡UHUHWVIRUI¡OJHOVH
6LHPHQV:LQG3RZHU$6
7KLVGRFXPHQWPXVWQRWEHFRSLHGRUPDGHDYDLODEOHWRDQ\ 7HJQQU'UDZQR
WKLUGSDUW\ZLWKRXWRXUZULWWHQSHUPLVVLRQ 6LHPHQV:LQG3RZHU$6

1='*
7KHFRQWHQWVPXVWEHXVHGRQO\DVDJUHHGZLWKXV
%UHDFKRIWKHDERYHZLOOFDXVHOHJDODFWLRQ %RUXSYHM'.%UDQGH
'DWR (&1QU ,QLW 6LHPHQV:LQG3RZHU$6 7HO
'DWH (&1QR ,QLW


Rev: 01-11-2009 / ECN 50015

Fig. 0.9

%
/ /
.
1 .
1
- -
, ,
1
$
(
+ +
&
1
*
& ( *
1
) 1 )
1
7
( (

' '
)

'
& &
1
1
%
1 %
9 JWFD
:HLJKWDSS
NJ 0DWU
0DWU

(PQH 7HJQIRUPDW
3DUW 'UDZIRUPDW ,62

$
$

6LHPHQV:LQG3RZHU$6

1='*
'DWH (&1QR ,QLW


Rev: 01-11-2009 / ECN 50015

Fig. 0.10

$
/ /
% 1
1
. .
$
%
- -
&
&
1
, ,
1
' 1 ( )
+ +
1
* *
1
) 1 )
( )
'
( (
' '
*
& &
$
% %
9 JWFD
:HLJKWDSS
NJ 0DWU
0DWU

(PQH 7HJQIRUPDW
3DUW 'UDZIRUPDW ,62

$
$

6LHPHQV:LQG3RZHU$6

1='*
'DWH (&1QR ,QLW


Rev: 01-11-2009 / ECN 50015

Rev: 01-11-2009 / ECN 50015

- Chapter 05 LUBRICATION

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 05 LUBRICATION
SWT - 2.3 - 82VS/93/101
• Lubrication chart oververview
• General rules for lubrication
• When should a gear oil sample be taken ?
• Replacement of gear oil
• When should a hydraulic oil sample be taken ?
• Sampling of hydraulic oil for pitch system
• Replacement of hydraulic oil
• Changing yaw gear oil
• Lubrication charts

yyyy)

Document history

93/101
ECN30997 R1 30-03-2009 Lubrication of chain hoist (service crane)

added.
106 / 128 SWT - 2.3 - 82VS/93/101 / Chapter 05 LUBRICATION / R1. / edition 1 /

Lubrication chart overview

UNDER NO CIRCUMSTANCES USE OTHER LUBRICANTS THAN THE ONES SPECIFIED BE-
LOW
PLACE OF LUBRICA- FIRST LUBRICATION PERIODICAL LUBRICA- LUBRICANT QUANTITY

TION INTERVAL TION INTERVAL
Main gear After 500 hours of oper- If the oil is not analyzed, TRIBOL 1710-VG320 System approx. 575 li-
Winergy / Hansen ation take an oil sam- it must be changed ev- Castrol Optigear Syn- ters
ple. ery 2 years. thetic X VG 320 Gear approx. 420 liters
The oil must be
changed every 5 years.
Filters for gear: TRIBOL 1710-VG320

In-line oil filter Replace after 500 hrs. Replace every year (approx. 10 liter refilled) 1 filter element
Off-line oil filter Replace after 1 year Replace every year 1 filter element
Air filter Replace after 1 year Replace every year 1 filter element.
Main bearing Refill grease container Every year BEM 41 - 141 10 liters
(central lubrication) after 1 year of operation Refill grease container Klüberplex (Pump)
Labyrinth seals at main After 1 year of opera- Every year OPTIMOL OPTIPIT Approx. 200 g to be dis-
bearing tion tributed among all
grease nipples
Yaw claws, sliding Refill grease container Every year OPTIMOL OPTIPIT 5 liters
shoes and teeth on yaw after 1 year of opera- Refill grease container (Pump)
plate and yaw pinion tion.
(central lubrication)
Yaw gear Change the oil after 5 Change the oil every 5 TRIBOL 1710 - VG320 Approx. 8 liters
years of operation years. Castrol Optigear Syn-
thetic X VG 320
Generator bearings Refill grease container Every year KLÜBER PLEX BEM 1 liter
(central lubrication) after 1 year of opera- Refill grease container 41-132 (Pump)
tion.
Blade bearing Refill grease container Every year Shell Rhodina BBZ 6 liters
(central lubrication) after 1 year of operation Refill grease container (Bellows)
The pumping station for Take an oil sample after Take an oil sample ev- MOBIL DTE 13 M 225 liters
the pitch system (hy- 2 years of operation ery year.
draulic oil) Change the oil every 5 Arctic: Shell Tellus Arc-
years. tic oil 32
Bleed the brake calli-
pers when changing the
oil
Filter for pumping sta- Replace the filter ele- Every year
tion ment after 500 hrs. of Replace the filter ele- 1 filter element
Pressure filter operation ment 1 filter element
Return filter after 500 hrs. of opera- Replace the filter ele- 1 filter element
Air filter tion ment
after 500 hrs. of opera- Replace the filter ele-
tion ment
Antifreeze liquid for fre- Replace after 7 years of Replace every 7 years Antifreeze liquid: BASF Mixing ratio: 1 part pure
quency converter operation Glysantine G30 antifreeze liquid to 2
parts tap water
Arctic mixing ratio: 1

part pure antifreeze liq-
uid to 1 part tap water
Chain hoist (service Every year Every year KEMA VET - 68 Sterile- Approx. 0,5ML
crane) oil

General rules for lubrication
Rules to remember It is extremely important that the lubrication procedures laid out in this chapter are
followed
• Care must be taken to ensure that no dirt gets into the lubricant (Never
use the first stroke of a grease gun)
• It is recommended to wear protective gloves when handling lubricants.
The latter often contains solvent which can cause skin irritation or a
rash.
• Always collect rags, empty packaging, grease cartridges, etc., and dis-
pose of them properly. KEEP THE ENVIRONMENT CLEAN.
For main bearings
• Always clean up the extra grease that is pressed out through the seals.
Note in the service report the amount of grease that has been pressed
out through the seals. This is very important as the amount of grease
used between services cannot be monitored otherwise.
• Notice the color of the grease and note it in the service report. If the
grease has an unusual color, e.g. rust-colored, it is an indication that
something is wrong.
IMPORTANT !! For blade bearings:
• Hydraulic oil may under no circumstances get into contact with grease
from the blade bearings.

When should a gear oil sample be taken?
Service after 500 hours: 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 or adding components to the gearbox, a 500 hour
service check must be performed on the gearbox.
Service every year: 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.
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 (e.g. in case of over-
speed or unusual noise).
Service every 5 years The oil must be changed.

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 con-
dition of both gearbox and lubricant.
• Take the oil sample from the oil sample valve on the CC-Jensen filter.
Start up the CC-Jensen pump, the in-line pump and the turbine. Wait
minimum 5 minutes, and then take the oil sample while the pumps and
the turbine are running (to ensure a proper mixture of oil and particles).
Remember to use the nacelle cover safety locks. If the turbine cannot be
started up, the in-line pump must run minimum 10 minutes before the
sample is taken. The in-line pump may not be stopped before the sample
has been taken.
• Open and close the sample valve a few times to loosen possible dirt in
the valve. Flush approx. 2 liters of oil out of the sample valve in a clean
plastic container before the sample is taken. Without closing the valve,
now take the sample continuously. I.e. the oil flow may not be stopped
as this may cause dirt particles to be loosened which may affect the oil
sample result.
• Remove the sample bottle when it has been filled. Close the sample
valve afterwards.
• The sample bottle must be closed immediately after it has been filled to
avoid contamination from the environment.
• Check that the oil sample valve does not leak.
• Write on the sample bottle:
— Turbine number: _______
— Date:_______
— Initials:_______
— Oil type:_______
— Duty hours (released to duty):_______
— / Production (big generator kWh):________
— / Production (small generator kWh):________
• Pour the oil from the plastic container back into the gear.
• Check gear oil level, and top up if necessary.
• Keep the lid on the plastic container to avoid dirt. Reuse it if possible.
The same plastic container may not be reused for different oil types.
Fig. 5.0
1. Oil sample valve on Off-line fil-
ter (CC Jensen)

Replacement of gear oil

• Stop the turbine, and secure it with the rotor lock.
• Take a gear oil sample in a plastic bottle as per the instructions in the
chapter on lubrication.
• Stop the pump for the off-line filter via the hand terminal, and close off
the filter suction hose.
• To pump the old oil out of the gearbox, remove the in-line return hose
from the gearbox by means of the purpose-made socket screw key. To
drain off the oil, use the purpose-made hose coupling with the ball plug
valve that has to be screwed onto the in-line return hose.
• Close the in-line filter bleed valve on the gear.
• Run the in-line pump and pump the oil into waste oil cans at low speed
using the hand terminal. Stop when the pump start sucking false air (the
pump gives off a different sound). Empty and change the off-line filter to
permit the remaining gear oil to run to the bottom drain tap.
• Empty the off-line filter of oil by connecting the universal hand pump to
the drain tap. When air is heard in the return hose, wait 5 minutes, and
then pump again. (Repeat this procedure 3 times.)
• Replace the off-line filter as well as the sealing rings for the filter cover,
the filter guide + top nut and the gasket for the bleed plug.
• Open the suction hose for the off-line filter again, but the pump must re-
main stopped.
• Start the in-line pump again at low speed, and pump the remaining oil
into waste oil cans. Run the pump until a gargling sound is heard at the
in-line return hose. IMPORTANT: If the pump is run dry unnecessarily,
the shaft seals will be overloaded, which will entail leakage in the gear
oil pump.
• Replace the in-line filter element by lifting it up with the chain hoist. As-
sess the degree of contamination of the magnetic rods, and then clean
them. Record the degree of contamination in the service check list or the
work instruction according to the reference pictures of the magnetic
rods which can be found in the chapter on service and maintenance of
the transmission system.
• Very carefully lower the new filter back down into the filter housing, and
torque-tighten the cover as per the directions.
• Remove the bolts from the top cover of the gear, and add approx. 500 lit-
ers of new oil to the gearbox. IMPORTANT: Make sure that the can is
completely clean and that the lock ring for the lid is NOT on the neck of
the can.
• Start the pump for the off-line filter. Check that the filter builds up pres-
sure, and bleed the filter housing. (It is o.k. if the pressure reading reach-
es the red area if the oil is cold.) Check the system for leaks when the
filter has been filled and bled.
• Disconnect the plug for the bypass valve at the cooler to empty the oil
cooler and the hose connections.
• Restart the in-line pump, and add 25 liters to the waste oil can.
• Fasten the in-line return hose to the gear with the appropriate torque.
• Connect the plug for the bypass valve at the cooler.
• Open the in-line filter bleed valve.
• Start the in-line pump at low speed, and stop it again after a minimum of
5 minutes’ operation.
• Assess the oil level after 10 minutes’ standstill, and top up the gear with
oil until the level reaches the max. indication on the sight glass.
• Replace the air filter on the top cover of the gear.
• Make a computer reset via the hand terminal. The rotor lock can now be
disengaged, and the turbine is ready for starting.

When should a hydraulic oil sample be taken?
The condition of the hydraulic system and of the oil is monitored by sampling oil
as indicated below:
Service • At the 2-year service check-up after oil filling

• Upon every subsequent annual service check
• If necessitated by the condition of the hydraulic system.
Service every 5 years The oil must be changed.

Sampling of hydraulic oil for pitch system
Oil sample Only take one oil sample.
• Use sterilized sampling bottle and label.

• Moisture or raindrops are not allowed in the sampling bottle.
• Take the sample via a test hose which is screwed onto the test nipple on
the pumping station. Hold one end of the test hose into the filling hole in
the tank. Screw the other end slightly onto the test nipple, reducing the
flow of oil.
• The first 0.5 liter is fed back into the oil tank.
• After this, fill up the sampling bottle.
The tests must be sent to Siemens Wind Power in a separate package within one
week.

Replacement of hydraulic oil
When changing oil, it is important to ensure that the entire oil quantity is changed.
Oil must be filtered through a 3 micrometer absolute filter before filling up.
Oil delivered from Siemens Wind Power in plastic containers is pre-filtered.
Oil change procedure:
• Insert a jumper in the level sensor on the tank to avoid error 70.
• Drive the piston rod fully out.
• Turn off the 3 valves no. 108.
• Turn on valves 103 and 116 by removing the plug.
• Press valve 117.
• Open valve 27.
• Remove the return hose on the pumping station and lead it into a con-
tainer.
• Connect the test hose from test nipple 111 to 112 on each hydraulic sys-
tem in the blade.
• Open the proportional valve by setting the pitch adjustment in menu 24
to +5°.
• The oil in the tank is pumped via the hub block to the return hose and
into the containers.
• Remove the drain plug in the tank and drain the last oil.
• Clean the tank inside using clean cloths.
• Fit the drain plug and dismount the test hoses.
• Fill up the tank with new oil.
• Start the pump for 10 seconds. The proportional valve must be open - in
this way the pressure pipe is flushed.
• Start the pump.
• The proportional valve must be closed - in this way oil is filled into the
accumulators.
• Open valve 108 slightly so that the cylinder moves towards the stop po-
sition.
• The used oil in the cylinder is in this way fed into the container via the
tank hose.
• Repeat the procedure on the 2 remaining blades.
• Start the pump for 10 seconds. The proportional valve must be open - in
this way the tank hose is flushed.
• Connect the tank hose to the pumping station.
System with external cooler: • Disconnect the tank hose on the pumping station from the cooler and
place the hose in the container.
• Operate the pump with bypass valve (25) opened for 5 seconds.
• Fill the tank with the correct amount of new oil.
• Remove the jumper from the level sensor on the tank.

Changing yaw gear oil
It is no longer permitted to drain off the oil from the yaw gear by pressuriz-
ing the oil container as that method may damage the glands in the gear.
1. Prepare the wet/dry vacuum cleaner for oil suction by removing the paper filters
from the vacuum cleaner.
2. Remove the bleed plug from the oil container and the sealing plug from the
drain tap.
3. Place the vacuum nozzle over the drain tap, and start the vacuum while open-
ing the drain tap on the yaw gear.
4. The vacuum can suck approx. 6 liters of oil off the yaw gear. The gearbox is
empty when air is being sucked in via the top of the oil container.
5. Close the drain tap, and pour the waste oil from the vacuum container into a
waste oil can. A new suction procedure can be initiated when the vacuum cleaner
is ready. Prepare at the same time for injecting new oil into the yaw gear just emp-
tied.
6. New oil must be added with a CLEAN universal hand pump. Add new gear oil
to the pump, and connect the pump pressure hose to the drain plug.
7. Initiate the injection of new oil, and watch the level in the sight glasses. Relieve
the pressure in the hand pump via the relief valve when the level reaches the low-
er edge of the top sight glass.
8. Mount the bleed plug on the oil container again. Open the drain tap again when
the sealing plug has to be screwed into the tap. This prevents pressure from being
built up, and consequently drain tap failure.

Lubrication chart
Lubrication chart Place for lubrication: Main gear (Winergy / Hansen)
Lubricant at the time of TRIBOL 1710 - VG320 / Castrol Optigear Synthetic X VG 320
delivery:
Lubrication
First interval: After 500 hours of operation take a sample of the gear oil and send it to the oil man-
ufacturer to be analyzed. Any further action depends on the results of the analysis.
See page 110 for oil sampling of gear oil.
Quantity: Main gear: approx. 420 liters
Total: approx. 575 liters
Lubricant: TRIBOL 1710 - VG320 / Castrol Optigear Synthetic X VG 320
Remarks: Lubrication of the gear:
• The purpose of the oil is first and foremost to prevent metal surfaces from getting
directly in contact with each other. An oil film must be produced between the con-
tact surfaces. The oil also acts as a heat conductor, conducting heat away from
the metal surfaces.
• The oil level is lower than the main shaft seals. These seals are labyrinth seals,
similar to the other seals in the gearbox. The gear is pressure lubricated.
• The first indication that the gear is not lubricated properly is that it gets hot. This
happens if there is too little oil, too much oil or the oil is of poor quality.
To maintain appropriate lubrication, it is important that the following two points are fol-
lowed:
• The oil level must be correct, i.e. the oil level must be at the mark in the oil
glass.
• Important: Wait 15 minutes after the turbine is stopped before checking the
oil level so that the oil can run back into the sump.
• The oil quality, i.e. the oil's ability to lubricate, must be optimal. This is checked
by regularly taking samples and having them analyzed.
Periodical lubrication:
Interval between lubri- Annual sampling of the gear oil and subsequent analysis by the supplier. Any further
cations: action depends on the result of the analysis.
If the oil is not analyzed, it must be changed every 2 years.
The oil must be changed every 5 years.
Quantity: See remarks above
Remarks: See remarks above
NEVER USE OTHER LUBRICANTS THAN THOSE STATED ABOVE

Lubrication chart Place for lubrication: Gear oil filter
Lubricant at the time of In-line oil filter / Off-line oil filter / Air filter
delivery:
Lubrication
First interval: In-line oil filter (FA2000): Change the filter element after 500 hours of operation.
Off-line oil filter (CC Jensen): Change the filter element after one year of operation.
Air filter: Change the filter element after one year of operation.
Quantity: 1 in-line oil filter element (FA2000)
1 off-line oil filter element (CC Jensen)
1 air filter element
Lubricant:
Remarks: Note degree of contamination.
Interval between lubri- Replace filter element every year.

cations:
Lubricant:
Quantity: 1 in-line oil filter element (FA2000)
1 off-line oil filter element (CC Jensen)
1 air filter element
Remarks: Note degree of contamination.

Lubrication chart Place for lubrication: Main bearing (with central lubrication system)
Lubricant at the time of KLÜBER PLEX BEM 41 - 141

delivery:
Lubrication
First interval: After one year of operation.
Quantity: 10 liters
Refill the grease container with the pump
Lubricant: KLÜBER PLEX BEM 41 - 141
Remarks: Underneath the main bearing is a tray which collects excess grease. Empty the tray
before lubricating the main bearing. Check the color of the grease, and estimate the
amount of excess grease. Note the quantity of the grease expelled from the seals in
the service report. If the color of the grease is abnormal (e.g. rusty), this should also
be noted in the service report, and a grease sample must be taken.
Always lubricate the main bearing first, then the labyrinth seals.
Interval between lubri- Every year.

cations:
Quantity: 10 liters
Remarks: See remarks above

Lubrication chart Place for lubrication: labyrinth seals (main shaft bearings)
Lubricant at the time of OPTIMOL OPTIPIT

delivery:
Lubrication
Quantity: Approx. 200 g distributed among all grease nipples
Lubricant: OPTIMOL OPTIPIT
Remarks: Always lubricate the main bearing first, then the labyrinth seals.

cations:
Quantity: Approx. 200 g distributed among all grease nipples
Remarks: Turbine must be idling.
Always lubricate the main bearing first, then the labyrinth seals.

Lubrication chart Place for lubrication: Yaw claws, sliding shoes and teeth on yaw plate and yaw pin-
ion (with central lubrication system).
Lubricant at the time of OPTIMOL OPTIPIT

delivery:
Lubrication
Quantity: 5 liters
Remarks: Check that the system does not over apply grease.
• At start-up the turbine is set to use extra lubrication. This means that refill-
ing is necessary.
REMEMBER! - Check that the parameter setting (10215) in the hand terminal is set
to 6 (Default).
If the service technician assesses that the grease is sufficient, further lubrication is
not necessary.

cations:
Quantity: 5 liters
Remarks: See above

Lubrication chart Place for lubrication: Yaw gear
Lubricant at the time of TRIBOL 1710 - VG320 / Castrol Optigear Synthetic X VG 320
delivery:
Lubrication
First interval: After 5 years of operation, the oil must be changed.
Quantity: 7 + 1 liters (1 liter in the oil reservoir).
Remarks: The oil can be drained through the oil drain valve.
Use the oil change kit (option)
After changing the yaw gearbox oil - check that the oil level is correct (between the
lower and the upper oil level glass).
Interval between lubri- Every 5 years the oil must be changed.

cations:
Quantity: 7 + 1 liters (1 liter in oil reservoir).
Remarks: See above
Check the oil level at every service visit.

Lubrication chart Place for lubrication: Generator bearings (with central lubrication system)
Lubricant at the time of KLÜBER PLEX BEM 41 - 132

delivery:
Lubrication
Quantity: 1 liter
Remarks: • Remove excess grease in the drain pipe.

• Clean away any excess grease underneath the generator (front and back)
• Listen for unusual noise at the bearings
• Clean away any spilled grease in the generator drain and the nacelle.

cations:
Quantity: 1 liter
Remarks: See above.

Lubrication chart Place for lubrication: Blade bearings (with central lubrication system)
Lubricant at the time of Shell Rhodina BBZ

delivery:
Lubrication
Quantity: 6 liters
Lubricant: Shell Rhodina BBZ
Remarks: • Check: The seals must be free from cracks and dirt.
• Empty the excess grease container.
• Apply Holdtite S72 to the surface touching the brass fittings - however,
make sure that NO Holdtite S72 is applied to the threading. If S72 is applied
to the screw thread it may break off when replacing the cup.

cations:
Lubricant: Shell Rhodina BBZ
Quantity: 6 liter
Remarks: See above.

Lubrication chart Place for lubrication: The pump station for the pitch system and brake (hydraulic oil)
Lubricant at the time of MOBIL DTE 13M - (Arctic: Shell Tellus Arctic oil 32)
delivery:
Lubrication
First interval: After 2 years of operation.
Quantity: 225 liters.
Lubricant: MOBIL DTE 13M
(Arctic: Shell Tellus Arctic oil 32)
Remarks: Take oil sample

cations:
Lubricant: MOBIL DTE 13M
(Arctic: Shell Tellus Arctic oil 32)
Quantity: 225 liters.
Remarks: Take oil sample
Change the oil every 5 years
NOTE: When oil is replaced, the brake callipers must be bled.

Lubrication chart Place for lubrication: Filter for the pumping station
Lubricant at the time of Pressure filter and return filter

delivery:
Lubrication
First interval: Change the filter element after 500 hours of operation.
Quantity: 1 filter element for the pressure filter
1 filter element for the return filter
1 filter element for the air filter
Lubricant:
Remarks:
Interval between lubri- Replace the filter every year.

cations:
Lubricant:
Quantity: 1 filter element for the pressure filter
1 filter element for the return filter
1 filter element for the air filter
Remarks:

Lubrication chart Place for lubrication: Antifreeze liquid for frequency converter
Lubricant at the time of Antifreeze liquid: BASF Glysantine G30

delivery:
Lubrication
First interval: Change after 7 years of operation
Quantity:
Lubricant: Antifreeze liquid: BASF Glysantine G30
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.
Interval between lubri- Change after 7 years of operation

cations:
Lubricant: Antifreeze liquid: BASF Glysantine G30
Quantity:
Remarks: See above

Lubrication chart Place for lubrication: Chain hoist (Service crane)
Lubricant at the time of KEMA VET - 68 Sterile oil.

delivery:
Lubrication
First interval: Every year
Quantity: Approx. 0,5L
Lubricant: KEMA VET - 68 Sterile oil.
Remarks: Estimate the amount of oil needed.
Interval between lubri- Every year

cations:
Lubricant: KEMA VET - 68 Sterile oil.
Quantity: Approx. 0,5L
Remarks: Estimate the amount of oil needed.


- Chapter 06 CONTROLS

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 06 CONTROLS
SWT - 2.3 - 82VS/93/101
• Controller and associated electrical installations
• Electrical system
• Service and maintenance of the controller
• Check after repair of controller switchboard
• Service and maintenance of associated electrical installations
• Checking the frequency converter cooling system

yyyy)

Document history

93/101
ECN30997 R1 16-06-2009 New dust collector added for the cooling-

system for frequency converter.
ECN32453 R2 10-09-2009 Brushes at main shaft has been modified.
ABB power unit fig. 6.3 - 6.4 added

Controller and associated electrical installations
WARNING ! Prior to commencing work on any circuit, it must be ensured that the work
area is de-energized. See SI 545781 “General Health and Safety Rules for
Service Technicians Working in Siemens Wind Power’s Turbines”, para-
graph “LIVE WORK”
Working with live voltage is only permissible for testing or error detecting.
(See rules for “LIVE WORK”)
Info The connection of the main switch (circuit breaker) is performed by the controller
and may not be performed manually.
It is mandatory to follow the 3 safety rules in the correct order to avoid the risk
of electric shock.
The 3 safety rules

1. De-energize These 3 safety rules must be fol-
lowed prior to commencing any
2. Secure against reconnection electrical work.
3. Confirm de-energized condition
Fig. 6.0
Hearing protection must be worn
in the bottom of the tower during
start-up and operation of the tur-
bine.

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 gen-
erator to the turbine transformer. It is also designed to control, regulate and mon-
itor all functions related to the operation of the turbine in order to ensure the
maximum output of the turbine production capacity within the general specifica-
tions of the turbine.
Controller switchboards The turbine control system consists of a number of large subordinate switch-
boards and cabling between these, including junction boxes.
Fig. 6.1 Converteam

1. A1 - Controller
2. A2 - Controller
5
3. A11 - Filter
4. A12 - Frequency converter

4
5. A14 - Reactor
1
Fig. 6.2 Converteam

1. A1 - Controller
2. A2 - Controller
5
3. A11 - Filter

4
5. A14 - Reactor
1

Fig. 6.3 ABB power unit

1. A1 - Controller

(power modules)
3. A12 - Frequency controller

incl.reactor, filter and main-
1 breaker.
3 2
Fig. 6.4 ABB power unit

1. A2 - Controller
2: A12 - Frequency converter

2 (power modules)

3 incl. reactor, filter and main-
breaker.
All controller switchboards are marked with a label indicating the name and posi-
tion of the switchboard in the turbine.
Fig. 6.5
1 The name of the controller.
2 3
1 (V3=WTC 3 styring -
023=2.3MW)
2 The position of the controller
in the turbine.
3 Version.
The large subordinate switchboards are listed below:
A1: Switchboard for main cir- Main switchboard in the tower (power section). It is fitted in the power unit. The
cuit breaker switchboard contains the following main components/functions:

• Connection for the cables from the turbine’s 33/0.69 kV transformer.

• Overload circuit breaker for 3x690 V for the generators and motors, in-
cluding functions for manual and automatic breaking as well as manual
and remote-controlled reclosing.
• Connection terminals for emergency generator.
• 3-phase voltage measurement, including 3-phase current measurement
in the generator circuit.
• Terminal for overload circuit breaker for lights, control voltage, service
lift, etc.
• Single-phased 690/230 V transformers for lights, control voltage, etc.
• Grid module for 3-phase voltage and current measurement, including
frequency measurement, calculation of electrical parameters on the ba-
sis of these measurements, and controlling of thyristors.
• Terminal for connection of 690 V emergency supply.
A2: Switchboard for UPS, Main switchboard in the tower (controller section). It is fitted in the power unit to-
hand terminal and computer gether with the main switchboard A1. The switchboard contains the following
main components/functions:
• I/O module incl. control panel for the WTC-3 controller.

• The controller’s communication interface with the remote monitoring
system.
• On-line UPS for controlled 230 VAC control voltage ensuring the func-
tionality of the turbine functions during grid drops and ensuring con-
trolled cut-out of turbine production and controlled braking of the
turbine in case of power failure. Furthermore it functions as emergency
supply ensuring the functionality of communication systems and warn-
ing lights (optional) for at least one hour.
• Supply for the dehumidifier in the tower.
• Terminals for connection of warning lights.
• Terminals for connection of the meteorological measuring system.
• Terminal for connection of 230 V emergency supply.
A3: Main computer and relay Main switchboard in the nacelle. It is mounted on the nacelle wall next to the main
switchboard shaft at the front end of the nacelle. The switchboard contains the following main
components/functions:
• WTC-3 Main, the central computer module in the WTC-3 controller sys-
tem.
• WTC-3 I/O module, 2 units.
• Contactors and motor protection for various motors in the nacelle.
• Supply for the dehumidifier in the nacelle.
• Supply and relays for valves in the disc brake system.
• Connection terminals for TCM modules for machine monitoring.
• Connection terminals for aviation warning lights.
A4: Switchboard for genera- Subordinate switchboard in the tower. It is mounted on the tower wall. The switch-
tor and change-over relays board contains the following main components/ functions:
Connection terminals for AL-SE main cables between the -A1 (high voltage
switchboard at the bottom) and -A4 (this switchboard).
A6: Hub computer Subordinate switchboard in the hub (blade pitch control). This switchboard is
mounted on a galvanized iron plate at the very front of the hub (opposite the hub
flange up against the main shaft) in such a way that it turns together with the hub

on an axis through the center of the switchboard perpendicular to the switchboard

cover and base plate. The switchboard contains the following main components/
functions:
• Hub computer and I/O module for controlling and regulating the blades
and for controlling the proportional valves, position encoders, VCUs,
etc.
• Two contactors for the supply of safety systems.
• 2 switched-on power supply units.
A9: Switchboard for crane/ Subordinate switchboard in the nacelle. It is mounted on the left-hand side of the
hatch, hydraulic control, etc. nacelle, immediately in front of the hydraulic station and the service crane. The
switchboard contains the following main components/functions:
• 230 V supply for the hub.
• 24 VDC control voltage for the service crane.
• 3x690 V supply through the line circuit-breaker for the service crane.
• Connection terminals for the HCU in the nacelle (High-speed Centrifugal
Release switch).
• Connection terminals for solenoid valves for the disc brake system and
the service crane.
• Push-buttons for activating the service crane.
• Relays and terminals for heating elements for the wind vane(s) and ane-
mometer(s).
A11: Filter This switchboard is placed in the power unit. It contains the following main com-
ponents/functions:
• Together with A14, filter reactor.

• Condenser and resistors for filtering.
• Relays for cut-in of step 1 and 2.
• Internal cooling.
• Connection terminal for signal and power cables.
A12: Frequency converter This switchboard is placed in the power unit. It contains the following main com-
ponents/functions:
• Frequency converter for power control and regulation of turbine power.

• 3 liquid-cooled delta modules for generator connection.
• 3 liquid-cooled delta modules for grid connection.
• 2 computers for control of generator and grid converters respectively.
• Internal 28 V DC power supply.
• Grid synchronization measurement unit.
• Optical interface for communication with WTC 3.
• Internal heating element.
A14: Filter reactor This switchboard is placed in the power unit. It contains the following main com-
ponents/functions:
• Filter reactor for PWM* filtering of main power (*Pulse-Width Modula-

tion).
A18: Frequency converter for This switchboard is placed in the nacelle. It is mounted on the nacelle wall next to
yaw motor the main shaft at the front end of the nacelle. The switchboard contains the fol-
lowing main components/functions:

• Yaw frequency converter.

• Yaw switch CCW/CW.

Service and maintenance of the controller
WARNING ! Circuit switching and measurement are “LIVE WORK”
IMPORTANT !! See controller diagram of the turbine for de-energizing the switchboard.
(Option: See yellow sign for Fig. 6.6

de-energized condition of the Example of sign, mounted on
switchboard) switchboard A1.
Service and maintenance of • Check that the emergency lighting is switched on when the supply volt-
the controller age to the turbine is switched off.
• Tighten all screws and bolts with a torque wrench according to the list
of tightening torques. Se: Kapitel 4, “Boltetilspænding,” .
• Visually check that all connectors have been mounted correctly on the
circuit boards.
• Visually check that all cable eyes in the main current connections are
correctly crimped (no sign of overheating).
• Torque all the main current connections on the aluminium cables.
• Torque all the main current connections on the copper cables in A4.
• Visually check that all clamps in auxiliary relays are mounted correctly.
• Visually check that the auxiliary contact blocks on all contactors are
mounted correctly.
• Check that the controller cabinet is properly sealed at the doors and the
cable entry glands. The closing device must form a perfect seal.
• Check that the OK marks on the varistors are green. Also check the
varistor fuses.
• Check the grid voltage.
• Check the software version.
• Read out the error stack, and note it in the work report.

Check after repair of controller switchboard
WARNING ! Circuit switching and measurement are “LIVE WORK”
IMPORTANT !! See controller diagram of the turbine for de-energizing the switchboard.
(Option: See yellow sign for Fig. 6.7

de-energized condition of the Example of sign, mounted on
switchboard) switchboard A1.
If an error occurs in the controller, the status display on the monitor must be spec-
ified in the work report.
Check after repair of control- • Tighten up all relevant screws and bolts with a torque wrench as per the
ler switchboard list of tightening torques in Chapter 4.
• Check that all ribbon cables and multiple connectors are correctly con-
nected.
• Visually check that all cable eyes in the main current connections are
correctly crimped (no sign of overheating).
• Visually check that all clamps on the auxiliary relays are mounted cor-
rectly.
• Check for correct main grid voltage and phase sequence.
• Check that the software in the turbine computer is in accordance with
the turbine's specifications.

Service and maintenance of associated electrical installa-

tions
Emergency lighting A specific number of the light fixtures have batteries for emergency light supply in
order to ensure emergency lighting in the turbine in case of power failure.
In emergency light fixtures with 2 fluorescent tubes, only one tube is connected
to the back-up battery for the emergency lighting.
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.
Check of emergency light fixtures
• Disconnect the power supply.

• The emergency lights must now function for minimum 15 minutes.
• Replace the batteries in the emergency light fixtures if they do not func-
tion for the specified time.
Checking the emergency Engage all emergency stops, and reset them individually.
stops
• Engage one emergency stop, and check for an error message on the
hand terminal. Then move on to the next one until all emergency stops
have been tested.
General information for To prevent damage caused by humidity, heating elements have been installed in
checking the temperature the generator. Moreover, a temperature monitoring system has been installed by
monitor in the generator means of PTC elements in the winding heads of the generator.
The purpose of this check is to ensure reliable and correct function of the above-
mentioned generator protection.
Visually check:
• Remove the cover of the generator terminal box. Check that the diagram
on the inside of the cover is identical with the terminal strip on the gen-
erator.
• Check the wiring of the temperature monitoring and the heating ele-
ments.
See controller diagrams from KK Electronic A/S.
The check is carried out from the terminal box in the nacelle.
Checking the heating ele- The turbine must be live for the check, but the generator must be cut out. 1 x 400
ments in the generator W heating element is connected to the terminal row in the controller.
In order to check the heating element in the generator, change parameter

UP2200 to maximum value.

Measure the current in the heating element with a clamp ammeter on one of the
cables from the terminal in the controller. The current must be 174 ± 0.1 A.
(See drawings and diagrams for the controller.)
Checking the generator tem- To check the temperature in the generator, the parameter UP 181 (WTC 2), UP
perature monitoring system 2200 (WTC 3) must be changed to max. value.
(See drawings and diagrams for the KK Electronic A/S generator)
Checking the heating ele- Three 1000 W 2 x 690 V power consumption 1.45 ± 0.2 amp.
ments in the gear
Check that the reading is realistic.
Checking the heating ele- One 785 W 2 x 690 V power consumption 3A ± 0,3 amp.
ments in the hydraulic system
(option) Check that the reading is realistic.
Checking the heating element • In order to check heating element in the controller, the thermostat set-
in the controller (option) ting must be lowered (remember to raise it again after checking). Mea-
sure the current in the heating element with a clamp ammeter. (The
heating element is cut in at approx.+ 5°C and cut out again at approx.+
9°C.)
690 V cables • Visually check 690 V cables in the controller switchboards and genera-
tor.
Generator cables Check generator cables for cracks and surface changes. Note any cracks or
changes in the check list under remarks, and notify the Service Department.
Also check that:
• the cables are correctly tightened. Test with a torque wrench (See “Bolt
tightening” ).
• check visually that all cable eyes on the generator cables are correctly
crimped (no sign of overheating).

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 4 x d [diameter] 6 x d [diameter]
1x240 mm2 Ø36 MM. 4 x d [diameter] 6 x d [diameter] 150
LIHCH 10 x d [diameter] 15 x d [diameter]
LIHH 10 x d [diameter] 15 x d [diameter]
LIYCY 10 x d [diameter] 15 x d [diameter]
Optical fiber 2-pair and 3-pair 18 x d [diameter] 7.5 / 8.5
Optical fiber 4-pair 10 x d [diameter] 10
Optical fiber 6-pair 20 x d [diameter] 12.5
Type 110CY 6 x d [diameter] 20 x d [diameter]
Aluminum cable (3x150) 10 x d [diameter] 15 x d [diameter]
• When using repair sleeves, remove excess glue.
Check the aluminum cable • All aluminum cable joints in the wind turbine must be inspected for
joints at the tower joints for marks and cuts from the cable ladders. There must not be any cuts in the
damage cable insulation from the side members of the cable ladders. If the cables
have visible cuts, this must be reported to the Service Department at Si-
emens Wind Power A/S for further action. If possible, append the report
with pictures with measurements indicating the scope of the damage.
• Cuts are defined as open “gashes” where the cable insulation is dam-
aged.
• Marks are defined as changes in the structure of the insulation material,
as if the cables had been exposed to heating.
Electronic vibration sensor The G sensor (frequency-dependent) / TCM module register oscillations in the
turbine. If these oscillations exceed those expected during ordinary turbine oper-
ation, a signal is sent to the controller, and the turbine is shut down.
Testing the G sensor • Engage the rotor lock.

• Unscrew the cover and loosen the four screws in the corners of the box
(inside) to dismount the G sensor.
• Start the turbine and activate the G sensor by shaking the box. 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 controller reg-
ister an error.
• Refit the G sensor.

Fig. 6.8
1 G sensor fitted in the nacelle
Testing the TCM module • Engage the rotor lock.

• Loosen the three screws and remove the TCM module
• Release the turbine for operation, thereby disengaging the brake, and
activate the TCM module by shaking it. Shake the module with a frequen-
cy of approx. 2 cycles per second (2 Hz), a distance of 50 MM.
• After approx. 30 seconds, the relay should “click” and the controller reg-
ister an error.
• Apply grease to the bottom surface of the TCM module, and refit it with
screws (use Locktite)
Fig. 6.9
1 Cover for TCM module.
2 TCM module on main bear-
ing.
1
Tightening of TCM modules Check and tighten all TCM modules.
Fig. 6.10
1 TCM module on generator.
2 Cover.

Fig. 6.11
1 TCM module at the front of
the gearbox.
Fig. 6.12
1 TCM module at the rear of
the gearbox.

Lightning protection system • Check that the carbons move correctly by lifting them and checking that
they are able to move fully onto the surface of contact. The carbons
should be easy to move and should have a play of ½ MM. all way round.
If the carbons do not move easily and without jamming, the holders and
carbons must be cleaned with sandpaper (do not use emery) until the
gap is appropriate.
• Check the length of the carbons. Replace the carbons when they have
been worn to a length of less than 25 MM.
• Check and adjust all carbon sliding shoes and spark arresters.
Fig. 6.13
1 Carbon sliding shoe
1 2 Spring/carbon
3 Spark arrester
4 Adjustment 3 mm +/-1 mm
2 The carbon sliding shoe must be

replaced if the spring has re-
coiled unevenly or hangs on the
edge of the holder.
3 The carbon sliding shoe must be

4 adjusted to 3 MM. +/-1 MM. from
the surface of contact.
Fig. 6.14
1 Spark arrester (hub)
2 Adjustment 3 mm +/-1 mm
2
The spark arrester must be ad-
justed to 3 MM. +/-1 MM. from
the surface of contact.
Lightning protection system Fig. 6.15

between the nacelle bedplate 1 Carbon sliding shoes (yaw)
and tower
1


between the main shaft and 1. Carbon sliding shoe (main
nacelle bedplate shaft)

between the blade and hub 1. Carbon sliding shoe (hub)
Brushes at main shaft and • Check that the brushes provide contact between the main shaft/nacelle and
yaw ring the yaw ring/tower flange. If necessary, adjust the brushes to provide a “light”
contact.
• Replace the brushes between yaw ring/tower flange when brush wear
prevents correct adjustment.
Fig. 6.18
Brushes at main shaft
Checking the tower lightning Check that lightning protection (equipotential bonding) has been fitted on the
protection flanges at the tower joints.
Check the lightning protection at the aluminum floor plate.

Checking the lightning pro- Check that cables for lightning protection at gearbox suspension, generator,
tection hatches, hub, controller switchboards, etc. are intact and without damage.
Checking the lightning detec- If the trip-out of the lightning detector is assessed to be caused by an error, the
tor, and subsequent proce- turbine may be reset and restarted. If the trip-out of the lightning detector is as-
dure sessed to be caused by lightning, the turbine must be inspected for damage be-
fore restart.
Inspection of lightning dam- Use strong binoculars to inspect the area around the lightning receptors on the
age blades. Each blade has 6 receptors. One pair 24 m from the root, another pair at
32 m and a third pair in the blade tip (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 fiberglass in the area around the receptor.
If the receptor is severely damaged, i.e. more than 90% of the surface is dam-
aged, it must be replaced as soon as possible. Slightly damages receptors are
still functional and can be left as they are. Damaged receptors must be sent to
Siemens Wind Power A/S, Attn.: Electrical Department, with due specification of
the turbine no. and blade no.
The magnetic lightning cards in the blades, at the aircraft warning lights and at the
wind vane stand must be checked for burns.
NOTE ! If lightning damage is found, all lightning cards must be replaced and returned to
Siemens Wind Power A/S.
Replacement of lightning Replace the lightning cards only if it is suspected that the blade, lightning rod or
cards tower has been hit by lightning.
When a card is replaced it is important to make sure that the label on the card is
filled in with the following information:
• Turbine no. and perhaps name.

• Date of fitting and date of replacement.
• Measuring point. For blades, the serial no. must be stated.
• The initials of service technician.
NOTE ! The cards must be kept away from magnetic materials, as they may damage the
magnetic pattern and make the read-out unreliable. Minimum distance depends
on the strength of the magnet.
Do not put the cards in the tool box. Place them in a plastic bag or similar.

Fig. 6.19.
1 Lightning card.
1 Fit the card in the card holder

which is attached with cable ties.
Fig. 6.20
One lightning card mounted in
each blade (approx. 1 m from
blade root).
Fig. 6.21
(option)
Lightning card fitted on lightning

rods at aircraft warning lights.
This card also protects the visi-

bility meters.
Fig. 6.22
Lightning card on the ground ca-
ble for the wind vane holder.

Replacement of lightning de- Fig. 6.23

tector battery Lightning detector.
Disconnect the cables and change the battery. Return the battery to Siemens
Wind Power A/S.
Fig. 6.24
1 Lightning detector
1 2 Battery
Replacement of UPS battery The UPS is fitted in a separate compartment in the controller.
(Type Rack - Live work)
• To interrupt the UPS, press the “off” button placed on the front panel
(yellow diode lights up).
• Interrupt the supply to the UPS.
• Disconnect the cables and replace the batteries. Return the batteries to
• After replacing the battery, test the connections/interconnection of indi-
vidual parts.
• Connect the supply to the UPS.
• To start the UPS, press the button “on” (yellow diode switches off).
Fig. 6.25
Master UPS with eight batteries
(and eight battery modules as
option).
Connect 3 cables placed in the

controller to the corresponding
connectors on the UPS.

Fig. 6.26
UPS.
5 3 2 1
7
1 > 105% load (red)
2 85-105% load (yellow)
3 Load OK (green)
4 UPS Offline
5 UPS Online
6 Battery status
7 Grid OK
4
6
Replacement of UPS battery The UPS is fitted in a separate compartment in the controller.
(Type Tower - Live work)
• To interrupt the UPS, press the “off” button placed on the front panel
(yellow diode lights up).
• Interrupt the supply to the UPS.
• Disconnect the cables and replace the batteries. Return the batteries to
• After replacing the battery, test the connections/interconnection of indi-
vidual parts.
• Connect the supply to the UPS.
• To start the UPS, press the button “on” (yellow diode switches off).
Fig. 6.27
Master UPS with 3 batteries (and
eight battery modules as option).
Connect 3 cables placed in the

controller to the corresponding
connectors on the UPS.
Fig. 6.28
UPS.
5 3 2 1
7
1 > 105% load (red)
2 85-105% load (yellow)
3 Load OK (green)
4 UPS Offline
5 UPS Online
6 Battery status
7 Grid OK
4
6
Resetting of UPS batteries A piece of reset software is required to reset the UPS batteries. This software can
be found on VPST (Reset-batt.zip).

Fig. 6.29
Reset software.
• Connect serial cable 30989

+ 30989 + A9B10003209 be-
tween the PC and the outlet
control socket Com 3 on
the back of the UPS.
• Open the file Reset-batt.zip.
• When the file has opened,
use COM port 01.
• Slave address: 00.
• Click the “read battery age”
button, and then click the
“set battery age to 0” but-
ton.
• The display will indicate
“go \ 0” that the reset was
successful. If not, try again.
Checking of battery modules Check the number of battery modules connected to the UPS.
First count the number of battery modules in A2, and if there is an additional con-
troller switchboard next to A2 (batteries for aviation warning lights, marine light
system and foghorn), these must also be included in the count.
Checking the UPS The turbine has to be stopped to check the setting on the UPS. Press and hold
the OFF button on the UPS until the UPS gives an acoustic signal. The LEDs in
the battery circuit of the UPS (Fig. 6.24) will switch on for approx. 1 sec. and then
indicate the number of battery modules for approx. 1 sec. (see item 6) If every-
thing is ok, the test has been completed and the UPS may be switched back on.
Adjustment of the UPS If an incorrect number of battery modules is indicated, push within 3 sec. the OFF
button the same number of times as there are battery modules connected, and
then hold the button until an acoustic signal is given. The adjustment has now
been saved.
Perform another check.

Check the aircraft warning Fig. 6.30

lights (option) Check that the lights work. (Re-
place light bulb if necessary.)
The 230VAC supply for the aircraft warning lights is connected to a central UPS
backup facility. The UPS facility has capacity for supplying the aircraft warning
lights for one hour if the turbine is not connected to the grid.
Aircraft warning light error • Aircraft warning light error: In case of an error on the lights, a defective
messages light bulb or a communication error, an error message will be sent.
• Service message: Warning indicating that the bulb will soon need
changing.
• GPS message: Indicating no communication with satellite. The synchro-
nization of lights may be affected. The error will be automatically reset
as soon as communication is restored.
• After inspection: Check that the light is level on the fixture.
Fig. 6.31
1. Bubble level on aviation lights.
Se: Kapitel 25, “Appendix - Data

1 sheet - aviation light (option),”
Check the visibility meter (op- In order to check the visibility meter, hold a piece of milky plastic between the two
tion) tubes on the meters and check that the lights change to high intensity.
This test is only possible in clear weather, i.e. when the lights are at low intensity.

Fig. 6.32
1. Visibility meter.
1
Se: Kapitel 24, “Appendix - Data
sheet - visibility meter (option),”

Replacement of filters in con- Replace all filters, and check all connectors. Clean components if they are dirty.
troller cabinets
Fig. 6.33
1 Remove the filter holder from
the controller cabinet, and
replace the filter.
Fig. 6.34
1. Replacement of filters in cabi-
net A6 (hub)
Fig. 6.35
net A18 (frequency converter for
yaw motor).
Fig. 6.36
net A18 (frequency converter for
yaw motor).
(Do not change when marked

with yellow sign.)
1

Fig. 6.37
net A3 (controller in nacelle).
Fig. 6.38
net A9 (cabinet for hatches and
crane).
Fig. 6.39
net A2 (controller in tower).

Fig. 6.40
net A1 (controller in tower -
front).
Fig. 6.41
net A1 (controller in tower -
back).
Fig. 6.42
net A11 (filter box at A2).

Fig. 6.43
net A4
(and A19 (if used))

1
Replace fan in frequency con- Disconnect the power supply (24 V DC and 400 V AC) - Wait 5 minutes while the
verter for yaw gear DC link energy discharges!
Remove the fan.
Fig. 6.44
1 Filter and fan in the controller
cabinets.
Fig. 6.45
1 Fan.
1

Fig. 6.46
Remove the fan cover.
Fig. 6.47
Remove the fan.
Fig. 6.48
Remove the connector.
Installing the fan:
• Before installing the fan, check the through-flow direction (the arrow on
the fan must point towards the fins).
• Push the connector fully home.
• Push the fan fully home. Do not pinch the connection cables!
• Mount the fan cover.

Check of smoke detector sys- Se: Kapitel 19, “Bilag - Data blad for brandmeldeudstyr (option),”
tem (option)
Test smoke/fire detection equipment in A1, A2, Alstom converter board, Alstom
filter board, A3, A4, and, where relevant, the transformer.
Fig. 6.49
1. Smoke detector in frequency
converter
Fig. 6.50
1. Smoke detector above reac-
tor.
Testing the smoke detector Test smoke detection equipment in all controller boards, nacelle and tower.
(option)
• The signal box is in normal condition
• Disable the end resistor. This must cause the signal box to report error.
• Short circuit the end resistor. This must cause the signal box to report
fire.
• Test the smoke detector by using the smoke dispenser (SOLO 330 from
supplier).
• The test is finished. See the data sheets for signal box and smoke sensor
(Se: Kapitel 20, “Appendix - Data sheet - fire / smoke detector (option),” ).
Testing the shadow detector Adjust the shadow detector timer.

and light sensor (option)
Se: Kapitel 21, “Appendix 10 - Data sheet - shadow detector (option),”
Reset of max. and min. tem- Reset the max. and min. temperature annually and whenever work has been car-
perature ried out on temperature sensors.
Use the remote control, MENU 7
• Press “arrow” to the right.

• Press “.” to reset.

Checking the frequency converter cooling system

Se: Kapitel 13, “Components and diagrams,”
Fig. 6.51
1 4 7 10 11 16
14
12
15 13
17
18
19
5 2 3
8 9 6
1. Lubricate clip with anti-rust paste and tighten to 20 Nm. Lubricate 11. Manometer
hose boss with silicone spray (oil/ grease will dissolve the hose!) 12. Pressure sensor
2. Temperature sensor pt100 13. Pump
3. Thermometer 14. Aut. vent. The dust cap must be on loosely.
4. Pressure relief valve 3.5 bar 15. Outlet
5. Thermostat valve or three way actuator valve. 16. Inlet
6. Accumulator with air valve 17. Ball valve
7. Ball valve 18. Pump bleed screw
8. Filling valve 19. Put the end of the hose into the 25 l container.
9. Filter 20: Three way valve
10. Test nipple (bleeding 21: Actuator
Fig. 6.52
21
20

Replacement of cooler hoses • Lubricate the hose boss with silicone spray before pushing on the hose
(Oil or grease will dissolve the hose!)
• Antifreeze: BASF Glysantine G30 - 33% (1 part coolant to 2 parts water).
• Cold climate: 50% (1 part coolant to 1 part water).
Fig. 6.53
1 Water cooler clips
1 2 2 Stainless steel paste on the
3 4
threading and sliding sur-
face.
3 wipe of
4 Tighten 20Nm
Changing antifreeze When changing antifreeze, the bleed valves at the top of the frequency converter
modules must be opened to bleed off all of the old antifreeze.
Servicing the cooling system • Close the ball valves (pos. 7+17), and bleed off the water with a power-
drill pump at pos. 8.
WARNING ! • Do not use the relief valve (pos. 4, fig. 6.45) as bleed valve as it will easily
begin to leak.
Fig. 6.54
1 Power-drill pump
2 2 Hose for water bleeding
valve
1
NOTE: Check the arrow on the

pump to ensure correct flow
direction. It may leak if the direc-
tion is wrong.

Fig. 6.55
1 Old dust collector for the
2 cooling system for frequency
1 converter.
2 New dust collector for the
cooling system for frequency
converter.
Clean the filter element and re-

use the O-ring if it´s an old dust
collector. ( 1)
9
Fig. 6.56
1 Filter element.
2 O-ring.
1
Change the filter and the O-ring if
it´s a new dust collector.
• Measure the air pressure on the expansion tank: 0.5 bar +/- 0.1 bar.
• If the pressure is below 0.1 bar, do not refill. Replace expansion tank in-
stead.
• Pos. 9 if it´s an old dust collector clean the filter element and reuse the
O-ring.
• Pos. 9 if it´s a new dust collector change the filter element and the O-ring.
• When the system is without pressure, check that the pressure transduc-
er read-out on the hand terminal is 0 bar +/- 0.1 bar.
• Add coolant until the pressure is 1.5 bar on the hand terminal. Check the
pressure transducer hand terminal readout with a calibrated manometer
attached at pos. 10.
• Open both ball valves upon completion of service check. (Pos. 7+17)

WARNING ! If no transparent plastic shielding is in front of the cabinet:
Fig. 6.57
dU/dt filter and dU/dt filter and dU/dt filter and

sharing reactor sharing reactor sharing reactor
position 1 position 2 position 3
Generator CDC*1
(control computer)
Bleeding valves Bleeding valves

Network CDC*1
(control computer)
Generator SMPS
position 1
Network SMPS*2
Network SMPS position 3
position 1
Grid measurement Generator SMPS
module position 3
Ribbons for
DELTA network control
*3
I/O panel DIB Delta
Interface Board Ribbons for
Generator control
+ DC LINK
Coolant and Heating elements

bleeding hoses*4 in manifold access
CDC - WTC-3 from side panel
Cobber to optical
converter DC fuses - DC LINK
Interface to
A1 & A2
*
References zoom on the following pages for detailed information
• Cut out the main switch.

• Switch off F1.1 and F4.1 in the A1 cabinet.
• Check with a multimeter that all systems near the bleed valves are dead
IMPORTANT !! Fig. 6.57 is the procedure to follow before bleeding if no transparent plastic
shielding is in front of the cabinet.
Fig. 6.58.
Open the valves in the frequency
converter cabinet.
2
When fluid is seen in the trans-
parent hose, close the valve (2).
• When adding water, bleed with a test hose at (pos. 10).

• Check that the water pump functions, and listen for air in the pump dur-
ing circulation.
• Bleed at (pos. 10) the pump and screw (pos 18) and the frequency con-
verter valves (fig. 6.56).
• Add coolant until 1.5 bar is attained.
• Wipe the entire cooler system clean.
• Check for leaks in the cooler system after 30 minutes’ operation.
• Remember to open both ball valves upon completion of service check.
(Pos. 7+17)
Fig. 6.59
Position the overflow container.
1. Container for cooling system.
2. Container for frequency con-

verter.
2
1
Fig. 6.60
The cooler fan for the water cool-
ing system is placed outside the
tower under the staircase.
The cooler under the staircase must be cleaned at the service visit. The cooler
must blow upwards, which is checked both at low speed and high speed fan op-
eration.
• Check the water cooler for leaks / cracks and corrosion of cooler fins.
• Suck dirt out of the cooler with a heavy-duty vacuum cleaner (new bag
and filters increase the suction dramatically!).
• Point the beam of a flashlight through the fins. If the air passage is still
not free, start the fans and spray with an oil-soluble fluid (if motor clean-
er is used, always end by using oil-soluble fluid to dry the fins complete-
ly as dirt will otherwise build up again very quickly). Wait until the cooler
is completely dry and finally vacuum again. (Note: If the cooler is wet
from the oil-soluble fluid it may cause the vacuum cleaner to explode!)
• If the air passage is still not fully open, inject compressed air or nitrogen
and use pressure reduction equipment at approx. 10 bar.
• If the cooler sweats 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.
• Check data module capacitor fan operation and monitoring.
• Visually check all electrical connections for signs of heating.

Cleaning Check plug and socket connections in the frequency converter, and clean with a
vacuum cleaner.

- Chapter 07 TOWER

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 07 TOWER
SWT - 2.3 - 82VS/93/101
• Service and maintenance of tower

yyyy)

- Chapter 07 TOWER
Document history
ECN no. Rev. Date Description for changes

no.
ECN30446 R0 10-02-2009 Added in ZSM1005840 for SWT-2.3-

82VS/93/101

- Chapter 07 TOWER
Service and maintenance of tower
Bolt tightening See “Chapter 04 BOLT TIGHTENING ONSHORE”
The following connections must be tightened:
• foundation bolts
• tower joints
• platforms
• tower damper (Option)
Tension If the tower has been tightened with tensions, there will be a sign inside the tower
indicating this.
• See “Chapter 17 TENSION”
Visual check of foundation Visually check for cracks and damage to foundation/grouting and railing. (If any
and railings (option) of the above are observed, contact Siemens Wind Power’s Service Department.)
Visual check of tower access Visually check the stairs / railing for damage and tighten the bolts if necessary
staircase (option)
Check of foundation bolt caps 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.
WARNING ! The caps must only be screwed on to the bolts. Never hammer the caps on.
Procedure for inspecting of Welds in and around flanges must be inspected to ensure that any cracks forming
welds on tower in these areas are discovered as soon as possible.
IN THESE AREAS, CRACKS ARE ABSOLUTELY UNACCEPTABLE!
If, however, a crack is discovered in one of these areas, contact the Service De-
partment at Siemens Wind Power A/S.
The following welds require 100% visual inspection:
• all welds in and around flanges.
Welds in and around the door and the bottom flange must be inspected both in-
side and outside.
When inspecting these areas it is important that:
• all surfaces are meticulously cleaned of e.g. grease, dirt, loose paint, etc.
• the light conditions are satisfactory.
• since the welding check is only visual, the entire seam must be very thor-
oughly checked.

- Chapter 07 TOWER
Visual inspection of door Check the rubber weather seal and door locking mechanism.
Visual check of paint work for Check the tower paint work for signs of corrosion. If there are signs of corrosion,
corrosion please contact the Service Department at Siemens Wind Power A/S.
Painting repair procedure for See Chapter 18 - Painting repair procedure for towers.
towers
Visual inspection of the fall ar- Visually check that the wire is not damaged.
rester and anchorage points
Visually check the anchorage points for defects and significant wear. Should
these be visibly defect, they must be replaced and returned to Siemens Wind
Power A/S
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 pre-
pared 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 mount-
ed before starting the work
Visual inspection of the plat- Visually check the platforms and brackets for damage and tighten the bolts if nec-
forms and brackets essary.
Pay special attention to welded brackets placed close to round and long seams
in the tower. Check the welding of these brackets and their immediate vicinity for
cracks and other damage.
Notify the Service Department at Siemens Wind Power A/S if any cracks are
found.
All brackets placed closer to the round and long seams than approx. 3 times the
width of the welding must be checked.
Fig. 7.0
1 Bracket placed on/close to
welded round/long seam.

- Chapter 07 TOWER
Checking of tower damper Fig. 7.1

1 Bearer bolts.
Visually check the tower damper

for damage, and retighten the
bearer bolts.
Checking of service lift in tow- • See: chapter , “Chapter 27 SKY MAN TH250 SERVICELIFT (option),” - (ser-
er (option) vice/ repairs may only be performed by authorized personnel).
• The wire rope for the service lift must be checked/adjusted at first service visit.
• The wire rope counterweight moves up or down depending on the load. If the
rope end hits the floor plate, the rope must be shortened/adjusted after a pe-
riod of usage, because it initially stretches somewhat.
Fig. 7.2
1. Wire rope for counterweight
2. Wire clamp
1
2
1
2
• Check the wire rope for kinks, compression damage, ripping, unwinding, se-
vere formation of corrosion, and reduction of the rope diameter to less than
7.6 mm measured on unloaded rope. A maximum of 8 individual strands are
permitted to be broken for each 240 mm of rope.
• The counterweight must engage a minimum of 10 mm of rope when the chair
is at the top, and the counterweight may not rest on the platform when the
chair is at the bottom.
• The wire clamp must be of the correct model, be tightened, and securely
fixed.

- Chapter 07 TOWER
Fig. 7.3
1. Wire for block stop
2. Lock nut
• Check the block stop wire for kinks, compression damage, ripping, unwinding,
severe formation of corrosion, and reduction of the rope diameter to less than
7.6 mm measured on unloaded rope. A maximum of 8 individual strands are
permitted to be broken for each 240 mm of rope.
• Check that the lock nut is mounted and tightened. Also check that the lock
nuts on the large turnbuckle are tightened.
• Turnbuckles may not be tightened to such an extent that they cannot be re-
adjusted.
• The wire must be pretensioned to between 50 and 100 kg.
Visual inspection of dehumid- Visually check that the system is working and the drain is connected correctly.
ification system in tower (op-
tion) • Test the hygrostat by turning it up and down, and check that the dehumidifier
starts and stops.
• Set the hygrostat to (40%).
• Replace the filter.
Fig. 7.4
1. Dehumidification system.
1 No dehumidifier on US model
(option).
Fig. 7.5
1. Hygrostat.
1 No hygrostat on US model (op-

tion).
1
2

- Chapter 07 TOWER
Fig. 7.6
1. Replace filter for hygrostat
system.
1 NOTE!
When installing the new filter, the

arrow must point towards the hy-
grostat.
Check and replacement of fil- Fig. 7.7

ter in tower door (option). Filter in tower door.
Fig. 7.8
Replace filter.

- Chapter 07 TOWER

- Chapter 08 NACELLE

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 08 NACELLE
SWT - 2.3 - 82VS/93/101
• Nacelle
• Check the liquid level of the tower damper in the nacelle. (option)

yyyy)

Document history

no.
ECN30446 R0 10-02-2009 Added in ZSM1005840 for SWT-2.3-82VS/93/101
ECN30997 R1 30-03-2009 Check of the liquid level of the tower damper in the
nacelle added. (page 168)
ECN32453 R2 10-09-2009 Figure 8.0 - 8.1 : The items has been modified.
Page 6 - New point added -When measuring there

is a tolerance on +/-5mm.

Nacelle
See “Chapter 04 BOLT TIGHTENING ONSHORE” Torque wrench settings.
Front nacelle cover suspen- Tighten the bolts holding:

sion
• the front nacelle cover suspension to the nacelle bed plate.
Fig. 8.0
1. The front nacelle cover sus-
pension.
1
2. Bolts for nacelle cover sus-
pension / nacelle bed
plate.(front)
3: Bolts for the lockplate to na-

celle suspension axle. (front)
3 4: Bolts for nacelle cover sus-

2 4 pension. (front)
Rear nacelle cover suspen- Tighten the bolts holding:

sion
• the rear nacelle cover suspension to the nacelle bed plate.
Fig. 8.1
1. Nacelle cover suspension.
(rear).
2
2. Bolts for nacelle cover sus-
pension / nacelle bed plate.
(rear).
3: Bolts for nacelle cover sus-

pension. (rear)
1
4: Bolts for the lockplate to na-
3 4 celle suspension axle. (rear)
Nacelle hatch hinges • Visually check the wires on the hatches.

Fig. 8.2
1. Hatch hinge
Retighten the bolts of the nacelle

hatch hinges.
Check of hatch wire Visually check the hatch safety wires for damage
Nose cone (hub cover) Retighten the nose cone/hub brackets
Check of sealing strips in the Visually check that all sealing strips are intact and firmly attached.
nacelle
Inspection of the service Se: Kapitel 15, “Appendix - Installation and service manual for service crane,”
crane
Inspection of anchorage Visually check the anchorage points for defects and significant wear. In case they
points have visible defects, replace the parts and return them to Siemens Wind Power
A/S.
Check tower / nacelle rubber Fig. 8.3

collar for sealing Check the rubber collar, and lu-
bricate with yaw grease.
1
Visual inspection of dehumid- Visually check that the dehumidifier works.

ifier (option)
• Test the hygrostat by adjusting it up and down. Check that the dehumid-
ifier starts and stops.
• Adjust hygrostat to the original level (40%).
• The air filter must be changed annually.

Fig. 8.4
1.Dehumidifier (option)
Fig. 8.5
1 Replacement of the dehu-
midifier salt filter.
1 Note!
When fitting a new filter the ar-

row on the filter must point to-
wards the dehumidifier.

Check the liquid level of the tower damper in the nacelle

(option)
General The volume of liquid in the tower damper is determined by the oscillation frequen-
cy 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 en-
sure that a correct measurement is obtained.
The oscillation frequency can be read in the handterminals MENU 16 “WTC Ser-
vice 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 below
to determine whether the tower damper contains the correct volume of liquid.
Conversion table for liquid Fig. 8.6

level in tower damper
Measurement of liquid level in • The liquid container of the tower damper in the nacelle can be found un-
tower damper der the coupling close to the oil filter.
• Measure the liquid level by means of a tape measure against the recom-
mended liquid level (specified in the conversion table above).
• When measuring there is a tolerance on +/-5mm.
Fig. 8.7
Unscrew the filler plug from the
1 2 tower damper, and insert a clean
dipstick vertically into the filling
hole until it reaches the bottom of
the tower damper.
1 Plug for liquid container.
Pull out the dipstick, and mea-

sure the liquid level on the dip-
stick with a tape measure.
2 Tape measure.

Topping-up of tower damper Use a BASF Glysantin mixture in the tower damper. Use 33% mixture in standard
turbines and a 50% mixture in cold climate turbines respectively. See the site set-
up to determine turbine type.




- Chapter 09 YAW SYSTEM

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 09 YAW SYSTEM

SWT - 2.3 - 82VS/93/101
• Yaw system
• Service and maintenance of the yaw system

yyyy)

Document history

93/101
ECN30997 R1 24-06-2009 New fig.

Yaw system
WARNING ! USE YAW LOCK AND ROTOR LOCK WHEN WORKING ON YAW CLAWS /
TEETH, WHEN REPAIRING ON THE OUTSIDE OF THE TURBINE AND WHEN
USING AN EXTERNAL CRANE BY / ON THE TURBINE.
IMPORTANT !! See: , “Chapter 02 TURBINE SAFETY INSTUCTIONS,”
Please note that the “Basic Health and Safety Rules” for service technicians
working in Siemens Wind Power’s turbines, SI 545781, always apply.

Service and maintenance of the yaw system
Description of the yaw system Yaw movement is driven by 8 electric motors, each mounted on a 4-step plane-
tary gear with a yaw pinion meshed with the yaw plate. The motors are controlled
by a joint frequency converter. The yaw brake is passive, based on the friction
from the yaw plate. The frequency converter and the yaw plate hold the nacelle
in place when it is not yawed. The yaw system will slip if there are very large loads
or no power.
Testing the yaw motor Measure the power consumption on each motor and each phase with a clamp
ammeter. A single motor without consumption is not accepted when the others
have a consumption. A single motor with a consumption of 30% above the others
is not accepted.
Tightening of the yaw gear Tighten the bolts holding the:

bolts
• yaw gear level 1 to level 2.
• complete yaw gear to the nacelle bed plate.
Yaw gear Fig. 9.0

1. Yaw gear..
See lubrication chart in “Chapter

05 LUBRICATION” on page 105.
1

Checking the yaw gear oil lev- • Check the oil level on the oil level gauge. The oil level must be between
el the lower and the upper sight glass. If the bottom sight glass is not full,
add oil until it is just visible in the top sight glass.
• When adding oil, connect the hose from a pressurized oil container to
the oil drain valve (4). Oil type: see the lubrication chart in Chapter 5.
• When draining oil from the yaw gear, connect the hose from an empty
pressurized container to the filling nozzle (3) and a hose from the drain
valve (4) to an empty container or a vacuum cleaner.
Fig. 9.1
1. Motor.
1
2. Yaw gear
3 3. Oil filling hole/bleed valve.
4. Oil drain valve.
5. Upper oil sight glass.
6. Lower oil sight glass.

5
6
2
Dismantling the yaw gear Fig. 9.2

1. Pull-out bolt
Use the 3 external pull-out bolts

when dismantling the yaw gear.

Yaw claw bolt tightening Tighten the bolts securing the:
• yaw claws to the nacelle bed plate

• Tighten the adjustment bolts (See: 4, “Bolt tightening,” )
Fig. 9.3
1. Yaw claw.
1
2. Bolts for yaw claws.
3
1
4 3. Adjustment bolts (vertical)
3
4. Adjustment bolts (horizontal)
2
2
Tightening of bolts in tower/ Tighten the bolts holding the:

nacelle joint
Tower /nacelle (see chapter 4 - Torque Wrench Settings-onshore).
Checking the central lubrica- The yaw pinion, yaw gearwheel, sliding shoe holders and sliding shoes are lubri-
tion system for the yaw pin- cated by the central lubrication system - See Chapter 5 - Lubrication.
ion, yaw gearwheel, sliding
shoe holders and sliding • Check the lubrication of the teeth and check for wear on the teeth.
shoes • Visually check couplings for leaks at pump, distributor block and inlet.
Starting the lubrication system.
• Use the remote control, menu 24 - screen 14.

• Press”.” for Start
• Press”.” for Stop
• Press ESC - the lubrication will now continue until the cycle is finished.
• Read “grease total”, and check that it increases when activated.
• Check the “low level sensor” by removing the plug from the lubrication
system and inserting a jumper between pins 1 and 3 on the plug, thereby
obtaining a fault indication.
• Check the direction of rotation of the agitator in the grease container.
Fig. 9.4
1. Central lubrication system for
1 sliding shoe holders, yaw pinion
and yaw gearwheel.

Topping up the lubrication The following is important to observe when topping up the system
system for the yaw system
• Dirt and impurities in the grease is not accepted as this will cause the
pump element to malfunction.
• The 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: 5, “Lubrication,” .
Fig. 9.5
1. Fill the container with grease
using a pump.
Fig. 9.6
Connect the hose to the quick-
acting coupling on the pump
housing.
Fig. 9.7
Screw the grease cartridge into
the pump base.
Pump either 6 kg or 12 kg into

the grease container depending
on the size of the container. (Two
sizes are used).
1 Remove the hose after filling.

Yaw position indicator The yaw position indicator prevents overtwisting and subsequent breaking of both
the main power cables and the controller cables.
• The turbine untwists the cables when they have twisted 1.5 revolutions.
Untwisting will only take place if the wind speed is below 3.5 m/s.
• The turbine will under all circumstances untwist the cables if they are
twisted more than 1.6 revolutions.
Maintenance of yaw position The following must be checked and done.

indicator
• Check that the direction readout on the display is correct compared to
the nacelle position.
• Check the cables are not overtwisted.
• Check that the yaw position indicator is correctly tightened and that the
nylon gearwheel and the yaw ring are properly meshed.
• Yaw the turbine so that the cables hang straight, i.e. are fully untwisted.
Adjusting the yaw position in- • Use a compass to check that the nacelle is pointing “North”.
dicator • See also MENU 24 in the Operating Manual.
Fig. 9.8
Remove the cover from the yaw
position indicator.
Fig. 9.9
Loosen all screws, and push the
large gearwheel away from the
small gearwheel.

Fig. 9.10
Turn the large gearwheel to the
right or to the left until the yaw
position indicator is at 0° (the di-
rection is shown on the display).
Push the large gearwheel back

into mesh with the small gear-
wheel (not too tight). Tighten the
screws and mount the cover.
• Check the main cables for the number of twists (left or right)
• Type the number of twists on the display (+ = CW / - = CCW).
Cable twist switch The function of the cable twist switch is to stop the turbine when the nacelle has
turned 3 revolutions either CW or CCW.
Fig. 9.11
Cable twist switch with a weight
connected to the steel wire and
1 running in a plastic tube.
Maintenance of the cable twist The following must be checked and done:
switch
• Visually check the cable twist switch and the steel wire for correct instal-
lation.
• Remove the cover from the switch, visually check the terminals for cor-
rosion, and pull the wires to check that they are firmly attached.
• Check that the twist switch is correctly adjusted to “0” when the gener-
ator cables are hanging straight down in the tower.
• Shorten the twist switch wire to such a length that only 3 revolutions are
accepted before it trips
• Activate the cable twist switch to check that the controller responds cor-
rectly.

Checking of wind vane and Check that:

anemometer
• Wind vane and anemometer are securely fastened.
• The cups are correctly fitted and intact.
• Heating element option)
Fig. 9.12
1. Anemometer.
2. Wind vane.
2 1
Folding down the wind vane Please note that the “Basic Health and Safety Rules” for service technicians work-
stand ing in Siemens Wind Power’s turbines, SI 545781, always apply.
Fig. 9.13
Secure 2 fall arresters of 2
meters each to the back of the
harness...
2 1
Fig. 9.14
...and to both anchor bolts at the
rear of the turbine.
2 1

Fig. 9.15
Remove the bolt through the
middle of the wind vane stand.
2 1
Fig. 9.16
Fully remove the top bolt (1) at
the root of the wind vane stand,
and loosen the bottom bolt (2)
1 only just enough to allow move-
ment of the wind vane stand.
Fig. 9.17
Remove the cable cover.
2 1
Fig. 9.18
Lift the wind vane stand with a
crowbar, using the wind vane fix-
ing bracket as support.
Be careful not to damage the ca-

bles with the crowbar.
2 1

Fig. 9.19
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.
2 1
Fig. 9.20
Gently lower the wind vane stand
onto the generator 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.
2 1
Fig. 9.21
Raise the wind vane stand again
following the opposite proce-
dure.
2 1



- Chapter 10 TRANSMISSION SYSTEM

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 10 TRANSMISSION SYSTEM

SWT - 2.3 - 82VS/93/101
• Service and maintenance of the transmission system
• Main bearing and main shaft
• Gearbox
• Oil filter for gearbox
• Generator
• Hgh-speed contrifugal release unit
• Testing the low-speed monitoring unit
• Alignment of generator
• Generator alignment with laser equipment”
•

yyyy)

Document history

93/101
ECN30997 R1 30-03-2009 Added link to AI-WI566637 - Generator

alignment with laser equipment.
Grease discharge added

Service and maintenance of the transmission system
ENGAGED.
THE HS ROTOR LOCK MUST BE ENGAGED WHILE WORKING ON THE

TRANSMISSION.
“BLUE BRAKE HANDLE” - VALVE (252) ON THE HYDRAULIC STATION

MUST BE IN “SERVICE MODE ON”
IMPORTANT !! See “Chapter 02 TURBINE SAFETY INSTUCTIONS”
Please note that the “Basic Health and Safety Rules” for service technicians
working in Siemens Wind Power’s turbines, SI 545781, always apply.

Main bearing and main shaft
Main bearing housing Fig. 10.0

1. Main bearing housing.
2. Central lubrication system.
Tightening of bolts securing Tighten the bolts securing the:

the main bearing housing
• main bearing housing to the nacelle bed plate.
• labyrinth ring.
• bearing cover to the bearing housing.
Tightening of bolts securing Tighten the bolts securing the:

the hub
• hub to the main shaft.
Checking the central lubrica- The main bearing is lubricated by the central lubrication system. See Chapter 05
tion system for the main bear- LUBRICATION” .
ing
• Visually check the couplings for leaks at pump, distributor block and in-
let.
Starting up the lubrication unit:

• Read “grease total” and check that it increases when activated
system and inserting a jumper between pins 1 and 3 in the plug, thereby
Topping up the lubrication The following is important to observe when topping up the system
system for the main bearing
with grease • Dirt and impurities in the grease is not accepted as this will cause the
difficulties for the agitator in getting the air out of the product. The spe-
cific temperature depends on the type of grease.
• For volume and type of grease, See chapter 5 - lubrication.

Fig. 10.1
1. Fill the container with grease
using the pump.
Fig. 10.2
Connect the hose to the quick-
acting coupling on the pumping
housing.
Fig. 10.3
the base on the pump.

on the size of the container (we
use two different sizes).
1 Disconnect the hose after refill-

ing.

Drip plate Fig. 10.4

1. Drip plate
Empty and clean the drip plate.

1
Grease discharge Fig. 10.5

1. Grease discharge
Empty the 25L plastic can.

1
Lubrication of labyrinth seal Fig. 10.6

1. Labyrinth seal
Turbine must be idling.
1 See “Chapter 05 LUBRICA-

TION”

Gearbox
See “Chapter 13 COMPONENTS AND DIAGRAMS”
Oil level in the gearbox Fig. 10.7

(Winergy gear)
1
1. Oil level glass.
The oil level must be to the mark

on the level glass
Fig. 10.8
(Hansen gear)
1. Oil level glass.
The oil level must reach the mark

on the level glass.
1
Sampling of gear oil See lubrication chart, Chapter 05 LUBRICATION” .
When adding oil to the gearbox, open the gearbox cover, and add the correct
quantity.
Check the oil level sensor Check that the oil level sensor is connected to the controller:
• Disconnect plug (DI 8) in A3 - K2

• Read the error message on the hand terminal.
• Replace the oil level sensor in case of malfunctioning.(Replace the entire
oil level sensor. The sensor and oil container are callibrated as one unit.)
Checking the pressure trans- Check the pressure transducer for gearbox oil pressure by watching the display -
ducer for gearbox oil pressure MENU 2, screen 10.
• Mount the manometer (700 bar, class 0.1 up to 400 bar) on the test nipple.
• Read the pressure.
• Check the display of the hand terminal to ensure that the pressure is the
same as on the manometer.

Fig. 10.9
(Winergy gear)
1 Pressure transducer for gear

oil.
2 Test nipple.
1
Fig. 10.10
(Hansen gear)
1
1 Pressure transducer for gear
oil.
2. Test nipple.
Oil pump on gearbox Fig. 10.11

(Winergy gear)
1. Pump for oil cooler.

1
Check the oil pump for leakage.
(Leakage may occur in the shaft

seal between the pump and the
motor)
Fig. 10.12
(Hansen gear)
1. Pump for oil cooler.
1 Check the oil pump for leakage.
(Leakage may occur in the shaft

seal between the pump and the
motor)
Idle pump, valve and filter on • At 10-year service: replace idle valve.
gearbox • At 10-year service: replace idle pump
• At 1-year service: clean coarse filter in idle pump.

Gearbox idle pump Fig. 10.13

1. Idle valve.
2. Idle pump
1
3
3. Coarse filter.
Fig. 10.14
Check the oil flow through the
idle pump.
Dismount the coarse filter (1)

and allow the turbine to idle -
now oil should come out at the
coarse filter.
1
(Remove spilled oil with a cloth)
NOTE ! Tighten bolts in gear oil flange joints
Oil cooler for gearbox Check the oil cooler for leakage / cracks and cooling fins of the radiator for corro-
sion.
When replacing the hoses, check that the cooler is not clogged up.
Cleaning the outside of the oil cooling radiator fins (see Fig. 10.17):.
• Vacuum the cooling radiator with a powerful vacuum cleaner (a new bag
and filter increase suction significantly)
• Point a flashlight through the cooling fins. If the air passage is still not
perfect, start the fans and spray on Metal-clean (if motor cleaner is used,
always finish with Metal-clean in order to make the fins completely dry,
as dirt will otherwise quickly accumulate). Wait until the radiator is com-
pletely dry and finish by vacuuming again. (Note: If the radiator is wet
with Metal-clean, the vacuum cleaner may explode.)
• If the air passage is still not perfect, use compressed air or nitrogen and
pressure reduction equipment approx. 10 bar.
• If the radiator 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.
Inspection of drip plate (see Fig. 10.16):
• If any fluid is seen in the drip tray, this must be sucked out.

Fig. 10.15
1. In order to inspect the radiator
the checker plate cover must be
removed
Fig. 10.16
1. In order to see the radiator it is
necessary to stand on the grate.
2. Suction hole for drip plate
1
2
Fig. 10.17
1.Oil cooler
Clean the cooling fins

Testing the direction of rota- Fig. 10.18

tion of the oil cooler fan. 1. Inspection hatch for fan.
Fig. 10.19
1. Fan.
Start the ventilator by activating

the switches in the top box. Test
the direction of rotation at low
speed and high speed (if both
are available) by feeling if air
blows upwards.
IMPORTANT !! Replace rubber hoses every 7 years.
Replace Thermoplast hoses every 10 years.

Oil filter for gearbox
In-line filter for gearbox Fig. 10.20

1 In-line filter.
(Fairey Arlon filter)
Replacement of in-line filter See chapter 5 - Lubrication

element
Fig. 10.21
(Winergy gear)
1
1. Valve on gear.
Fig. 10.22
(Hansen gear)
1. Valve on gear.

Fig. 10.23
(Winergy gear)
1. Pump screw
1
Fig. 10.24
(Hansen gear)
1. Pump screw
1
(*) = To start the pump, go to MENU 30 - Test switches.
• Press 9 (DAHL 9 in zero position).

• Press ESC.
• In MENU 25, go to output control.
• Find gear oil pump Low-speed in the controller documentation.
• Use the arrow keys to find the required output.
• Press “.” to activate output.
• After testing, reset the computer in MENU 3.
• Close the valve on the gear (1).
• Close the filter bleeding valve (2).
• (*) Start the pump.
• Remove the pump screw (3).
• Run the pump until bubbles are heard at the return hose. The filter has
now been pumped full of air and empty of oil.
• Fit the screw (3) while the pump is running.
• Repeat the procedure 2 - 3 times.
• Remember to open both valves and tighten the screw after replacing the
filter.

Fig. 10.25
Fit a hook or lifting strap on the
cross bar of the filter.
Use the service crane for lifting

out the filter element carefully,
and allow the oil to drip off.
Fig. 10.26
The filter element is taken apart
by removing the nut at the bot-
tom of the element.
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 housing).
Fig. 10.27
Pack the filter element in a bag.
Then transport the element down

by using the service crane.
Dirt on the filter magnets Estimate the pollution of the magnets when replacing the filter.
• In the inspection check list, note the number corresponding to the de-
gree of pollution of the magnet.

Fig. 10.28
(1.) - Completely clean.
Fig. 10.29
(2.) - Slightly polluted.
Fig. 10.30
(3.) - Medium polluted.
Fig. 10.31
(4.) - Heavily polluted.
Fig. 10.32
(5.) - Very heavily polluted.

Fig. 10.33
Clean the magnets of the filter.
Fig. 10.34
Fit a new filter.
Fig. 10.35
1. Assemble the filter housing
and cross-tighten to 400 Nm.
WARNING ! Check for leakages. Check if the seal / O-ring is intact.
Air filter for gearbox Fig. 10.36

(Winergy gear)
1 Replace the air filter ele-

ment.

Fig. 10.37
(Hansen gear)
1. Replace the air filter element
Ball valve filter for bleeding of Interval: See “Chapter 03 INSPECTION AND MAINTENANCE”
in-line filter.
Fig. 10.38
1. Ball valve filter fitted in gear-
box.
Clean ball valve filter - (only after

the first year of operation).
Fig. 10.39
(Hansen gear)
1. Ball valve filter fitted in gear-

box.
Clean ball valve filter - (only after

1
the first year of operation).
Fig. 10.40.
Dismantling of ball valve filter.

Off-line filter for gearbox Fig. 10.41

1. Off-line filter.
(C.C. Jensen filter)
Replacement of Off-line filter Interval: See Chapter 05 LUBRICATION” .

element
Before replacing the filter cartridge, the filter housing must be drained of oil.
• Stop the pump for the filter and turn off the valve at the gearbox.
• The hand pump is fitted to the draining valve of the filter, which is
opened. Air is then pumped into the filter, which will press oil through
the return hose to the gearbox. When air is audible in the return hose,
wait for minimum 5 minutes and pump again (procedure is repeated 3
times).
• Bleed the filter after draining by loosening the bleed plug at the top of the
filter housing.
• Remove the top nut and remove the filter cap carefully. Unscrew the
wing nut and remove the spring and the spring guide. Remove the filter
element and pack it in a bag.
• After checking the seals, a new filter element may be fitted in the filter.
Before the spring guide and the spring are pressed into place, check that
the o-ring is placed correctly in its groove. The wing nut is tightened
loosely and then tightened another 4 turns approximately. The filter cap
is fitted and the top nut is tightened.
• The hand pump is removed, the draining valve is closed and a plug is fit-
ted (the draining valve may leak).
• Clean the filter and the surrounding area of oil.
• Open the valve at the gearbox, start the filter and let it run for a minimum
of 15 minutes. Then check for leakage and for pressure on the filter (It is
OK for the pressure to be in the red area if the oil is cold).
• Bleed the filter
• Check oil level in the gearbox.

Fig. 10.42
1. Valve at gearbox.
1 4
2. Draining valve on filter.
3. Hand pump.
5 4. Bleed plug.
5. Top nut.
3 2
Fig. 10.43
The off-line filter is dismantled
2 and the element is packed in a
bag.
1. Filter element.
2. Wing nut.
Repair the gearbox Use Low-speed lock (See “Chapter 02 TURBINE SAFETY INSTUCTIONS” ).
Gearbox suspension Fig. 10.44

1. Rubber bushing in gearbox
suspension.
Fig. 10.45
Visually check rubber bushings
for significant cracks and bulg-
ing.
Contact the service department

at Siemens Wind Power A/S if
damage is found.

Retightening of bolts secur- Retighten the bolts securing the:

ing the gearbox suspension
• gearbox suspension to the nacelle bed plate.
• shaft end plate to the gearbox suspension
Retightening of bolts secur- Fig. 10.46

ing the shrink element 1. Retighten the bolts securing
for main shaft / gear shrink ele-
1 ment.

Generator
Generator suspension Fig. 10.47

1. Generator suspension.
Retightening of bolts secur- Retighten the generator suspension bolts.

ing the generator suspension
Lubrication of the generator The generator bearings are lubricated by the central lubrication system. See
bearings Chapter 5 Lubrication.
• Visually check joints for leaks at pump, distributor block and inlet.
Starting up the lubrication unit:

• Press”.” for Start.
• Press”.” for Stop.
• Read “grease total”, and check that it increases when activated.
system and inserting a jumper between pins 1 and 3 in the plug, thereby
Refilling the lubrication sys- The following is important to note when refilling the system
tem for the generator bearing
• Dirt and impurities in the grease are not accepted as this will cause the
• The lubrication system with follower plate must be filled completely to
force air out of the escape valve.
difficulties for the agitator in getting the air out of the product. The spe-
cific temperature depends on the type of grease.
• For volume and type of grease, see Chapter 5 Lubrication.

Fig. 10.48
1. The container for the automat-
ic lubrication system must be
filled with grease.
Fig. 10.49
Connect the hose to the quick
coupling on the pump housing.
Fig. 10.50
the base on the pump.

on the size of the container (we
use two different sizes).
1 Disconnect the hose after refill-

ing.

Front generator drip plate Fig. 10.51

1. Empty the front generator drip
plate.
Fig. 10.52
1. Empty the rear generator
grease drip plate.
Cooling system for generator Fig. 10.53

1. Cooling system.
Check that the cooling system

and the generator fan are bolted
tightly together.
Rotor bypass system on the Clean carbon brushes and slip ring - At the D-end:
generator
• Clean the carbon brushes.
• Clean the slip ring on the rotor.
• NOTE: Only use dry rags for cleaning, do not use any cleaning agents.
•
Clean bearing liner on both end shields:
• Using a rag and some solvent, ensure all dirt and grease are cleaned
away. Clean both the inner part and the outer part which is within 5 cm
from the insulation.
Replacement of carbon brush:

• Replace bypass brush every year.
Measure resistance - at D-end • Measure the resistance with a calibrated resistance measuring device.
where carbon brushes are Hold one probe on slip ring and the other on chassis ground. Measure
mounted (resistance mea- the resistance and make sure it is less than 1 Ohm.
surement) • Write down the value.
Fig. 10.54
1 Brushes mounted.
3 2 Point of measurement (slip
ring).
3 Insulation
1
Fig. 10.55
1 Point of measurement for
chassis ground (place where
no paint is present).
Measure bearing insulation - • Remove the brushes from the brush holder, and place them on top of the
at D-end where the brushes bypass brush holder so that they do not touch anything but the brush
are lifted (insulation testing) holder.
• Use a calibrated resistance measuring device (Megger) which measures
resistance at 1000 V DC. Place one probe on the slip ring of the rotor and
the other probe on chassis ground. Measure the resistance for one
minute. The value must be above 1 GOhm. Write down the insulation val-
ue.

Fig. 10.56
1 Brushes lifted.
3 2 Point of measurement (slip
ring).
3 Insulation.
1
Fig. 10.57
1 Point of measurement for
chassis ground (place where
no paint is present).
Check the main terminal box:
• Remove the main terminal box cover

• Check for dirt and debris, clean if necessary
• Replace the main terminal box cover
WARNING ! The bearings must be kept insulated. After any service work has been done
to the machine, 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 around the air channel that could obstruct the air flow. Do not
place anything on the machine that could fall into the air channel.

High speed centrifugal release unit
Checking the HCU (manually See how the test is carried out in MENU 25-OUTPUT CONTROL in user's manual
when the turbine is stopped) for wind turbine controller in the HCU test paragraph (in some program versions
the text is blade tip test instead of HCU test).
Check that:
• the disc brake is activated when the “fuse” (piece of stainless steel pipe)
is removed.
• the whole unit looks as it should, i.e. no corrosion, bolts are well tight-
ened etc.
• the weight levers can be moved without resistance (use an adjustable
spanner).
• the Allen bolts for the HCU halves are well tightened.
• the fuse holder holds the fuse tightly.
• Test by rotating the high speed shaft (1 revolution - manually), that the
weight lever knocks the fuse out of the fuse holder.
WARNING ! The rotor must not rotate backwards when the fuse is fitted
Fig. 10.58
1. The HCU is installed between
the gearbox and the coupling.
Fig. 10.59
1. Weight lever.
1 2. Fuse.

Testing the low speed monitoring unit
LMU - Low speed monitoring unit
Independent monitoring of the LS shaft is incorporated through the WTC3 as an

additional safety measure. The monitoring is carried out through the monitoring
module “low speed monitoring unit (LMU)”. This chapter describes the following
code modules.
• LMU.MOD
1.1 Monitoring - A message is sent when the following conditions are met:
• The LMU is not in active test condition and

• The digital input is low for more than 100 [ms]
A message is sent when the speed difference between the LMU and the main
shaft exceeds the max. RPM deviation.
LMU monitoring is interrupted if the test signal is set to 0. This function is removed
as soon as all turbines with hardware profiles which support LMU are upgraded
with LMU.
1.2 Testing (Service function) - The LMU can be tested in two different ways:
• Automatically
• Manually
For both test types the manual switch 608.S1 must be set to service mode.
These tests are handled via the hand terminal, menu 24, screen 22 if the following
test conditions are met...
• The manual stop must be activated

• LS-RPM < 4 RPM
The test type is selected in the shown screen:
• ‘LMU test xx/xx'

• 'Activate RPM switch '
• 'Test type: Automatic/Manual '
• '[<]or[>]=Change type [EXP]=Execute test '
1.2.1 Automatically
The automatic test confirms that the LMU is connected correctly (Hardware) and
that the LMU is able to detect overspeed (Alarm OK).
During the test the following screen is shown:
• 'LMU automatic test '

• 'Result: Hardware | Alarm OK '
• ' Test running... '
• '[ESC]=Exit [EXP]=Execute test '

After the test the test results are shown:
• 'LMU automatic test '

• 'Result: Hardware | Alarm OK '
• Failure '
• '[ESC]=Exit [EXP]=Execute test '
1.2.2 Manually
Through the manual test a test vector can be defined and results can be received
from the LMU.
The screen below shows the manual test.
• 'LMU manual test '

• 'RPM LMU input: 18.0 [RPM]Result: '
• 'Signal ON time: 3100 [ms] '
• '[<][>]=RPM [E]=ON Time [EXP]=Exec. test '
Click [<] or [>] to change the RPM input within the interval 7.20 to 23.4
Click [E] to change the Signal ON time with the numeric keys.
Click [exp] to start the test. The alarm status result will be shown under “Result”
and the actual RPM from the LMU will be shown on the right:
• 'LMU manual test '

• 'RPM LMU input: 18.0 [RPM]Result: 18.1 '
• 'Signal ON time: 3100 [s] Alarm inactive'
'[<][>]=RPM [E]=ON Time [EXP]=Exec. test '

Alignment of generator
See ZWI566637 on page 231.
IMPORTANT !! Max. wind limit for alignment is - 12 m/s
Please note that the rotor must be locked when working on the coupling, but for
alignment the turbine must be yawed out of the wind 45° to the right and the
blades pitched in stop position to+80°. Use the turning motor to turn the main
shaft - see “Service safety - chapter 2”.
Coupling between gearbox Fig. 10.60

and generator 1. Remove the cover on the cou-
pling.
Fig. 10.61
1. Rubber bushing
Check the rubber bushing for slack in the knuckle joints.
• In case of slack the rubber bushing must be replaced.
Retightening coupling bolts Check and do the following during service of the coupling:
• Retighten the bolts for the coupling flange/ coupling at the gear.
• Retighten the bolts for the coupling flange/ coupling at the generator.
• Retighten the bolts for links on the coupling.
• Check the knuckle joints for wear.
(see chapter 4 for torque wrench settings).

Checking the coupling and If the measurements do not comply with the tolerances, the generator must be
generator alignment aligned. This is done as follows:
• Alignment with special-purpose tools. See ZWI1004240 on page 279.

• Alignment with laser equipment. (See “AI-WI566637” on page 235).
Adjustment of generator • Loosen the bolts which fix the generator to the generator plate.
• Adjust the generator by turning the adjusting screws up or down.
Fig. 10.62
Photo of the needed hydraulic
1 2
and adjusting tools.
4 5 6
3
Fig. 10.63
Adjust the generator suspen-
2
sions. Shims can be used.
Monitor the measurements on

the computer.
4 5 6 Use the hydraulic piston when fit-

3
ting shims.
Fig. 10.64
Hydraulic piston used for moving
1 2
the generator sideways.
4 5 6
3

Fig. 10.65
Moving the generator sideways.
1 2
The plate can be turned over and
shim plates can be inserted in
between.
4 5 6
3
Fig. 10.66
Moving the generator sideways.
1 2
4 5 6
3
Alignment with special-pur- Fig. 10.67

pose tools Special-purpose tool.
Fig. 10.68
Fit the special alignment tool on
one of the coupling bolts.
1

• Loosen the foundation bolts of the generator.

• Adjust the distance by pushing the generator and by putting shims un-
der the feet of the generator (Equal thickness in both sides).
Three “measurements” must be checked:
1 Axial deviation.
2 Angular deviation.
3 Parallel deviation.
1. Axial deviation Fig. 10.69

A A is measured at top and bottom.
A = 635 ± 1 MM.
2. Angular deviation Fig. 10.70

B B is measured 10 - 15 MM. in-
side the edge of the flange.
Fig. 10.71
Measurement of vertical dis-
B tance (B).
B
Reset dial indicator to top posi-
tion.
Turn coupling and dial indicator

to the bottom position.
Maximum allowed deflection: 0.5

MM.
Fig. 10.72
Measurement of horizontal dis-
tance (B).
B
B
Reset dial indicator to one side.
Turn coupling and dial indicator

to the opposite side.
Maximum allowed deflection: 0.5

MM.

3. Parallel deviation Fig. 10.73
0-1mm Vertical parallel deviation.

1
Gearbox Generator
Fig. 10.74
C is measured on outside edge
C of flange.
C
Measure vertical distance (C).
Reset dial indicator to top posi-
tion. Turn coupling and dial indi-
cator to the bottom position.
Maximum allowed deviation from

centre of the generator shaft is 0
- 1 MM. below the gearbox shaft.
Fig. 10.75
Horizontal parallel deviation.
Gearbox
1
0-1mm C
Generator
Fig. 10.76
Measure the horizontal distance
C (C). Reset the dial indicator to
C
one side. Turn coupling and dial
indicator to the opposite side.
The maximum allowed deviation

from the centre of the generator
shaft is 0-1 MM. left of the gear-
box shaft as seen from the gen-
erator.
• Torque-tighten the generator base plate bolts (see chapter 5 regarding

bolt tightening).
• A check measurement of the parallel deviation and the distance A must
be made. If the tolerances are not kept, the generator must be loosened
again and a new adjustment must be made.
Use shims with a thickness of 1.0, 2.0, 5.0, 8.0 or 10.0 MM. for the alignment.

WARNING ! Note: The rotor must be locked when tightening the coupling.
How to tighten the coupling The vibration level is very sensitive to how the bolts are tightened. Use the bolt
bolts tightening procedure described in the following pages when assembling and tight-
ening-up the coupling.
Use a torque wrench and a pry bar when tightening the bolts.
Assembling the coupling:
It is important that the “bones” are placed in groups on the coupling. They are
packed in groups and should be assembled in one group (contents of one bag)
per side.
Place all the “bones” and tighten them with the fingers - do not tighten the collar
all the way down on the space.
Fig. 10.77
1 Place the washers as shown
in the sketch.
1 1 2 Turn the metal part upwards.
2
3 Collar.
3
4 Spacer.
4
Fig. 10.78
Tighten the bolts so the collar is
all the way down on the space.
Tighten crosswise.
• Use a pry bar to centre the coupling pipe so there is an equal gap between the
pipe and the coupling flange at both ends.
• Then tighten all bolts on the back plate

Fig. 10.79
(If the generator is replaced, it
must be aligned here.)
Loosely tighten the transverse

bolts.
Tighten the bolts so the collar is

all the way down on the spacer.
Tighten crosswise.
• Torque-tighten all end bolts (see Chapter 4).

• Torque-tighten the front transverse bolt (see Chapter 4).
• Torque-tighten rear transverse bolt (see Chapter 4).
Fig. 10.80
Tighten the knuckle joints two by
two crosswise.
1
2
Fig. 10.81
Allow the turbine to idle followed
1 2
by slight braking.
Check-measure to see if the

generator has moved out of
alignment.
4 5 6
3

Generator alignment with laser equipment
See “AI-WI566637” on page 231)



SIEMENS
Aktivitet:Opera- Oplining og justering af generator med fix- ZWI 566637
tion:
turlaser Designer: TOCH
Aligning and adjusting the generator with fix- Design dato: 01-09-06
ture laser Design date:
Mølle type: SWT-2.3-82 / SWT-2.3-82VS / SWT-2.3-93 ECN nr.: 50085

Turbine type: ECN No.:
Dokument ref.: ECN dato: 22-10-09

Document ref.: ECN date:
Klassificering / Rating: 2
Vigtigt:
Vær opmærksom på at måleinstrumenter, værktøj og personligt sikkerhedsudstyr i de for-
skellige lande kan afvige fra de viste i denne instruktion.
Det sikres altid at måleinstrumenter, værktøj og personligt sikkerhedsudstyr overholder det
pågældende lands lovkrav for opgaven.
Note:
Please note that the measuring instruments, tools and personal protective equipment in var-
ious countries may deviate from those illustrated in this Work Instruction.
It is always ensured that the measuring instruments, tools and personal protective equip-
ment comply with the legal requirements for a specific job in the country in question.
Stop møllen. Husk at bære høreværn under drift og

opstart af møllen.
Stop the turbine. Remember: Hearing protection is

mandatory during turbine operation and startup.
Fig 1
Siemens Wind Power A/S Side/Page 235 / 278 Conveyed confidentially as trade secret
Flyt blåt håndtag til “Maintenance”.
Bemærk: Findes ikke i SWT-2.3-82 møller.
Shift the blue lever to “Maintenance”.

Note: Does not exist in SWT-2.3-82 turbines.
Fig 2
Monter HS rotorlås.
Mount HS rotor lock.
Fig 3
Afmonter afdækning for kobling. Mål afstanden

mellem bremseskiven og generatorflangen.
Remove the cover on the coupling. Measure dis-

tance between brake disc and generator flange.
Fig 4
Afstanden måles i top og bund = 635 +/- 1mm
Measure the distance at the top and at the bottom =

635 +/- 1mm
Fig 5
Afstanden måles mellem fladerne.

Vær opmærksom på at det er indvendige mål.
Measure the distance between the faces. Please

note that these are inside measurements.
Fig 6
Monter hvert laserhoved kl. 12. Det vil sige øverst
på/over flangen i hver ende af koblingen.
Laserhovederne skal være placeret overfor hina-
nden men vær opmærksom på at de ikke støder
mod andre mølledele når der drejes på flangen.
Bemærk at der er et “moveable” og et “stationary”
laserhoved.
Stationary: Gearsiden. Markeret med et “S” på for-
siden af hovedet.
Moveable: Generatorsiden. Markeret med et “M” på
forsiden af hovedet.
Fig 7
Each laser head is to be fitted at 12 o’clock, i.e. at
the top of the flange at both ends of the coupling.
The laser heads must be positioned directly oppo-
site each other but make sure that they do not
touch other turbine parts when the flange is turned.
Note that there is a stationary and a moveable laser
head.
Stationary: Gearbox side. Marked with the letter “S”
at the frontside of the head.
Moveable: Generator side. Marked with the letter
“M” at the frontside of the head.
Monter “stationary” laserhoved (mærket S) på gear-

siden med en magnet ind på bremseskiven.
Rengør bremseskiven inden opmontering for at
sikre at magneten ikke rykker sig.
Fit the “stationary” laser head (marked S) on the

gearbox side with a magnet on the brake disc.
Clean the brake disc before fitting to ensure that
the magnet does not move.
Fig 8
Monter “moveable” laserhoved (mærket M) på gen-
eratorsiden med et beslag på generatorflangen.
Flugt i midten mellem de to ben på beslaget og
monter laserhovedet så man kan se spejlbilledet af
det i modsatte laserhoved. (Kan ses i den lodrette
sprække).
Fit the “moveable” laser head (marked M) on the

generator side with a bracket on the generator
flange. Align with the center between the two
bracket legs and fit the laser head such that its mir-
Fig 9 ror image can be seen in the opposite laser head.

(Visible in the vertical slit.)
Juster de to laserhoveder så den røde streg ram-

mer ind i det lyse felt på laserhovedet. Start med at
justere stregen ind på M ved at justere på S hove-
det. Derefter omvendt.
Adjust the two laser heads such that the red line
hits the bright area on the laser head. First adjust
the line hitting M by adjusting the S head. Then
make the opposite adjustment.
Fig 10
Forefindes der ikke standardmål til at indplotte i
computeren, da opmåles afstandene:
Det første mål er mellem midt pindbolt til midt
pindbolt som laserhovederne sidder fikseret med.
Mål A.
If no standard measurements are available for

entering in the computer, measure the following
distances:
The first measurement is the distance between the
two middle studs with which the laser heads are
Fig 11 fixed.
Measurement A.
Det andet mål:

Delmål B1:
Fra midten på pindbolten ved laserhovedet til ende-
plade på generator + tykkelsen af endepladen.
The second measurement:

Partial measurement B1:
From the center of the stud bolt by the laser head to
the end plate of the generator + the thickness of the
end plate.
Fig 12
Delmål B2:
Fra endepladen på generatoren til midten af bolten
på forreste generator ophæng.
Disse delmål lægges sammen for at få:
Mål B
Partial measurement B2:

From the end plate of the generator to the center of
the bolt on the front generator suspension.
Add these two partial measurements to get:
Measurement B
Fig 13
Det sidste mål:

Foretages mellem midten af forreste bolt og midten
af bagerste bolt på generator ophæng.
Mål C.
The final measurement:

From the middle of the bolt on the front generator
suspension to the middle of the bolt on the rear
generator suspension.
Measurement C.
Fig 14
Monter tørnegear i indgreb.

Krøj møllen om i bagvind inden oplining af genera-
tor.
Turn hub in position and mount HS rotor lock.

Yaw the turbine to back wind before lining up the
generator.
Fig 15
Symboloversigt:
Tryk på dette symbol for at indstille eller kontrollere
offset.
Explanation of symbols:
Push this symbol to set or check the offset.
Fig 16
Symboloversigt:
Tryk på dette symbol for at få adgang til fil-bibli-
oteket.
Push this symbol to gain access to the file directory.
Fig 17
Symboloversigt:
Tryk på dette symbol for at starte oplining.
Push this symbol to start the alignment.
Fig 18
Symboloversigt:
Tryk på dette symbol for at forlade den menu fixtur-
laseren er i.
Push this symbol to exit the menu the fixture laser

is currently in.
Fig 19
Symboloversigt:
Tryk på dette symbol for at slette en evt. markeret
fil.
Push this symbol to delete a selected file.
Fig 20
Symboloversigt:
Tryk på dette symbol for at flytte en evt. markeret fil
uden at efterlade en kopi det oprindelige sted.
Push this symbol to move a selected file without

leaving a copy in the original location.
Fig 21
Symboloversigt:
Tryk på dette symbol for at flytte en evt. markeret fil
og efterlade en kopi det oprindelige sted.
Push this symbol to move a selected file and leave

a copy in the original location.
Fig 22
Symboloversigt:
Tryk på dette symbol for at indsætte en klippet eller
kopieret fil i den mappe man står i.
Push this symbol to paste a cut or copied file into

the current folder.
Fig 23
Symboloversigt:
Tryk på dette symbol for at kunne markere flere filer
på en gang.
Push this symbol to be able to select several files at

the same time.
Fig 24
Symboloversigt:
Tryk på dette symbol for at åbne en fil.
Push this symbol to open a file.
Fig 25
Symboloversigt:
Tryk på dette symbol for at skifte filnavn.
Push this symbol to change the file name.
Fig 26
Symboloversigt:
Tryk på dette symbol for at oprette en ny mappe.
Push this symbol to create a new folder.
Fig 27
Symboloversigt:
Tryk på dette symbol for at bladre nedad i filerne.
Push this symbol to scroll down a list of files.
Fig 28
Symboloversigt:
Tryk på dette symbol for at bladre opad i filerne.
Push this symbol to scroll up a list of files.
Fig 29
1: Tænd for fixturlaseren.
Vær opmærksom på at denne metode til opli-
ningen kun er mulig hvis offset værdierne er
3 lagt ind som en fil.
2: Hvis man er sikker på at offset indstillingen

er korrekt: Tryk på “Arkiv” for at hente offset filen.
1 2
Gå til Fig 31.
3: Hvis det er første gang man bruger værktøjet

eller andre har brugt værktøjet siden man selv
Fig 30 sidst har brugt det: Tryk på “Offset” for at kontrol-

lere eller oprette offset indstillingen iht. Bilag 1. (Se
Fig 82).
1: Switch on the fixture laser.

Please note that this alignment method is avail-
able only if the offset values have been stored
as a file.
2: If you are sure that the offset setting is cor-

rect: Push “File” to get the offset file. Go to Fig 31.
3: If this is the first time you use the tool, or if

others have used the tool since you last used it:
Push “Offset” to check or create offset settings in
accordance with Appendix 1. (See Fig 82)
1: Marker offset filen så den bliver grøn.
2: Tryk på mappen for at åbne offset filen.
Bemærk: Billedet viser en 3.6MW og vil blive
opdateret til 2.3MW ved førstkommende lejlighed.
1: Select the offset file - it must turn green.

1 2: Push the folder to open the offset file.
2
Note: Pictures shows a 3.6MW and will be updated
to a 2.3MW as soon as possible.
Fig 31
Det er vigtigt at man ikke gør noget inden dette

billede kommer frem.
1: Tryk på “Kobling” for at starte opliningen.
2: Dette symbol betyder at man opliner med offset.
It is important not to do anything until this image

2 appears.
1
1: Push “Coupling” to start the alignment.
2: This symbol means that you are aligning with off-
set.
Fig 32
Før oplining skal man ind i værktøjer og kontrollere

opsætning. Tryk på “værktøj” for at kontrollere at
det er indstillet med de rigtige tolerancer og oplin-
ingsmetode.
Before alignment, go into tools and check the

setup. Push “tools” to check that the setup has the
correct settings for tolerances and alignment
method.
Fig 33
1: Tryk på “Tolerance” for at opsætte tolerancen.
Bemærk: Hvis tolerance allerede er indstillet til
0.08 og 0.5 som vist på billedet skal tolerance ikke
ændres. Gå da til Fig 41.
1
1: Push “Tolerance” to set up the tolerances.

Note: If the tolerances have already been set to
0.08 and 0.5 as shown in the picture, the tolerances
should not be changed. In that case, go to Fig 41
Fig 34
De første 5 indstillinger er fabriksindstillinger. Tryk i

den første tomme kolonne for at navngive egen tol-
erancen.
The first five settings are factory settings. Push the

first empty column to name your own tolerance.
Fig 35
Navngiv tolerancen så beskrivende som muligt.

F.eks: “ 2,3mw Tol. ”
Afslut med tryk på “OK”.
Give the tolerance a very descriptive name, e.g.

“2.3mw Tol.”.
Confirm by pushing “OK”.
Fig 36
1: Kontroller at teksten man har skrevet i Fig 36 nu
står i første kolonne.
2: Tryk nu i den anden tomme kolonne for at ind-
taste tolerancer.
1 Bemærk: Billedet viser en 2.3MW og vil blive

2
1: Check that the text you have written in Fig 36 is

now showing in the first column.
2: Now push the second empty column to enter the
tolerances.
Fig 37 Note: Pictures shows a 3.6MW and will be updated

1: Den øverste række fortæller om hvor stort

knækket på koblingen må være.
1
“Vinkelafvigelsen”.
Indtast værdien 0.08 i vinkelafvigelsen.
1: The top line indicates the maximum bend of the

coupling permitted.
“Angular deviation”.
Enter the value 0.08 in the angular deviation.
Fig 38
2: Den nederste række fortæller om hvor stort
højde og sidevejs forskel der må være mellem gen-
erator og kobling.
“Parallelforskydning”.
Indtast værdien 0.5 i parallelforskydning.
2
2: The bottom line indicates the maximum eleva-
tional and lateral deviation permitted between gen-
erator and coupling.
“Parallel displacement”.
Fig 39 Enter the value 0.5 in the parallel displacement.
Når der står 0.08 ved vinkelafvigelse og 0.5 ved

parallelforskydning, markeres linien igen så den
bliver grøn. Tryk derefter på “ OK “.
When the angular deviation setting reads 0.08 and

the parallel displacement setting reads 0.5, select
the line again to make it turn green. Then push
“OK“.
Fig 40 to a 2.3MW as soon as possible.
1: Gå herefter ind i opliningsmetode.
1 1: Then go into the alignment method.
Fig 41
1: Tripoint metoden vælges altid.
1: Always select the tripoint method.
Fig 42
1: Kontroller at de tolerancer man har valgt står i

tolerancefeltet.
2: Kontroller at den oplinings metode man har valgt
2 1 er vist i metodefeltet.
3: Tryk på “ Exit” symbolet for at komme tilbage til
opstart af oplining.
3 1: Check that the tolerances you have selected are

shown in the tolerance field.
2: Check that the alignment method selected is
shown in the method field.
Fig 43 3: Push the “ Exit” symbol to return to starting up

the alignment process.
Tryk på fingeraftrykket.
Computeren vil nu spørge efter de mål der blev
taget i starten af opliningen.
Push the fingerprint.

The computer will now ask for the measurements
taken at the start of the alignment.
Fig 44
1: Første mål computeren spørger efter er mål A.

1 Der måles til midt af de 2 par pindbolte som laser
hovederne sidder monteret på. Målet indtastes og
tryk “ OK”.
1: The first measurement the computer asks for is

measurement A. Measure the distance between
the centers of the two stud bolts on which the laser
heads are fitted. Enter the measurement and push
“OK”.
Fig 45
Computeren deler nu mål A i to. Bekræft med “OK”
The computer now divides measurement A by two.

Confirm by pushing “OK”.
Fig 46
Nu fortæller computeren at den er klar, men der er
stadig 2 spørgsmålstegn. Tryk på mål B først.
The computer now says that it is ready. However,

there are still two question marks. First push meas-
urement B.
B C
Fig 47
Mål B er fra bageste sensor (sensor M) til midt for-

reste fod. Derefter trykkes på “OK”.
Tryk nu på spørgsmålstegn for mål C.
Measurement B is from the rear sensor (sensor M)

to the center of the front foot. Then push “OK”.
Now push the question mark for measurement C.
Fig 48
Mål C er mellem fødderne. Der skal måles fra midt

bolt til midt bolt på generatorfødderne.
Measurement C is between the feet. Measure from

center to center of the bolts in the generator feet.
Fig 49
1: Tryk her for at foretage det første mål.
2 2: Laser position.
1
1: Push here to take the first measurement.
2: Laser position.
Fig 50
Fig 51
Vigtigt:
Grønt område illustreret på billedet = OK at opholde sig under tørning.
Rødt område illustreret på billedet = Forbudt at opholde sig under tørning.
Benyt tørnegear til at dreje laserhovederne under oplining. Der må IKKE opholde sig personer i rødt
område under tørning.
Det er den der betjener tørnegearet der har ansvaret for at oplyse alle i nacellen om at der tørnes inden
tørning påbegyndes. Ligeledes er det den der betjener tørnegearet der har ansvaret for at kontrollere at
der ikke befinder sig personer i rødt område inden tørning påbegyndes.
Tørning afbrydes straks og HS rotorlåse monteres hvis nogen bevæger sig ind i rødt område.
Der må ikke bæres løstsiddende tøj eller sele under opliningen.
Important:
Green area illustrated above = It is OK to stay here during turning.
Red area illustrated above = It is prohibited to stay here during turning.
Use the turning gear for turning the laser heads during alignment. NO people are permitted to stay in the
red area during turning.
The person operating the turning gear is responsible for notifying everybody in the nacelle that turning is
going to be performed before turning is initiated. Also, the person operating the turning gear is responsi-
ble for checking that there are no people in the red area before initiating turning.
Turning must be stopped immediately and the HS rotor locks fitted if anyone moves into the red area.
Loose clothing or safety harness must not be worn during the alignment.
Monter barrierer i begge sider af nacellen iht. Fig
51
Mount barriers in both sides of the nacelle accord-

ing to Fig 51
Fig 52
Monter barrierer i begge sider af nacellen iht. Fig

51
Mount barriers in both sides of the nacelle accord-

ing to Fig 51
Fig 53
Fjern HS rotorlåse inden der tørnes.
Remove HS rotor locks before turning.
Fig 54
Drej nu laserne ud over det røde felt for at foretage
det næste mål.
Bemærk: Det anbefales at dreje laserne helt ud i
kl 9 og kl 3 ved hvert mål.
Now turn the lasers outside the red area to take the
next measurement.
Note: It is recommended to turn laser heads all
the way to 9 o’clock and 3 o’clock at each
measurement.
Fig 55
1: Tryk igen for at foretage det næste mål.

2 1 2: Bemærk at sensoren bliver grøn når den kom-
mer ud over det røde område.
Bemærk: Bemærk: Billedet viser en 3.6MW og vil
blive opdateret til 2.3MW ved førstkommende lej-
lighed.
1: Push again to take the next measurement.
2: Please note that the sensor turns green when it

gets outside the red area.
Fig 56
Det røde område bliver større for hvert mål der
foretages.
Drej nu modsatte vej for at foretage det sidste mål.
The red are gets bigger with each measurement

taken. Now turn in the opposite direction to take the
last measurement.
Fig 57
1: Tryk igen for at foretage det sidste mål. Når det
1 sidste mål er taget går computeren selv ind og viser

hvordan opliningen ser ud.
1: Push again to take the last measurement. When

the last measurement has been taken, the compu-
ter automatically shifts to showing what the align-
ment looks like.
Fig 58 to a 2.3MW as soon as possible.
Monter HS rotorlåse efter endt tørning.
Mount HS rotor locks when finished turning.
Fig 59
Dette billede viser hvordan generatoren står i

forhold til gearet. Det er vigtigt at gemme dette
1
billede i “ my measurement” da målene skal ind-
2 føres i checklisten.
1: Lodret vinkelafvigelse.
2: Lodret parallelafvigelse.
3 3: Vandret vinkelafvigelse.
4 4: Vandret parallelafvigelse.
5: Tryk på “ Gem” for at gemme filen i “my meas-
5 urements”.
Fig 60 This picture shows the position of the generator rel-

ative to the gearbox. It is important to save this
image in “my measurements”, because the meas-
urements must be recorded in the check list.
1: Vertical angular deviation.
2: Vertical parallel deviation.
3: Horizontal angular deviation.
4: Horizontal parallel deviation.
5: Push “Save” to save the file in “my measure-
ments”.
Tryk på den hvide linie for at skrive et navn til filen.
Push the white line to write a name for the file.
Fig 61
Det er vigtigt at det rigtige møllenummer bliver

skrevet i filnavnet. Møllenummeret finder man i
menu 14 i håndterminalen i møllen.
Når nummeret er skrevet skal der afsluttes med et
B for before (måling før oplining). Tryk “OK”.
It is important to write the correct turbine number in

the file name. The turbine number can be found in
menu 14 in the hand terminal in the turbine.
Fig 62
When this number has been entered, finally enter
the letter B for “before” (i.e. the measurement
before alignment). Then push “OK”.
Kontroller at det er det korrekte møllenummer og
tryk derefter på “OK”.
Check that the turbine number is correct, and then

push “OK”.
Fig 63
Filen gemmes nu i “my measurements” med

dataene fra opliningen, under det navn / møllenum-
mer man har navngivet den til.
The file is now saved in “my measurements” with

the data from the alignment process under the
name/turbine number stated in the file name.
Fig 64
Start med at justere generatoren i højden (lodret
parallelafvigelse) da der ved løft af generatoren er
1
mulighed for at generatoren flytter sig sidelæns.
2 Vær opmærksom på koblings symbolerne da de
viser hvad generatoren skal. I dette tilfælde skal
generatoren op og til venstre.
3 1: Lodret vinkelafvigelse. OK, ligger indenfor toler-
4 ancen som er 0.08mm.

2: Lodret parallelafvigelse. Der skal shimses 3mm
for og bag for at komme indenfor tolerancen der er
0.5mm.
Fig 65 3: Vandret vinkelafvigelse. OK, ligger indenfor toler-
ancen som er 0.08mm.
4: Vandret parallelafvigelse. Generatoren flyttes
1mm foran og 1.5mm bagtil, mod venstre i møllen
for at komme indenfor tolerancen der er 0.5mm.
Start by adjusting the height of the generatoren

(vertical parallel deviation) because the generator
might shift sideways when it is lifted.
Pay attention to the coupling symbols because they
indicate how the generator has to move. In this
case the generator has to move up and left.
1: Vertical angular deviation. OK, it is within the tol-
erance of 0.08 mm.
2: Vertical parallel deviation. Insert shims to elevate
by 3 mm at front and rear to get with the tolerance
of 0.5 mm.
3: Horizontal angular deviation. OK, it is within the
tolerance of 0.08 mm.
4: Horizontal parallel deviation. The generator must
be moved 1 mm at the front and 1.5 mm at the rear
towards the left-hand side of the turbine to get
within the tolerance of 0.5 mm.
Laseren viser nu hvor meget den skal flyttes. Tryk
på shims symbolet for at se live værdier.
The laser now shows how much it has to be

moved. Push the symbol for shims to see the live
values.
Fig 66
1: Gem data fra før oplining (se Fig 60 - Fig 64).

2: Tryk derefter på shims symbolet for at se live
værdier under opliningen.
1 2
1: Save the data from before alignment (see Fig 60
- Fig 64).
2: Then push the symbol for shims to see live val-

ues while alignment is performed.
Fig 67
Kontroller at laserne står i kl. 12.
Man kan nu tilføje/fjerne shims under generatoren,
samtidig med at man ser hvor meget man har
hævet/sænket generatoren. Grafikken viser om
2
generatoren skal hæves eller sænkes.
1: Tryk for at skifte mellem horisontal (vandret
afvigelse) og vertikal (lodret afvigelse) oplining hvis
ikke der automatisk skiftes om når laserne drejes.
1
2: Symbol for hvilken type oplining der udføres,
horisontal eller vertikal. På eksemplet vises der ver-
tikal oplining.
Fig 68
Check that the lasers at in the 12 o’clock position.
You can now add/remove shims under the genera-

tor while monitoring at the same time how much
you have raised/lowered the generator. The graph-
ics indicate whether the generator has to be raised
or lowered.
1: Push to change between horizontal (horizontal

deviation) and vertical (vertical deviation) alignment
if the system does not change automatically when
the lasers are turned.
2: Symbol indicating the type of alignment being

performed, horizontal or vertical. The illustrated
example shows vertical alignment.
Når højden er indenfor tolerancen drejes laserne til
kl. 3 og kontroller at der skiftes automatisk til hori-
sontal oplining. Grafikken viser hvilken vej genera-
toren skal flyttes både for og bag.
Når generatoren står indenfor tolerancerne, fore-
tages en kontrol oplining (start Fig 30 ).
When the height is within the tolerance, turn the

lasers to the 3 o’clock position, and check that the
system changes automatically to horizontal align-
ment. The graphics indicate the direction in which
Fig 69 the generator has to be moved, both front and rear.
When the generator is within the tolerances, per-

form a check alignment (start Fig 30).
Justering af generator med faste fødder:

Justér generator ophængene, benyt eventuelt
shims. Shims de mm som laserudstyret viser for
hver fod.
Benyt hydraulisk stempel til hjælp ved shimsning.
Bemærk: Efter hver justering/shimsning er det
nødvendigt at lave en ny kontrol oplining, fordi at
generatoren flytter sig en smule hver gang man
løfter i den.
Adjustment of generator with fixed feet:
Fig 70 Adjust the generator suspensions - use shims if

necessary. Use the mm shims at each foot as the
laser equipment shows.
Hydraulic piston used for shimming.
Note: It is necessary to perform the alignment
again after each adjustment/shimming because the
generator will move a little bit each time it is being
lifted.
Benyt hydraulisk stempel til hjælp ved forskydning
af generator.
Hydraulic piston used for horizontal alignment of

the generator.
Fig 71
Forskydning af generator. Vend eventuelt pladen
og brug shims som mellemstykke.
Horizontal alignment of generator. Turn over the

plate and use shims as spacers if necessary.
Fig 72
Forskydning af generator.
Horizontal alignment of generator.
Fig 73
Inden den sidste måling er det vigtigt at genera-
toren bliver spændt moment. Generatoren vil synke
op til 0.5mm når man spænder fødderne, derfor er
det en god ide at sætte generatoren lidt for højt.
Efter oplining skal alle resultater stå i grønne felter
og resultater skal indføres i checklisten.
1: Denne fil skal gemmes under “my measure-
1 ments”. Lav en ny fil med møllenummeret og afslut
filnavnet med et A for after.
Before taking the last measurement, it is important
Fig 74 to torque the generator. The generator will sink up

to 0.5 mm when tightening the feet, so it is a good
idea to adjust the generator a little too high. After
the alignment all results must be shown in green
fields, and the results must be recorded in the
check list.
1: This file must be saved under “my measure-

ments”. Create a new file with the name of the tur-
bine number followed by the letter A for “after”
Kontroller at det er det korrekte møllenummer og

tryk derefter på “OK”.
Bemærk: Billedet viser en 3.6MW og vil blive opda-
teret til 2.3MW ved førstkommende lejlighed.
Check that the turbine number is correct, and then

push “OK”.
Fig 75
Vent til computeren går tilbage til opliningen. Begge
filer ligger nu inde i computeren.
Tryk på “Exit” symbolet for at forlade menuen. For-
lad alle menuer så man kommer ud til hovedmen-
uen.
Wait until the computer returns to the alignment.

Both files are now in the computer.
Push the “Exit” symbol to exit the menu. Exit all

menus to return to the main menu.
Fig 76
Målene skal nu gemmes på en USB memory stick

og afleveres på site kontoret.
Tilslut USB stik til opliningscomputeren. Kontroller
at den grønne diode på USB memory stick blinker
grøn for at indikere at den er korrekt forbundet til
computeren.
1: Tryk på “Arkiv”.
1
The measurements must now be saved on a USB

memory stick and handed in to the site office.
Fig 77
Connect the USB plug to the alignment computer.
Check that the green diode on the memory stick is
flashing to indicate that it is correctly connected to
the computer.
1: Push “File”.
1: Marker de to målinger A+B der er lavet under
3
opliningen (klik på pil symbol for at markere flere
filer på en gang).
2: Tryk på kopier symbolet.
3: Tryk på tilbage symbolet.
1 Bemærk: Billedet viser en 3.6MW og vil blive
2
1: Select the two measurements A + B made during

the alignment (click the arrow symbol to select sev-
eral files at the same time).
Fig 78
2: Push the copy symbol.
3: Push the return symbol.

1: Marker USB så linien bliver grøn.

2: Tryk derefter på mappen for at åbne USB mem-
ory stick.
1: Select USB - the line must turn green.
2: Then push the folder to open the USB memory

1 stick.
2
Fig 79
1: Tryk på “indsæt” for at fører filerne over på USB
memory stick.
1: Push “paste” to transfer the files to the USB

memory stick.
Fig 80
Når de to filer ligger på USB memory stick kan man

gå ud i hovedmenuen og lukke ned for værktøjet.
Send filerne til pgr63.energy@siemens.com

When the two files have been transferred to the

USB memory stick, go back to the main menu and
shut down the tool.
Send the files to pgr63.energy@siemens.com

Fig 81
Bilag 1: Offset værdier.
Offset nulpunkt
Tolerance 0.5mm
0mm offset -1mm

-0.5mm
Nulpunkt ved stilstand
Fig 82
Når møllen producerer rykker gearet sig i forhold til generatoren. Opliningen skal sikre at gear og generator står
neutralt ud for hinanden under drift. Men da opliningen foregår ved stilstand og fixturlaserne arbejder indenfor de
opgivne tolerancer, rundt om et nulpunkt, skal der tages højde for denne forskydning. Dette gøres ved at lægge
en offset værdi ind tilsvarende den afstand som gearet rykker sig, på pågældende mølletype, fra stilstand til drift.
Tolerance = Afstanden som målene i opliningen må variere på begge sider af nulpunktet.
Offset = Afstanden som nulpunktet skal forskydes for at være i neutral position under drift ift. ved stilstand. Husk
at lave plads til tolerance. F.eks. på en 2.3MW skal generatoren stå 0-1mm over nulpunktet og har en tolerance
på +/-0.5mm. Dvs. at offset flyttes til -0.5mm så der er plads til de +/- 0.5mm i tolerance.
When the turbine is producing, the gearbox shifts relative to the generator. The alignment has to ensure that the
gearbox and generator are neutrally positioned relative to each other during operation. However, since the align-
ment is performed during standstill and the fixture lasers are operating with the tolerances given, around a zero
point, allowance must be made for this displacement. This is done by adding an offset value corresponding to the
distance the gearbox shifts from standstill to operation in the turbine type in question.
Tolerance = The distance by which the measurements in the alignment may vary on both sides of the zero point.
Offset = The distance by which the zero point must be displaced to be in the neutral position during operation as
opposted to during standstill. Remember to make room for tolerance. In a 2.3MW, for example, the generator
must be 0-1 mm above the zero point and have a tolerance of +/-0.5 mm. This means that the offset is moved to
0.5 mm, making room for the +/-0.5 mm tolerance.
1: Tryk her for at komme ind i offset menuen.
1: Push here to get into the offset menu.

1
Fig 83
Lodret parallelafvigelse.
0-1mm Vær opmærksom på altid at benytte den nyeste
version af servicemanualen for evt. ændringer
af offset værdier.
Vertical parallel deviation.
Make sure that you always use the latest ver-

sion of the Service Manual to allow for any
changes to the offset values.
Fig 84
Vandret parallelafvigelse.
Vær opmærksom på altid at benytte den nyeste
version af servicemanualen for evt. ændringer
af offset værdier.
Horizontal parallel deviation.
Make sure that you always use the latest ver-

sion of the Service Manual to allow for any
changes to the offset values.
Fig 85
Tryk på “kobling”.
Push “coupling”.
Fig 86
1: Tryk her for at indtaste lodret parallelafvigelse.

(Hvor højt generator må stå ift. gearet.)
1 1: Push here to enter the vertical parallel deviation.

(How high the generator may be relative to the
gearbox.)
Fig 87
Der skal kun indtastes den parallele del af

afvigelsen.
Only enter the parallel part of the deviation.
Fig 88
Indtast de -0.5mm som offset er på lodret paralle-
lafvigelse på en 2.3MW mølle (se servicemanu-
alen). Afslut med tryk på “OK”.
Enter the -0.5 mm as offset for the vertical parallel

deviation in a 2.3MW turbine (see the Service Man-
ual). Confirm by pushing “OK”.
Fig 89
2: Tryk her for at indtaste vandret parallelafvigelse.

(Hvor langt til siden generator må stå ift. gearet.)
2: Push here to enter the horizontal parallel devia-

tion. (How far to the side the generator may be rela-
tive to the gearbox.)
Fig 90
Der skal kun indtastes den parallele del af

afvigelsen.
Indtast de -0.5mm som offset er på vandret paralle-
lafvigelse på en 2.3MW mølle (se servicemanu-
alen). Afslut med tryk på “OK”.
Only enter the parallel part of the deviation.
Enter the -0.5 mm which is the offset for the hori-

zontal parallel deviation in a 2.3MW turbine (see
the Service Manual). Confirm by pushing “OK”.
Fig 91
Tryk på mappen for at gemme opsætningen som
en offset fil.
Push the folder to save the setup as an offset file.
Fig 92
Tryk i det hvide felt for at navngive filen.
Push in the white field to name the file.
Fig 93
Kald filen et let genkendeligt navn så den er nem at

genkende. F.eks. “2301offset”.
Give the file an easily recognizable name that

makes it easy to find it later, e.g. “2301offset”.
Fig 94
Kontroller teksten og tryk “OK”. Filen vil nu blive
gemt i mapper “My measurements”.
Check the text, and push “OK”. The file is now

saved in the folder “My measurements”.
Fig 95
Når filen er gemt trykkes på “kobling” for at starte

oplining.
When the file has been saved, push “coupling” to

start the alignment.
Fig 96
Afmonter HS rotorlåse.
Remove HS rotor locks.
Fig 97
Flyt blåt håndtag til “Operation”.
Shift the blue lever to “Operation”.
Fig 98
Start møllen. Husk at bære høreværn under drift og

opstart af møllen.
Start the turbine. Remember: Hearing protection is

mandatory during turbine operation and startup.
Fig 99
SIEMENS
Aktivitet/Operation: Oplining og justering af generator med ZWI1004240
måleur.
Designer: SPE
Alignment and adjustment of generator
with dial gauge Designer dato/date: 15-10-08
Mølle type / Turbine: SWT-2.3-82 / SWT-2.3-93 / SWT-2.3-82 VS ECN nr./no.: 50085
DK- Vigtigt: Klassificering / Rating: 3

Vær opmærksom på at måleinstrumenter, værktøj og personligt sikkerhedsudstyr i de for-
skellige lande kan afvige fra de viste i denne instruktion.
Det sikres altid at måleinstrumenter, værktøj og personligt sikkerhedsudstyr overholder det
pågældende lands lovkrav for opgaven.
Der må ikke bæres løst hængende tøj eller faldsikringssele i nærheden af koblingen, imens
der køres med tørnergearet.
INT- Note:
Please note that the measuring instruments, tools and personal protective equipment in var-
ious countries may deviate from those illustrated in this Work Instruction.
It is always ensured that the measuring instruments, tools and personal protective equip-
ment comply with the legal requirements for a specific job in the country in question.
No loosely hanging clothes or safety harness must be worn near the coupling while the turn-
ing gear is being operated.

Fig 1
DK- Kun SWT-2.3-93 og SWT-2.3-82 VS:

Flyt blåt håndtag til “Service Mode ON”
position.
INT- Kun SWT-2.3-93 and SWT-2.3-82 VS:

Shift the blue lever to “Service Mode ON”
Fig 2
DK- Monter HS rotorlåse.
INT- Mount HS rotor locks.
Fig 3
DK- Afmonter afskærmning rundt om kobling.
Vigtigt: HS bremsen skal være
aktiveret under montering af måleud-
styr og løsnes kun under udmåling af
vinkler hvor montørene placere sig
iht. Fig 11.
INT- Dismount shielding around the coupling.

Important: The HS brake must be acti-
vated during mounting of equipment
for measuring, and it is only loosened
during measuring of angles were the
technicians must be placed according
to Fig 11 .
Fig 4
DK- Der skal bruges en 30mm top og en for-

længer til at løsne en af koblingsboltene
ved bremseskiven.
INT- A 30 mm. top and an extension is used

to loosen one of the coupling bolts by
the brake disc.
Fig 5
DK- Løsn og afmonter koblingsbolt.
INT- Loosen and dismount coupling bolt.
Fig 6
DK- Monter beslag til måleur med en af
koblingsboltene.
INT- Mount brackets for measuring dial with

one of the coupling bolts.
Fig 7
DK- Monter tørnegear i indgreb. Brug tør-

negear til at dreje kobling under
målinger. Når tørnergear er monteret,
kan HS rotorlåse afmonteres.
INT- Engage turning gear. Use turning gear to

turn coupling during measuring. When
turning gear is mounted, HS rotor locks
can be demounted.
Fig 8
DK- Beslag med måleur.
INT- Bracket with dial gauge.
Fig 9
DK- Monter måleur på beslaget.
Der er tre mål, der skal checkes.
Aksialafvigelse.
Vinkelafvigelse.
Parallelafvigelse.
Ved målepositioner ses der altid frem
mod rotorplan. Dvs. at højre side er
hvor off-line filter står og venstre side
er hvor hydraulikstationen står.
Kl. 12 = toppen af akslen
Kl. 6 = bunden af akslen
Kl. 9 = til venstre for generator
Kl. 3 = til højre for generator
INT- Mount the dial gauge on the bracket.

Fig 10 Check three measurements.
Axial deviation.
Angle deviation.
Parallel deviation.
When talking about the different mea-
surement positions, it’s always look-
ing towards the rotor. Meaning the
right side is on the side where the off-
line filter is. Left side is the side with
the hydraulic station.
12 oćlock = top of shaft
6 oćlock = bottom of shaft
9 oćlock = left of generator
3 oćlock = right of generator
Fig 11
DK- Vigtigt:
Grønt område illustreret på billedet = OK at opholde sig under tørning.
Rødt område illustreret på billedet = Forbudt at opholde sig under tørning.
Benyt tørnegear til at dreje laserhovederne under oplining. Der må IKKE opholde sig per-
soner i rødt område under tørning.
Det er den der betjener tørnegearet der har ansvaret for at oplyse alle i nacellen om at der
tørnes inden tørning påbegyndes. Ligeledes er det den der betjener tørnegearet der har
ansvaret for at kontrollere at der ikke befinder sig personer i rødt område inden tørning
påbegyndes.
Tørning afbrydes straks og HS rotorlåse monteres hvis nogen bevæger sig ind i rødt
område.
Der må ikke bæres løstsiddende tøj eller sele under opliningen.
INT- Important:
Green area illustrated above = It is OK to stay here during turning.
Red area illustrated above = It is prohibited to stay here during turning.
Use the turning gear for turning the laser heads during alignment. NO people are permitted
to stay in the red area during turning.
The person operating the turning gear is responsible for notifying everybody in the nacelle
that turning is going to be performed before turning is initiated. Also, the person operating
the turning gear is responsible for checking that there are no people in the red area before
initiating turning.
Turning must be stopped immediately and the HS rotor locks fitted if anyone moves into
the red area.
Loose clothing or safety harness must not be worn during the alignment.
DK- Monter barrierer i begge sider af
nacellen iht. Fig 11
INT- Mount barriers in both sides of the

nacelle according to Fig 11
Fig 12
DK- Monter barrierer i begge sider af

nacellen iht. Fig 11
INT- Mount barriers in both sides of the

nacelle according to Fig 11
Fig 13
DK- Aksialafvigelse:
Afstanden A måles i top og bund (kl. 12
og kl. 6) mellem bremseskiven og inder-
siden af generatorflangen.
A = 635 ± 1 mm
Ligger målet udenfor tolerancen, flyttes
A generatoren.
INT- Axial deviation:

Measure distance A at top and bottom
(12 oćlock and 6 oćlock) between the
brake disc and the inside of the flange of
the generator.
A = 635 ± 1 mm
Move the generator if the measurement
Fig 14 is not within tolerance.
DK- Lodret/vandret vinkelafvigelse:
10-15mm Afstanden B måles 10-15 mm indenfor
flangekanten.
B
INT- Horizontal/vertical angle deviation:

Measure distance B at a point 10-15mm
below the edge of the flange.
Fig 15
DK- Lodret vinkelafvigelse = Op/ned

vinkelafvigelsen på bagenden af genera-
toren.
B Afstanden B fra Fig 15 måles lodret (kl.
12 og kl. 6).
Uret nulstilles i top (kl. 12)
Kobling med ur drejes til bundstilling
(kl.6).
Max. udslag: ± 0,5 mm
INT- Vertical angle deviation = Up/down

deviation on the rear end of the genera-
tor.
Measure distance B at Fig 15 vertically
(12 oćlock and 6 oćlock).
Fig 16 Zero the dial gauge when positioned at
the top (12 oćlock).
Turn the coupling with the gauge to bot-
tom position (6 oćlock).
Max. tolerance: ± 0.5 mm
DK- Vandret vinkelafvigelse = Venstre/
højre vinkelafvigelsen på bagenden af
generatoren.
Afstanden B fra Fig 15 måles vandret
B (kl. 3 og kl. 9).
Uret nulstilles i højre side (kl. 3).
Kobling med ur drejes til venstre side (kl.
9).
Max. udslag: ± 0,5 mm
INT- Horizontal angle deviation = Left/right

deviation.
Measure distance B at Fig 15 horizon-
tally (at 3 oćlock and 9 oćlock).
Zero the gauge when positioned at the
Fig 17 right side (3 oćlock).
Turn the coupling with the gauge to the
left side (9 oćlock).
Max. tolerance: ± 0.5 mm
DK- Lodret parallelafvigelse.
INT- Vertical parallel deviation.
0-1 mm
Gearbox Generator
Fig 18
DK- Lodret parallelafvigelse = Generator-
ens placering, højere eller lavere i for-
hold til gearkassen.
Afstanden C fra Fig 18 måles på flan-
gens yderside.
Afstanden C fra Fig 18 måles lodret (kl.
12 og kl. 6).
Uret nulstilles i top (kl. 12).
Kobling med ur drejes til bundstilling (kl.
6).
Generator justeres så center af genera-
torakslen ligger 0 - 1 mm under gear-
akslen.
INT- Vertical parallel deviation = Generator

Fig 19 standing higher or lower than the gear-
box.
Measure distance C at Fig 18 on the rim
of the flange.
Measure C at Fig 18 vertically (12
oćlock and 6 oćlock).
Zero the gauge at the top (12 oćlock).
Turn the coupling with gauge to bottom
position (6 oćlock).
Adjust the generator until the center of
the generator shaft is 0 - 1 mm below
the gear shaft.
DK- Vandret parallelafvigelse.
Gearbox INT- Horizontal parallel deviation.
0-1mm C
Generator
Fig 20
DK- Vandret parallelafvigelse = Generator-
ens placering sidevejs i forhold til gear-
kassen.
Afstanden C fra Fig 20 måles vandret
(kl. 3 og kl. 9).
Uret nulstilles i højre side (kl. 3).
Kobling med ur drejes til venstre side (kl.
9).
Generator justeres, så centrum af gene-
ratorakslen er forskudt max. 0 - 1 mm til
venstre for gearakslen.
INT- Horizontal parallel deviation = Genera-

tor standing side ways compared with
the gearbox.
Fig 21 Measure distance C at Fig 20 horizon-
tally (3 oćlock and 9 oćlock).
Zero the gage at the right side (3
oćlock).
Turn the coupling with gauge to the left
side (9 oćlock).
Adjust the generator until the center of
the generator shaft is displaced max. 0 -
1 mm to the left of the gear shaft.
DK- Justering af generator med faste fød-

der:
Justér generator ophængene, benyt
eventuelt shims.
Hydraulisk stempel til hjælp ved shims-
ning.
INT- Adjustment of generator with fixed

feet:
Adjust the generator suspensions - use
shims if necessary.
Hydraulic piston used for shimming.
Fig 22
DK- Hydraulisk stempel til hjælp ved forskyd-
ning af generator.
INT- Hydraulic piston used for horizontal

alignment of the generator.
Fig 23
DK- Forskydning af generator. Vend eventu-

elt pladen og brug shims som mellem-
stykke.
INT- Horizontal alignment of generator. The

plate can be turned over and shims can
be used in between.
Fig 24
DK- Forskydning af generator.
INT- Horizontal alignment of generator.
Fig 25
DK- Justering af generator med justerbare
fødder:
Monter justeringsbeslag på de forreste
generatorfødder. Skru justeringsskruer
på beslagene ind, så de ligger an mod
generatorfødderne.
INT- Adjustment of generator with adjust-

able feet.
Mount the adjusting plate at the front
base of the generator. Tighten the jack
screws on the adjusting plates until they
meets the base.
Fig 26
DK- Monter justeringsbeslag på de bagerste

generatorfødder. Skru justeringsskruer
på beslagene ind, så de ligger an mod
generatorfødderne.
INT- Mount the adjusting plate at the rear

base of the generator. Tighten the jack
screws on the adjusting plates until they
meet the base.
Fig 27
DK- Mærk gevindstangen op.
INT- Mark the threaded bar.
Fig 28
DK- Løsn møtrik med Hytorc. Hold gevind-
stangen med en skraldenøgle for at
beholde justeringen af højden.
INT- Loosen the nuts with the Hytorc. Hold

the threaded bar with a wrench to main-
tain the height adjustment.
Fig 29
DK- Monter et måleur i begge sider af gener-

atoren for at holde øje med bevægelsen
under justering.
INT- Mount a dial gauge on the left and right

of the generator to check position during
alignment.
Fig 30
DK- Juster axial afstand med bagerste juster-

ingsskrue iht. reference.
INT- Use the jack screw from the rear adjust-

ing plate to adjust the axial distance to
reference.
Fig 31
DK- Monter måleure på toppen af de forreste
generatorfødder i begge sider for at
holde øje med højdejusteringen.
INT- Mount a dial gauge at the top of the front

generator base on both left and right side
to monitor the height adjustment.
Fig 32
DK- Placer hydraulikcylinder under hver af de

forreste generatorfødder. Benyt den
ekstra stålplade (fastgjort til cylinder)
som afstandsstykke.
Man justerer:
Lodret vinkelafvigelse + lodret parallel-
afvigelse.
INT- Place a hydraulic cylinder under each of

the front generator bases. Use the extra
steel plate (Screwed onto the cylinder)
as spacer.
This adjusts:
Vertical angle deviation + vertical parallel
deviation.
Fig 33
DK- Når den korrekte højde er nået, justeres
dæmperne. Brug en 17 nøgle til at just-
erer højde med på gevindstangen.
For at løfte, drej venstre om
For at sænke, drej højre om.
Fjern hydraulik stempler og tjek justerin-
gen på måleurene. Ret afvigelse pga.
gummisætning hvis nødvendigt.
INT- If the correct elevation is reached adjust

the dampers. Use wrench size 17 to
adjust the height of the thread rod.
Up: Counterclockwise
Down: Clockwise
Remove the hydraulic pistons and check
Fig 34 the adjustment with the dial gauges.
Correct deviation by rubber settlement if
necessary.
DK- Gentag proceduren på bagenden af gen-

eratoren.
INT- Repeat the process at the rear end of the

generator.
Fig 35
DK- Monter måleure på siden af generator-
fødderne for at justere vandret afvigelse
(et i for og et i bag). Flyt generatoren
med justeringsskruerne. Husk at løsne
justeringsskruerne på modsatte side.
Man justerer:
Vandret parallelafvigelse + vinkelafvi-
gelse.
Vigtigt: Spænd gevindstængerne for-
sigtigt ned til generatorfødderne efter
endt justering. Løft nu generatoren en
gang i for og en gang i bag med hydrau-
likstemplet, så dæmperne aflastes.
Dette er meget vigtigt, da dæmper
gummiet sidder i spænd pga. side-
Fig 36 vejsjusteringen af generatoren.
INT- For adjustment of horizontal deviation

mount the dial gauges at the sides of the
generator base (one at the front and one
at the back). Adjust the generator with
the jack screws. Remember to loosen
the jack screws on the opposite side.
This adjusts:
Horizontal parallel deviation + angle divi-
ation.
Important: When adjustment is com-
plete, screw down the threaded bars
onto the generator base. Now lift the
generator with the hydraulic cylinders
once in the front and once in the back to
relieve the dampers.
This is very important because the
damper rubber is stressed from the
sidewards movement of the genera-
tor.
DK- Spænd møtrikker efter justeringen. Hold

gevindstangen med en skraldenøgle for
at sikre justeringen af højden. Tjek oplin-
ingen igen.
INT- When the adjustment is finished, tighten

the nuts. Secure the threaded bar with a
wrench to maintain the height adjust-
ment.
Confirm the adjustment by measuring
the generator alignment again.
Fig 37
DK- Monter HS rotorlåse.
INT- Mount HS rotor locks.
Fig 38
DK- Træk turnegear ud af indgreb.
INT- Disengage the turning gear.
Fig 39
DK- Afmonter specialværktøj for oplining, og

spænd koblingsbolt moment iht service-
manual.
INT- Remove the special tools for alignment,

and torque tighten the coupling bolt in
accodance with service manual.
Fig 40
DK- Monter afskærmning rundt om kobling.
INT- Mount shielding around the coupling.
Fig 41
DK- Afmonter HS rotorlåse.
INT- Dismount HS rotor locks.
Fig 42
DK- Kun SWT-2.3-93 og SWT-2.3-82 VS:

Flyt blåt håndtag til “Service mode OFF”
position.
INT- Kun SWT-2.3-93 and SWT-2.3-82 VS:

Shift the blue handle to “Service mode
OFF”
Fig 43
DK- Start møllen. Husk at bære høreværn
INT- Start the turbine. Remember: Hearing

protection is mandatory during operation
and startup of turbine.
Fig 44
- Chapter 11 BRAKE SYSTEM
aSiemens Wind Power A/S

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 11 BRAKE SYSTEM

SWT - 2.3 - 82VS/93/101
• Brake/hydraulic system
• Function description
• Service and maintenance of the hydraulic system
• Service procedures for pumping station
• Brake service

yyyy)

Document history

no.
ECN30446 R0 10-02-2009 Added in ZSM1005840 for SWT-

2.3-82VS/93/101
ECN30997 R1 18-06-2009

Brake / Hydraulic System
ENGAGED.

ENGAGED.

IMPORTANT !! Se: Kapitel 2, “Turbine safety instructions,”
For working in the turbine see the “Basic Health and Safety Rules” for Working in
Turbines.
References Numbers in brackets refer to item. no. on the hydraulic diagram,.See “Chapter 13
COMPONENTS AND DIAGRAMS”

Function description
Positive HS brake The turbine has a positive brake and will not automatically brake during a normal
stop procedure as the turbine normally idles when stopped.
During installation and service the following is carried out:
• Always engage the HS rotor lock.

• Turn valve (252) on the pumping station into “Closed” position in order
to brake the turbine manually in “MENU 24”.
• The turbine can only be started automatically when the valve is in posi-
tion “Open”.
What components does the The brake system consists of a hydraulic unit and two positive brake callipers on
braking system consist of one brake disc.
Disc brake The brake calliper and the brake discs are placed on the high speed shaft. The
brake is a positive brake, i.e. when the brake is activated, the pressure in the sys-
tem builds hydraulic pressure in the calliper. The brake calliper is relieved of hy-
draulic pressure.
The brake uses only one hydraulic work pressure which means that the brake is
always activated at full braking torque. Yet, pressure increase will be slower at
idle brake than at operational brake
Braking When the disc brake is activated during braking, operation braking is applied. The
turbine controller distinguishes between the severity of the individual errors and
applies a stop type depending on the error type. This makes it possible to use the
mechanical brake only when this is absolutely necessary and use the blade brake
when there is no risk in stopping the turbine more slowly.
Types of stop The turbine has 5 different ways of braking or stop types S10- S50. The stop type
depends on the fault register.
• Stop type S10 Emergency stop. Can. error.

• Stop type S20 The HCU has registered overspeed.- Pitch error.
• Stop type S30 The controller has registered brake error, grid drop or
overspeed.
• Stop type S40 Manual stop
• Stop type S50 Normal stop sequence
See the table

Figure 11.0 - Stop types
S10 S20 S30 S40 S50
Emergency stop circuit

is opened
Pitch reference is set Pitch reference is set Pitch reference is set Pitch reference is set Pitch reference is set
to +97º to +97º to +97º to +97º to +97º
Disc brake is activated

after 30 s
Disc brake is activated Disc brake is activated Disc brake is activated OR when generator
speed < 50 RPM
”Safepitch” is activated ”Safepitch” is activated ”Safepitch” is activated ”Safepitch” is activated ”Safepitch” is activated
(emergency stop (emergency stop (emergency stop (emergency stop (emergency stop
valves in hub are valves in hub are valves in hub are valves in hub are valves in hub are
opened) opened) opened) after 40 s opened) after 40 s opened) after 40 s
Hydraulics is set to Hydraulics is set to Hydraulics is set to Hydraulics is set to Hydraulics is set to
”Inactive” mode ”Stop” mode ”Stop” mode after 40 s ”Stop” mode after40 s ”Stop” mode after 40 s
Generator power is Generator power is

Generator power is Generator power is Generator power is
reduced proportional reduced proportional
ramped down to 0 kW ramped down to0 kW ramped down to0 kW
to speed, reaches 0 to speed, reaches 0
in UP13214 s in UP13214 s in UP13214 s
kW at UP13200 RPM kW at UP13200 RPM
Main circuit breaker is

cut out after 9 s
No No No No No
Main circuit Safepitch Safepitch Safepitch Safepitch
breaker cut out? activated? activated? activated? activated?
Yes Yes Yes Yes Yes
End of stop sequence End of stop sequence End of stop sequence End of stop sequence End of stop sequence

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 bear-
ing and gear in case of long periods of stand still. The turbine has two Idle modes
• 1. Controlled idling
• 2. Free idling
Controlled idling During controlled idling the blades are pitched to +85 degrees. In addition to this
the turbine hydraulic system functions as during normal operation.
Free idling Free idling is for idling in case of long periods of grid failure.
Description of grid failure fol- The grid fails.

lowed by free idling:
• Error type 16 is registered which is followed by stop type S30 (see List
of Error Messages)
Stop type S30 (Safe pitch and normal brake)
• The controller registers that the three blades are locked in stop position
(See pitch lock design and function)
• The brake callipers are emptied of oil and the turbine starts to idle. (See
the hydraulic diagram)
• After app. 24 hours the battery backup of the controller (UPS) 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 re-
leased for free idling, also in case of grid failure. However, idling is not allowed in
all types of stop situations (e.g. manual stop and emergency stop).
Idle types The computer has 3 different procedures available. I10, I20 and I30. The chosen
idle mode depends on the error type.
• Idle type 10 (no idling).

• Idle type 20 (free idling).
• Idle type 30 (controlled idling).
See the table

Figure 11.1 - Idling types
I10 I20 I30
Set hydraulic into

Activate disc Brake module state =
”Inactive” state ”Idling, Grid drop” ?
brake No
Brake-module is
Yes
placed in ”Start
idling, Grid drop” Brake module is
state placed into
”Change, griddrop
- normal, step 1 ”
Brake module state

= No
”Idling, Normal” ?
Yes
Brake module is
placed into
”Idling, normal ”
Start up after idling The supply for valve (253 and 254) is stopped and at a delay of 1 second valve
(215 and 216) are fed. This builds brake pressure.
• The blades pitches to operating position.

• After this, the normal start procedure is followed.
• The pressure in the callipers is checked via pressure transducer pos 228.
Design and function of the The pitch lock is important for the safety during free idling. For that reason it is
pitch lock important to check that all three pitch locks have been engaged before the turbine
is ready to idle.
Procedure before idling. The following must be fulfilled before free idling:
• Positive feedback from minimum two pitch pals.
Start up after grid drop To prevent use of the hard brake in the case of power failure, a UPS is installed
(UPS = Uninterruptedly Power Supply). If a power cut/grid failure occurs, the UPS
takes over and supplies power for up to a minute, allowing the turbine to be
stopped with soft braking (see chapter 13).
Overspeed Three independent safety systems are installed to prevent overspeed:

• The control system’s over speed monitoring.

• Highspeed centrifugal release unit (HCU).
• Low speed Monitoring Unit (LMU)
Overspeed monitoring If an error situation occurs where the generator speed exceeds 1800 RPM, a sen-
sor in the generator and main shaft registers over speed, the controller activates
the disc brake and the blades are pitched to stop position so the turbine stops
(stop type S30).
High speed Centrifugal re- The HCU is a mechanical safety feature that prevents over speed. If an over
lease Unit (HCU) 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 acti-
vated 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, pitch the blades in stop position and apply the disc brake (stop type S20).
Low Speed Monitoring Unit As an extra precautionary measure, the low speed shaft is also monitored inde-
pendently of WTC3 via the monitoring module: Low Monitoring Unit (LMU).
Feedback when the following condition has been met:
• LMU is not active during test and the digital input is low in over 100 (ms)
• Feedback if the difference in speed between LMU and main shaft ex-
ceeds max. RPM deviation.
• LMU monitoring is stopped, if test signal is set at 0. This function is re-
moved as soon as all turbines with hard ware profiles supporting the
LMU have been LMU upgraded.

Service and Maintenance of the Hydraulic System
Leakages Check for leakages and check the oil level at each service visit. If a leakage has
occurred, clean up thoroughly after repairing the fault.
Cleaning before dismantling Before disconnecting any valves, hoses, etc., thoroughly clean the spot where the
components defective part is connected to the system.
NB: When dealing with the hydraulic system, be extremely careful not to get dirt
into the system.
Safety glasses and protective When working on the hydraulic system, safety glasses must be worn to protect
gloves the eyes if a seal, hose or other pressurized hydraulic component should burst
when under pressure.
Protective gloves must also be worn as the hydraulic oil can cause skin irritation.
Lock the rotor during service
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 - see chapter 02, safety.
Testing the brake system after When service has been performed, or there has been interference otherwise in
service the brake and hydraulic system, the brake system must be tested thoroughly be-
fore the turbine is returned to automatic operation.
Pressure values All pressure values are shown in the hydraulic diagram,.See “Chapter 13 COM-
PONENTS AND DIAGRAMS”

Service Procedures for Pumping Station
IMPORTANT !! Turn valve (252) on the pumping station to “Closed” to brake the turbine
manually.
Checking the oil level in the • Check oil level when the turbine is stopped (normal stop), and the sys-
hydraulic system tem in the hub is filled.
• Read the oil level on the inspection glass (22), (Se: Kapitel 13, “Compo-
nents and diagrams,” ).
• The oil level must be between the minimum and the maximum indica-
tions. Otherwise refill oil to correct level. (See Fig. 11.5)
Figure 11.2
Oil level inspection glass.
Figure 11.3
Oil level when the turbine is
stopped.
The oil level must be between

the minimum and the maximum
indications.
Replacing and Refilling new • Check the oil level in the inspection glass (read when the system is not
oil pressurized).
• Remove the plug on the return filter.
• Refill new oil. Place a clean funnel on the return filter.
• Check the hydraulic oil level by the inspection glass. (Se: Kapitel 13,
“Components and diagrams,” )
Figure 11.4
Refill new oil.
See “Chapter 05 LUBRICA-

TION”

Test the oil level sensor in the • Test the oil level sensor in the pumping station by dismounting the sen-
pumping station sor and lifting it above the oil level until an error is registered.
Figure 11.5
1 Level sensor.
Replacement of the filter ele-

ment in the pressure filter 11
Figure 11.6
1. Pressure filter
• Activate the emergency stop

• Open valve 14
• Remove the bowl and take out the filter element.
• Empty the bowl of oil and clean it inside with a clean cloth.
• Put a new filter element in the bowl.
• Carefully push the bowl onto the O-ring (BE CAREFUL! Do not jam the o-
ring).
• Screw the bowl onto the filter housing by hand.
• Tighten the union nut lightly with pliers.
• De-activate the emergency stop
• Run the pump an check for leaks
• Check the oil level.
• Close valve 14
Replacement of the filter ele- • Activate the emergency stop

ment in return filter 30 • Open valve 14

Figure 11.7
1. Return filter
Figure 11.8
Loosen the nuts and carefully re-
1 move the lid.
Remove the spring (1).
Figure 11.9
Lift up the filter with the crane
and hold it to allow the oil to drip
into the tank.
Figure 11.10
Unscrew the filter nut/spring.
The nut at the opposite end must

remain tightened.

Figure 11.11
1. Filter element
2. Magnet.
3. Nut / spring
2
1
Figure 11.12
1. Filter element.
Replace the filter element.
Figure 11.13
Replace the filter element and
clean the magnets (1).
If dirt is found on the magnets,

this must be reported.
• Close valve 14 (50)

• De-activate the emergency stop.
Test of pressure transducer • Connect a manometer to the test nipple (18).

(17) • Open valve 14 slightly to start the pump / or close bypass (25).
• Read the manometer when the pump / bypass (25) closes.
• Close valve (14)
• Read the manometer when the bypass is open.
IMPORTANT !! • Valve (27) on the pumping station must be closed during operation in or-
der to avoid damage to the rotating union.
• Valve (14) must be closed in order to build system pressure
• Valve (31) must be open in order to build system pressure in the hub.
Test and of relief valve (10) • Connect a pressure gauge to the test nipple (32).
• Close valve (31)
• Start the pump. Be ready to open valve (14) if the pressure becomes too
high.
• Disconnect the plug on transducer (17)

• Read the manometer when the pressure is constant even with the pump
running. The measurement is the opening pressure of relief valve 10
• Reconnect the plug on the transducer (17)
• Open valve (31)
Test and adjustment of the The pressure transducer monitors the pressure in the entire brake circle. When
pressure transducer (218) the pressure drops to a certain level the pressure transducer opens valve (35)
which means that pressure is added to the system. The software makes sure that
the valve is re-closed when the necessary pressure for normal operation is
reached. (see the hydraulic diagram)
• Lock the rotor with the HS rotor lock

• Connect a manometer to the test nipple (212).
• Read the max pressure and check that it stabilizes (see MENU 24).
Test pressure transducer The pressure transducer monitors the pressure in the entire brake circle. When
(228) the pressure drops to a certain level, the pressure transducer opens valve (35)
and pressure is fed to the system. The software re-closes the valve when the nor-
mal operation pressure has been reached. (See the hydraulic diagram).
• Lock the rotor with the HS rotor lock.

• Fit a manometer on test nipple (227).
• Read the max. pressure and check that is stabilises (see MENU 24).
Test and adjust excess pres- The excess pressure valve is installed for safety reasons. If valve (35) does not
sure valve (210) close when it is expected to close, pressure will build in the system. Excess pres-
sure valve (210) prevents overpressure
• Lock the rotor with the HS rotor lock.

• Fit a manometer in test nipple (212).
• Stand by to open valve 14 if the pressure exceeds 230 bar.
• Disconnect the plug on the pressure transducer (218). Valve (35) opens. The
pressure will build until the excess pressure valve (210) opens. Then the pres-
sure will remain constant also when valve (35) is open.
• Read the pressure when the pressure is constant.
• Adjust excess pressure valve (210) if the read pressure is not identical to the
one indicated in the hydraulic diagram.
Test of brake valves (215) and • Lock the rotor lock with the HS rotor lock
(216) • Attach a manometer to the test nipple (227).
• Release the brake in MENU 24 - (manometer pressure = 0 bar)
• Disconnect he plug on the solenoid valve (215)
• Check that the pressure builds.
• Connect the plug to solenoid valve (215) and check that the pressure is
0.
• Repeat the procedure for valve (216)
Check valve (211) • Lock the rotor lock with the HS rotor lock
• Fit manometer on test nipple position 227
• See MENU 24:
• Slip the brake (pressure drops to 0 +)
• Disconnect the plug on valve (211) and check that pressure build-up
takes 6-10 seconds.

Test the preload pressure of • Lock the rotor with the HS-rotor lock.
the accumulators (82), (220) • Start the turbine.
and (230) in the hydraulic sta- • Change the grid voltage limit (UP 5163 min. Lower Voltage 5) from de-
tion in the nacelle. fault to 500V, which simulates a grid drop.
• Open valve (14).
• Check through test nipples (18)-(212) and (227) that the system is re-
lieved of pressure.
• Wait for 5 minutes to allow the gas in the accumulator to reach the same
temperature as the accumulator housing.
• Check the temperature in the accumulator housing (82)-(220) and (230)
and correct the pre-pressure according to the table in page 12.
• Connect a manometer to the accumulator and read the nitrogen pres-
sure.
• Replace the accumulator if the pressure is below the minimum limit.
• Reset the parameters to default and close valve (14).
Figure 11.14
1. Manometer.
2. Test hose.
2
1
1
Figure 11.15
1. Nitrogen bottle
Check the preload pressure of all

three accumulators and refill if
necessary.
1 1
Refilling the accumulator • Fit the hose from the nitrogen bottle on the accumulator
• During filling, open the tap on the bottle very carefully.
• When the required pressure has been reached, close the tap on the ni-
trogen bottle.
• See the table Se: Kapitel 13, “Components and diagrams,”

Figure 11.16
1. Accumulator (82) for hydrau-
licsystem.
2
2. Accumulator (220) for hydrau-
licsystem.
3
3. Accumulator (230) for brake
system.
1
Replacement of hydraulic Replace hydraulic hoses every 10 years.

hoses.

Brake Service
Inspection of brake Visually check brake disc and lining for wear and discoloration.
Check the air gap between the Visually check the air gap between the brake disc and the brake blocks and listen
brake disc and the brake pads for noise.
• The air gap must be between 1mm and 1.5mm on both sides of the disc.
If the brake disc wears on the brake lining, adjust the calliper travel by adjusting
the positioning screw.
Adjustment of BSAK 300-

MS30S-200 brake pads
Figure 11.17
1 BSAK 300 brake calliper.
• Remove the covers.
•
Figure 11.18
1 Adjust the rear brake pads
with the positioning screw
(1).

Figure 11.19
1 Adjust the brake pads with
the positioning screw (2).
Adjustment of BSAJ 300-

MSXXS-102 brake pads
Figure 11.20
1 BSAJ 300 brake calliper.
• Remove the covers.
1 Adjust the brake pads in the

same way as for BSAK 300.
Checking the brake linings The brake pads must be replaced - at the latest - when the thickness of the brake
lining + the back plate is a minimum of 19 MM.
Replacing the brake pads See “Chapter 16 BRAKE”
Bedding in new brake pads Bed in new brake pads by starting up the turbine. Let it run at operational speed
for a short time and then stop it by pressing the emergency stop button. This must
be done 2 (two) times (at 15 min. intervals), before the turbine can be released
into automatically operation.
Tightening the brake calliper Tighten the bolts holding the calliper (See the torque wrench setting in chapter 4).
bolts
Checking for leakage from the Check that no oil is coming out from the lower drain port (plastic hose connected
piston seals on the brake cal- to the waste tray). (See chapter 15 - Installation and maintenance manual for
liper brake).
Control of brake disc Inspect brake disc for signs of cracks and discoloration each time the HCU is ac-
tivated.

Brake disc replacement • Press the emergency stop button and the blades are pitched to stop po-
sition.
• Lock the rotor (use LS rotor lock NB.: max. wind speed 18 m/sec.).
• Remove disc.
• Fit new disc
• Rotate disc and tighten bolts evenly. (Tightening torques - see chapter 4)
• Start the turbine and test the brake.
• Run in the brake pads
Replacement of hydraulic Replace all hoses every 10 years.

hoses in brake system
Rotating union
Figure 11.21
1. Pressure hoses for the sys-
1 tems in the hub - (blades)
2
2. Return hoses from the sys-
tems in the hub (blades)
4
3. Drain hose from the rotating
union
4. Rotating union.
5
3
5. Slip ring.
Hydraulic oil for cooler

Figure 11.22
1. Cooler for hydraulic oil.
Clean the radiator fins.


- Chapter 12 PITCH SYSTEM

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 12 PITCH SYSTEM

SWT - 2.3 - 82VS/93/101
• Pitch system
• Service/maintenance of the mechanical part of the pitch system
• Service/maintenance of the hydraulic part of the pitch system
• Service procedures

yyyy)

Document history

93/101
ECN30997 R1 15-06-2009 See ECN30997

Pitch System
Safety For working in the turbine see the “Basic Health and Safety Rules” for Working in
Turbines.
See , “Chapter 02 TURBINE SAFETY INSTUCTIONS,”
ENGAGED.

ENGAGED.

IMPORTANT !! BEFORE ENTERING THE HUB, FILL OUT “CH 579264” Lockout / Tag-out
procedure - HS rotor lock
References Numbers in parenthesis refer to the position numbers in the hydraulic diagram -
See , “Chapter 13 COMPONENTS AND DIAGRAMS,”
Functional description of the Blades are mounted on bearings, and each blade can pitch 82° in relation to the
pitch system normal operating position. In this way, the blades act as air brakes, which can
stop the turbine. Pitching the blades also makes variable control of the maximum
effect possible.
The system consists of a pump station positioned in the nacelle. Through a hy-
draulic connection through the rotating union and the hollow main shaft, the pump
maintains the hydraulic pressure in three individual hydraulic systems, one for
each blade.
Each blade is mounted on a blade bearing with 2 hydraulic cylinders which turn/
pitch the blade.
Excess to the hub Fig. 12.0

1. Open the hatch at the front of
the nacelle.

Fig. 12.1
1. Remove the hatch at the hub.
Be careful when you climb into
1 the hub.
IMPORTANT!
Before climbing into the hub,

read the safety regulations (see
chapter 2).

Service and Maintenance of the Mechanical Part of the Pitch

System
WARNING ! When working in hubs with maintenance free joint bearings, lubrication
must under no circumstances be in contact with the joint bearings, as it will
reduce the life time of the bearing drastically. If any lubrication is observed
on or at the joint bearings, the bearings must be degreased with ethyl alco-
hol.
Procedure for oil spillage in If there is oil spillage in the hub due to loose fittings, worn hoses, worn pis-
the hub ton rings etc. the following procedure must be carried out:
Blade bearing - inside:
• Clean up oil and grease.

• Replace oil-absorbers in hub
• Remove all drain cups.
• Apply Holdtite T43 to threading and contact surface on brass fittings.
Blade bearing - outside
• Clean gaskets, blade and spinner as far as possible.

• Turn the blade 90 degrees.
• Clean again.
• Turn the rotor 1/3 and repeat the procedure above.
• Turn the rotor 1/3 and repeat the procedure above.
This way the gasket can be cleaned all around.
Lubricate the blade bearings with the following quantities:
• Blade bearing - 9,6 kg per bearing

• Pitch the blade minimum 2 times before mounting drain cups
Clean 3 times subsequently at 1 week intervals.
Remember to check the drain cups at every cleaning and replace them if
required.
• Drain coups containing grease must be replaced with new cups.

• Check: Mounting of drain cups on blade bearings on page 7
• Use silicone to close the drain hole on the drain cups placed on the back
part of the blade bearing (As seen when the turbine is in operation) Or
use drain cups without holes.
• Note that the position of the drain cups changes when the turbine is
stopped.
Re-tightening of bolts See , “Chapter 04 BOLT TIGHTENING ONSHORE,”

Tighten the blade / bearing Fig. 12.2

bolts 1. Blade / bearing bolts
2 (Drawbolts)
2. Accumulator clamps
Tighten the bolts.
Tighten the rod end axles Fig. 12.3

(Granat) bolts. 1. Rod end axles (Granat)
Tighten the bolts.
Fig. 12.4
1. Hydraulic mounting plate
Tighten the bolts.
Fig. 12.5
1. Accumulator plate
Tighten the bolts.
1
1 2

(If no grease nipple is mounted, the pitch cylinder has maintenance free joint
bearings.)
Fig. 12.6
Cross-tighten or y-tighten the
bolts.
One times
The bolt should be marked with a

pen after it has been tightened in
order to remember which bolts
have been tightened.
Check the ventilating fan in • Before checking the fan, make sure that the valve receives voltage.
the hub. (option) • Use the remote control, menu 24 - screen 7
• Enter”arrow right” - To start the pump.
• Check the fan visually and replace it if there are any unfamiliar sounds
• Check filter
Fig. 12.7
1.Ventilating fan
Fig. 12.8
1. Filter

Check the central lubrication The blade bearings are lubricated through the automatic lubrication system. See
system for the blade bearings the lubrication chart, chapter 5.
• Visually check joints for leaks at the pump, distributor block and inlet.
Starting the lubrication system.
• Use the remote control, menu 24 - screen 7

• Enter”arrow right” - To start the pump.
• Read “grease total” and check that it increases when activated
system and insert a jumper between pin 1 and 3 in the plug, thereby in-
dicating faults.
• Check the direction of rotation of the stirrer in the grease container.
Fig. 12.9
1. Plug for the lubrication unit.
Fig. 12.10
1. Lift the piston.
• Fit the lid and connect the plug on the lubrication unit.
• Check the direction of rotation of the stirrer in the grease container.
Refilling the lubrication sys- The following is important to note when refilling the system
tem for the blade bearing.
• Dirt and impurities in the grease is not accepted as this will cause oper-
ational failure of the pump element.
difficulties for the stirrer in getting the air out of the product. The temper-
ature depends on the type of grease.

• For amount and type of grease, see chapter 5 - lubrication.
Fig. 12.11
1. Fill the grease container for
the central lubrication system
SWT-2.3-82VS, 93
Fig. 12.12
1. Fill the grease container for
the central lubrication system
SWT-2.3-101
Fig. 12.13
Connect the hose to the quick
coupling on the pump housing

Fig. 12.14
the base in the pump.
Pump 6kg or 12 kg into the

grease container depending on
the size of the container (we use
2 different sizes).
1 Disconnect the hose after filling.
Replacement of excess Fig. 12.15

grease cups 1. Blade hatch
Remove the hatch to the blade in

1 order to access the excess
grease cups
Fig. 12.16
1. Replace the excess grease
cups
Description of functioning of The pitch lock is designed as an additional safety device. In extreme winds it will
the hydraulic pitch lock: prevent the blade from pitching into operating position as a result of the aerody-
namic influence. During normal operation the pitch lock will be kept open by the
hydraulic pressure. This means that the lock is passive.
• 60 seconds after a normal stop the valve is activated, the pressure is re-
lieved 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 pres-
sure is rebuilt.

Fig. 12.17.
1. Hydraulic pitch lock
Checking the hydraulic pitch • Tighten the bolts.

lock • Lubricate sliding surface with grease.
• Check that the lock is able to engage.
Check of pitch angle Fig. 12.18

1. Pitch encoder
Calibration of sliding valve Proportional valves with feedback system for the movement of the valves are
signal used in the hub. These must be calibrated.
IMPORTANT! Blade valve must remain open
IT IS VERY IMPORTANT THAT THE CALIBRATION IS COMPLETED WITHOUT

ERRORS BEFORE THE BLADES ARE CALIBRATED.
1) Enter MENU 24 screen 11.
• Choose blade A,B or C with the arrow keys and start the calibration with
the ENTER-key.
PITCH VALVE-CALIBRATION 11/21
Choose blade with </> Blade-A
E = Start calibration

2) When the calibration is completed the following screen appears:
Calibration completed: Blade-A
If the calibration fails, the following appears: Check connections etc. before trying
again.
Calibration error: Blade-A
3) Calibrate the two other sliding valves in the same way.

Offset adjustment of blades Calibrate each blade individually.
Fig. 12.19
1. Arrow for check of tip angle.
The offset adjustment is made on the basis of the position mark on the bar at 0
on the hub and a small metal arrow (Arrow for tip angle meaurement) on the blade
plate. The blade is also calibrated at 60 , where the pitch encoder is used as an-
gle meter.
Enter MENU 24 screen 11.
Select blade A, B, or C with arrow keys and start the calibration by pressing En-
ter.:
PITCH CALIBRATION Blade A 0 9/29
Value A: 88 B: 87.9 C: 89.8 AE: 84.9
Choose blade with </>
E = Start calibration (1. pos.)
1) Use the right/left arrows to move the blade until it is at exactly 0 . The size of
steps can be adjusted with the up/down arrows.
Value A: 0.0 B: 80.3 C: 80.9 AE: -2.6
Step size with ^/v Direction with </>
Step: 0.1 E = End calibration
2) When the blade is at exactly 0 press ENTER
Value A: 0.0 B: 80.3 C: 80.9 AE: -2.7

3) Press ENTER again. Now the pitch encoder is reset to 0 . Then turn the blade
towards 60 . Adjust the blade until the pitch encoder (shown in the photo next to
EA) shows 60.0 .
Value A: 60.4 B: 80.3 C: 80.9 AE: 59.3
Wait, auto calibration in progress...
Abort: (ESC) / (E)
4) 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 </>
5) Reset the turbine and check the positions visually via MENU 24 screen 7.

Service / maintenance on the hydraulic part of pitch system
Safety goggles and protective Note: Goggles must be worn when working on the hydraulic system to protect the
gloves eyes if a seal, hose or other pressurized hydraulic component should burst when
under pressure.
Protective gloves must also be worn as the hydraulic oil can cause skin irritation.
Pressure values All pressure values are shown in the hydraulic diagram See 13, “Components and
diagrams,”
References Numbers in brackets refer to item. nos. in the hydraulic diagrams.See 13, “Com-
ponents and diagrams,”
Leakages Check for leakages and check the oil level at each service visit. If a leakage has
occurred, clean up thoroughly after repairing the fault.
Cleaning before dismantling Before disconnecting any valves, rotating union, etc. thoroughly clean the spot
components where the defective part is connected to the system.
Note: When dealing with the hydraulic system, be extremely careful not to get dirt
into the system.
Replacement of hydraulic Replace all hydraulic hoses in the pitch system every 10 years.
hoses in the pitch system.

Service procedures
Operating the Combistall® Use screen 7 and 10 in menu 24, when performing service and maintenance on
system in menu 24 the pitch system. Also see the User's Manual for the wind turbine controller.
NOTE: The below mentioned service procedures describe only the procedure on
one blade (one blade at a time). Repeat the procedure on the two remaining bla-
des. Perform the procedures while in stopped position.
Checking the prepressure on • Turn off the valves (108).

the accumulators 106A to • Turn on tap (27) and (14) pumping station.
106D • Pressure on valve (117). In so doing, accumulators are depressurised.
• Wait 15 minutes for the gas in the accumulators to be the same temper-
ature as the accumulator house.
• Measure pre-pressure with special tools used for measuring the nitro-
gen pre-load pressure.
• Measure the temperature on the accumulator house and correct pre-
pressure according to schedule in: Chapter 13.
• Turn off valve (27) and (14).
Fig. 12.20
1. Temperature gauge
2 3
2. temperature sensor
3. Pressure gauge
4. Accumulator
4
1 Note: Replace the accumulator
is pre-pressure is below min.
Refill of accumulator • Measure the nitrogen pressure on the accumulator with the pressure
gauge.
• Mount the hose from the nitrogen bottle on the equipment (branch pipe).
• Turn the valve on the bottle very carefully when filling up.
Turn off the valve on the nitrogen bottle when the required pressure is reached.

Fig. 12.21
Remember! Tighten the accu-
2 3 mulator cover plug well.
4
1
Checking valve 103 and 120 • Pitch the blade into operating position (one blade at a time) and wait until
the pump has stopped refilling.
• Disconnect the plug in valve 103 and (119). The blade must pitch into
stop position immediately.
• Pitch the blade into operating position and wait until the pump has
stopped refilling.
• Remove the plug in valve 120 and (119). The blade must pitch into stop
position immediately, in the same way as disconnecting the plug in valve
103.
• If valve (120) is slower acting than the other, then change the valve (120).
•
The function of valve 109 and The purpose of valve (109) and (119) is to act as seals for valve 103/120. Valve
119 103/120 is a valve type which is not quite tight in closed position.
Checking the valve 119 / 109 Enter screen 7 (Pitch position / Reference) in MENU 24.
• Loosen the screws on both valves.

• Key in 0 (zero degrees) as new pitch position.
• Start the pump.
• Press Enter and the blade starts to pitch to 0 (zero degrees).
• Disconnect the plug on valve (119) when the blade begins to pitch to 0
(zero degrees).
• The blade must stop immediately when the plug is disconnected.
• Reconnect the plug and pitch the blade in 0 (zero degrees).
• Disconnect plug valve (109) - same procedure.
Checking the valve 116 and • Pitch the blade in operation position (0 degrees).
preprocessor valve 26 • Connect a pressure gauge to test nipple (112) (or 114).
• Activate the emergency stop button in the nacelle.
• Measure 1 bar when the blade is in stop position (1 bar is measured be-
cause of the nonreturn valve 26).
Checking the pressure trans- • Close valve 108.

ducer 107 • Fit a manometer on test nipple 111.
• Start the pump and compare pressures in the controller (see MENU 24
screen 10).
Replacement of valves and When replacing valves it is important that:

tightening of fittings

• The correct valve is fitted in the correct position -See 13, “Components
and diagrams,”
• That the correct torque setting is used - See 4, “Bolt tightening,”
General Remove any loose objects from the hub / control box.

- Chapter 13 COMPONENTS AND DIAGRAMS

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 13 COMPONENTS AND DIAGRAMS

SWT - 2.3 - 82VS/93/101
• Components and diagrams
• Components on the hydraulic block
• Components in the pitch system
• Diagram for hydraulic system (nacelle)
• Hydraulic diagram for pump system (standard)
• Hydraulic diagram for blade block (light model)
• Hydraulic diagram for blade block
• Hydraulic diagram for pitch lock
• Diagram for gear oil cooler
• Water cooling diagram
• Correction table for prepressure in accumulators

yyyy)

Document history

93/101
ECN30997 R1 21-07-2009 New hydraulic diagrams and pictures are

added.

Components and diagrams
References Numbers in brackets refer to the position numbers in the hydraulic diagram.
Pressure values All pressure values are printed in the hydraulic diagram.

Components on the hydraulic block
Numbers in brackets are the numbers punched into the hydraulic block.
Pumping station Fig.13.0

1 Motor (4)
1 2 Air filter (20)
3 Return filter (30)
4 4 Oil filling hole
5 Oil tank (23)
5
2
Fig. 13.1
1 Motor (4)
1 2 Air filter (20)
3 Return filter (30)
4 Oil filling hole.
5 Temperature monitor (21)
5
(SWT-2.3-101)
2 4 3
Fig. 13.2
1 Hydraulic block (9)
3 2 2 Hydraulic block - brake (55)
3 Accumulator for brake (230)

Fig. 13.3
1 Hydraulic block (9)
2 Hydraulic block - brake (55)
3 Oil level glass (22)
2 4 Oil tank (23)
5 Level monitor (21)
(SWT-2.3-101)
1
3 4
Fig. 13.4
1 High-pressure filter (11)
4 2 Oil level glass (22)
3 Level monitor and tempera-
3 ture monitor (21)
4 Accumulator (82) for hydrau-
lic system
5 Accumulator (220) for hy-
draulic system
1
2
5
Fig. 13.5
1 High-pressure filter (11)
3 2 Accumulator for brake (230)
3 Accumulator (82) for hydrau-
lic system
4 Accumulator (220) for hy-
draulic system
4 (SWT-2.3-101)
2
1

Fig. 13.6
PT 100 sensor.
Fig. 13.7
PT 100 sensor.
(SWT-2.3-101)
Fig. 13.8
Heating element for HY tank
(arctic).

Fig. 13.9
Heating element for HY tank
(Standard).
Valve block on hydraulic Fig. 13.10

pump for pitch system 1. Relief valve (10)
2 1 2. Relief valve (13)
6 3. Relief valve (34)
4. Solenoid valve (33)
5 5. Pressure transducer (17)
6. Test nipple (18)
7. Hatches P.
8. Crane P.
3 9. Hatches / Crane R.
10. ACC (accumulator)
9 8
10 4
7
Fig. 13.11
1. Relief valve (10)
2. Relief valve (13)
4 3. Relief valve (34)
4. Solenoid valve (33)
5. Pressure transducer (17)
6. Test nipple (18)
7 7. Hatches / Crane R.
5
(SWT-2.3-101)
3
2
1

Fig. 13.12
1. Solenoid valve (25) (bypass).
1 2. Solenoid valve (35).
3. Hatches P.
2 4. Crane P.
5 5. ACC (accumulator)
6. Quick-release couplings (84,
85) / Dust caps for quick-release
coupling.
7. Valve (14) - System pressure.
6 8. Valve (31) - Hub.
8 7 (SWT-2.3-101)
3
4
Fig. 13.13
1. Valve (27) - Return pressure.
(SWT-2.3-101)
1
Fig. 13.14
1. Solenoid valve (25) (bypass).
4 2. Solenoid valve (35).
3
3. Solenoid valve (28).
4. Valve (14) - System pressure.
5. Valve (31) - Hub.
6. Valve (27) - Return pressure.
2 5 7. Test nipple (32).
8. Nonreturn valve (26).
1 9. P (Hub) (pressure for hub).
7
9
6 8

Component list for pumping Fig. 13.15

station for pitch system
Pos. Pos.
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 sensor & temp. sensor 82 Accumulator for hydraulic system.
22 Oil level glass 220 Accumulator for hydraulic sys-
23 Oil tank tem.
25 Solenoid valve (bypass). 230 Accumulator for brake
26 Nonreturn valve
Valve block for pumping sta- Fig. 13.16

tion for brake system 1 Relief valve (222)
1 2 2 Solenoid valve (253)
3 Pressure transducer (228)
3 4 ACC - accumulator (230)
5 Test nipple (227)
6 Pressure for calliper
4 7 To 6 l ACC
8 Return to calliper
8
7
6 5
Fig. 13.17
1 Solenoid valve (254)
3 Test nipple (212)
4 Relief valve (210)
7
1 7 Valve (252)
6
2
5
4 3

Component list for pumping Fig. 13.18

station for brake system
Pos. Pos.
55 Hydraulic block 227 Test nipple
210 Relief valve 228 Solenoid valve
212 Test nipple 230 ACC - accumulator
216 Solenoid valve 252 Valve
215 Solenoid valve 253 Solenoid valve
218 Pressure transducer 254 Solenoid valve
222 Relief valve
Rotating union Fig. 13.19

1. Pressure hoses for the sys-
1 tems in the hub (blades)
2
2. Return hoses from the sys-
tems in the hub (blades)
4
3. Drain hose from the rotating
union
4. Rotating union
5
3
5. Slip ring
Hydraulic oil cooler Fig. 13.20

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

Fig. 13.21
1. Valve block for cooler.
Block "C"

Components in the pitch system
The pitch system in the Note: Numbers in brackets are the numbers punched into the hydraulic block.
blades
Fig. 13.22
The pitch system shown for one
blade.
1. Hydraulic block
2. Accumulators (106A, 106B,

3 106C, 106D)
3. Hydraulic cylinders (109 and

110)
1
2
Fig. 13.23
1 Solenoid valve (120) (NO)
2 On / off valve (103)
1 4 Manual on / off (117)
5
3
Fig. 13.24
1 Proportional valve (102)
1 2 2 On / off valve (116)
3 Ball valve (108) (shown
open)
3 4 Test nipple (111)
5 4

1 Solenoid valve (109) (NC)

2 Relief valve (101)
Fig. 13.25
1 Distributor block for pitch
2 pawl.
2 Pitch pawl.
Component list for hydraulic Fig. 13.26

system in one blade 100Hydraulic block 107 Pressure transducer
101 Relief valve 108 Valves
102 Proportional valve (P 020) 109 Solenoid valve (EM 21V)
103 Solenoid valve (BVE 3S) 109A Hydraulic cylinder
104 Nonreturn valve 109B Hydraulic cylinder
106A Accumulator 110 Nonreturn valve
106.1A Orifice valve 111 Test nipple
106B Accumulator 112 Test nipple
106.1B Orifice valve 113 Test nipple
106C Accumulator 114 Test nipple
106.1C Orifice valve 115 Test nipple
106D Accumulator 116 Solenoid valve (EM 32S)
106.1D Orifice valve 117 Manual on/off valve
106E Accumulator 118 Non return valve
106.1E Orifice valve 119 Solenoid valve (EM 22V)
120 Solenoid valve (EM 31S)
130 Solenoid valve

Diagram for hydraulic system (nacelle) SWT-2.3-82VS, 93
Fig. 13.27

Diagram for hydraulic system (nacelle) SWT-2.3-101
Fig. 13.28

1 2 3 4 5 6 7 8
P-håndpumpe./P-hand pump.
352 / 364
80
P-cover
33 230
69
P-crain
10 bar Cyl. 1 Cyl. 2

R-crain
228
34 227
R-cover 222 254
190 bar
61
220 250
190 bar
15 liter 218
6 liter 216 253
180 bar 251
35 50 bar
82 81 221
36
P-brake
28

252
Acc. 215
P-hub
13
31
18
26 212
R-hub
Fig. 13.29
3,0 bar
300 bar 65 211

27
14 83
17
213
11
25 my
210
10 P
12
206
90 bar
270 bar
200
32 P-cooler
T T1
25
16
R-cooler
9 bar
R-brake 66
32 71
P T
64
Drænledning fra drejeunion.
63
Drain hose from the rotating union.
21 70 20
22 Vægt ca.: Matr.: Matr. nr.:
4 30 Matr.: Matr. no.:
Weight app.:
1,5 bar
24
Hydraulic diagram for pump station (standard)
Tg. skala:
SWT - 2.3 - 82VS/93/101 / ZSM1005840_13 / R1. / edition 1 /

M Emne: Init: PS
Part: Draw. scale:
5-6-7-8
1/2"
041008
71.1 71.1 Hydr. diagram for pumpestation.
03 1-2-3 Checked:
23 1:1
Hydr. diagram for pump station.
Dette dokument må ikke kopieres eller gøres tilgængeligt for trediemand uden vor skriftelig tilladelse.
Indholdet må kun benyttes som aftalt med os. Overtrædelse af dette vil medføre retsforfølgelse.
Del af:
BONUS Energy A/S Part of:
Pos. 10: Indstilles til/Adjust to 270 bar ± 5 bar.
100806 21740
This document must not be copied or made available to any third party without our written permission.
Pos. 34: Indstilles til/Adjust to 190 bar ± 5 bar. 220206 19051 The contents must be used only as agreed with us. Breach of the above will cause legal action. 2,3MW MK II
BONUS Energy A/S
Pos. 210: Kontrolleres til/Test to 90 bar ± 3 bar.
051205 18429 Teg. nr.:
Pos. 82: Forladetryk/pre-charge pressure 180 bar ± 5 bar. Draw. no.:
Pos. 220: Forladetryk/pre-charge pressure 50 bar ± 3 bar. 280905 17836
Pos. 230: Forladetryk/pre-charge pressure 10 bar ± 3 bar. Dato: ECN nr.:
BONUS Energy A/S
Date: ECN no.: Fabriksvej 4 DK Brande Telefon 97 181122 Telefax 97 183086 557585
1 2 3 4
1 2 3 4 5 6 7 8
P-håndpumpe./P-hand pump.
80
P-cover
23 230
69
P-crain
10 bar Cyl. 1 Cyl. 2

R-crain
228
34 227
R-cover 222 254
83
190 bar
61
250
220
190 bar
15 liter 218
6 liter 216 253
20 bar 251
35 50 bar
82 81 221
36
P-brake

252
215
P-hub
13
31
18
26 212
R-hub
Fig. 13.30
3,0 bar
280 bar 65 211

27
14
17 83
213
11
25 my
210
10 P
12
206
270 bar 90 bar
200
32 P-cooler
T T1
25
16
R-cooler
9 bar
R-brake 66
SWT - 2.3 - 82VS/93/101 / ZSM1005840_13 / R1. / edition 1 /

32 71
P T
64
Drænledning fra drejeunion.
Hydraulic diagram for pump station (arctic)
63
Drain hose from the rotating union.
21 70 20
22 Vægt ca.: Matr.: Matr. nr.:
4 30 Matr.: Matr. no.:
Weight app.:
1,5 bar
24 Tg. skala:
M Emne: Init: PS
Part: Draw. scale:
5-6-7-8 73
1/2"
041008
71.1 71.1 Hydr. diagram for pumpestation.
03 1-2-3 Checked:
23 1:1
Hydr. diagram for pump station.
Del af:
Pos. 10: Indstilles til/Adjust to 270 bar ± 5 bar. This document must not be copied or made available to any third party without our written permission.
100806 21740 The contents must be used only as agreed with us. Breach of the above will cause legal action. 2,3MW MK II ark
Pos. 34: Indstilles til/Adjust to 190 bar ± 5 bar. BONUS Energy A/S
Pos. 210: Kontrolleres til/Test to 90 bar ± 3 bar. 220206 19051 Teg. nr.:
Pos. 82: Forladetryk/pre-charge pressure 180 bar ± 5 bar. Draw. no.:
280905 17836
Pos. 220: Forladetryk/pre-charge pressure 50 bar ± 3 bar. BONUS Energy A/S
Pos. 230: Forladetryk/pre-charge pressure 10 bar ± 3 bar. Dato: ECN nr.:
Date: ECN no.: Fabriksvej 4 DK Brande Telefon 97 181122 Telefax 97 183086 557767
1 2 3 4
353 / 364
Hydraulic diagram for pump station SWT-2.3-101
Fig. 13.31

Hydraulic diagram for blade block (light model)
Fig. 13.32
1 2 3 4
125/85x453
A 125/85x453
3/8"
3/8"
1/2"
1/2"
A A B B
108A 108B
110 121
B
119
120 103
102
116
A B
P T
122
C 109
104
101
20/40
300 bar
(280 bar Arktisk/
Arctic)
1/4"
1/4"
4 x 15 liter
120 bar 107
111
117
TP
D 106 106 106 106
ACC PP
5/8"
130
118
P T
P T
E
Pos. 106: Forladetryk/pre-charge pressure 120 bar ± 5 bar.
Vægt ca.: Matr.: Matr. nr.:

Weight app.: Matr.: Matr. no.:
Tg. skala:
Emne:
Part: Draw. scale:
Init: PS
060106
Diagram f vingeblok, let model
Diagram for blade block, light model 1:1 Checked:
Del af:
This document must not be copied or made available to any third party without our written permission.
The contents must be used only as agreed with us. Breach of the above will cause legal action. 2,3MW MK II
BONUS Energy A/S
1008+6 21740 Teg. nr.:
020306 19120
BONUS Energy A/S Draw. no.:
Dato:
Date:
ECN nr.:
ECN no.: Fabriksvej 4 DK Brande Telefon 97 181122 Telefax 97 183086 561942

Hydraulic diagram for blade block - SWT-2.3-82VS, 93
Fig. 13.33

Hydraulic diagram for blade block - SWT-2.3-101
Fig. 13.34

Hydraulic diagram for pitch lock
Fig. 13.35

Diagram for gear oil cooler
Fig. 13.36

Water cooling diagram
Fig. 13.37

Correction table for prepressure in accumulators
Fig. 13.38 - Pressure (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
Example: See below.
The prepressure in the accumulator is always stated in the hydraulic diagram in

bar at 20°C (see the bold column to the right).
The prepressure on an accumulator must be measured. In the hydraulic diagram

it is set to a prepressure of 100 bar (measured at 20°C). The temperature of the
accumulator housing is found to be 10°C. This means that the gas is also 10°C.
Do the following in order to correct the prepressure in accordance with the tem-
perature.
• Find 100 bar in the bold column to the right

• Find 10°C in the bold row at the bottom of the table.
• Move up in the 10°C column and stop when you reach 100 bar (in the
right-hand column)
• Read the pressure

• The pressure must be 97 bar when the preloading gas is at 10°C.



- Chapter 14 BLADES

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 14 BLADES
SWT - 2.3 - 82VS/93/101
• Blades
• Servicing the blades

yyyy)

- Chapter 14 BLADES
Document history

93/101
ECN32453 R1 21-09-2009 Fig. 14.1 - 14.2 - 14.3 placeing of vortex

generator new updated drawings added.

- Chapter 14 BLADES
Blades
Safety Please note that the “general safety rules for service and assembly work”
always apply. See the “Basic health and safety rules” for service techni-
cians working in Siemens Wind Power’s turbines, SI 545781.
See “ZWI1001712” on page 53..
IMPORTANT !! THE HS ROTOR LOCK AND YAW LOCK MUST BE ENGAGED BEFORE EN-
TERING THE HUB.
BEFORE ENTERING THE HUB, FILL OUT “CH 579264” Lockout / Tag-out
procedure - HS rotor lock
WARNING! 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, etc.
• No person is allowed to climb into the blade until the manual pitch lock
has been installed and the double valve (108) closed.
• 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 in-
stalled and the double valve (108) closed.
• Check before leaving the hub that all three blades have been pitched into
the “STOP POSITION”, and check that all three double valves (108) are
OPEN.
• Remove any loose objects from the hub before turning it.
Fig. 14.0
Valve handle illustrated in
closed position.
1 Double valve (108) on blade

valve block.
2 Check that the locking pin

has been inserted.
2
1

- Chapter 14 BLADES
Servicing the Blades
Noise caused by the blades? It is important to listen carefully to the noise created by the rotor blades. Any un-
usual noise indicates a fault. Any other type of noise indicates that something is
wrong and an immediate check must be made of the blades.
Scratches/cracks in the The Service Department must be informed about all types of damage and cracks
blades in the rotor blades, whether it is cracks 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 the following:
• Listen for noise coming from the rotor blades.

• Visually check the blades, blade roots and tips from either the sky lift or
the crane basket, from the ground and from the nacelle. Look for cracks
and other abnormalities.
Service and maintenance of blades
Blade bearings Wipe grease off the blade bearings. Check that the seal is mounted correctly. If
the seal is pinched, it must be adjusted.
Bolt tightening See Chapter 4, Bolt tightening. The following bolted connections must be retight-
ened:
• blade / bearing.
• bearing / hub.
Adjusting the blades Tip angle: Standard 0 and 60 .
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 ex-
amined.
Checking the vortex genera- Count the total number, and visually check they are not damaged.
tors - B40 - B45 - B49

- Chapter 14 BLADES
Fig. 14.1
B40
Fig. 14.2
B45
Fig. 14.3
B49
Checking lightning protectors Check the lightning protection visually. (See figure 14.4)

- Chapter 14 BLADES
Fig. 14.4

- Chapter 15 CRANE

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 15 CRANE
SWT - 2.3 - 82VS/93/101
• Appendix - Installation and service manual for service crane

yyyy)

- Chapter 15 CRANE
Document history

93/101
ECN30997 R1 30-03-2009 New link added in chapter for service

crane. Open link on page 8

- Chapter 15 CRANE
Appendix - Installation and service manual for service crane

See: chapter , “Service crane,”
See: chapter , “Auxiliary tool,”

- Chapter 15 CRANE

Auxiliary tool
ARBEJDS-INSTRUKTION
AI/WI 535051
WORK INSTRUCTION
Designer: SPE Beskrivelse: Montage af skinne for cyl. til nav
Description: Assembly of rail for cylinder on hub
Dato/Date: 24-03-03 Operation: Hjælpe værktøj
Auxiliary tool
ECN Nr.: 12154 Suppl. Tegn: 529847

Add. drawing:
ECN Dato/Date: 24-03-03 Mølle type: 1,3MW
Turbine type:
Der henvises i øvrigt til servicemanualens sikkerhedsafsnit.

Refer also to the precautions chapter in the service manual.
Bemærk SWL på skinne 80KG
Notice SWL at rails 80KG
DK – De to skinner samles.
GB – Join the rails
DK – Slidklods på overkappe afmonteres og

skydearm for skinne monteres.
GB – Disassemble wear block on top cover

and assemble roller bracket for rail.
Siemens Wind Power A/S / Auxiliary tool / 375 / 378

Rev: 26-05-2005 / ECN 17026
DK – Indsats i lampe i overkappe afmonteres.
Stripses evt. fast til lampehuset.
GB – Disassemble the fitting for fluorescent

lamp in the light fittings mounted on
top cover. Fasten cables with cable clip.
DK – Skinnen føres ind i skydearm for

skinne.
GB – Place the rail in the roller bracket for

rail.
DK - Øverste bolt i navafdækning bruges til

af monteres skinnen indefra.
Støttebeslag på enden af skinnen hviler
på navet lige over mandskabshul.
GB – Top bolt in hub cover is used to

assemble the rail from within the hub.
Support bracket at the end of the rail
bear on the hub right above the
manhole.
_____________________________________________________________________________________________________
AI/WI 535051-12154 Side/page 2 af 3
376 / 378 Siemens Wind Power A/S / Auxiliary tool /

Rev: 26-05-2005 / ECN 17026
DK – Rulle føres ind i skinnen.
GB – Lead roller into the rail.
DK – Bolte monteres som endestop.
GB – Assemble bolts as backstop.
DK – Talje monteres i rulle.
GB – Assemble tackle in roller.
_____________________________________________________________________________________________________
AI/WI 535051-12154 Side/page 3 af 3
Siemens Wind Power A/S / Auxiliary tool / 377 / 378

Rev: 26-05-2005 / ECN 17026
378 / 378 Siemens Wind Power A/S / Auxiliary tool /
Rev: 26-05-2005 / ECN 17026
Service crane
Service crane
Position of service crane The following additional information is found at the crane:
• Crane journal
• Safety manual
• Instruction book for “HMF Handy 265 T2-M”
Fig. 9.1
Service crane.
Fig. 9.2
Control panel for service crane.
Operating the Service Crane / AS 545792 / 13. November 2005 159 / 166
Rev: 13.11.2005 / ECN 18245

Operating the service crane
Before using the chain hoist, check that the brake and hoisting stop works.
(The chain may be lubricated either with a wrung cloth with chain oil which is held
on the chain while it is being unrolled or with a spray containing a lubricant that
dries so that the chain will not be left too oily.)
WARNING ! When using the crane/chain hoist, the weight of the lifting object must always be
taken into consideration in order to avoid exceeding the max. load.
For additional information, please refer to the crane/chain hoist “instruction book”
which is found in the nacelle.
Fig. 9.3
1. Start / Stop switch for the
crane.
2. Plug for the chain hoist.
Start the pump for the crane.

1
Fig. 9.4
The operator’s position in front of
the control panel when the crane
is in use.
Fig. 9.5
Lift the jib
160 / 166 Operating the Service Crane / AS 545792 / 13. November 2005
Rev: 13.11.2005 / ECN 18245

Fig. 9.6
Position of chain hoist.
Fig. 9.7
Fit a star washer under the venti-
lation bolt on the chain hoist.
Fig. 9.8
Hook on the chain hoist to the jib.
1
(placed at the rear end of the na-
celle)
Fig. 9.9
Plug in the chain hoist at the
crane control box.
Rev: 13.11.2005 / ECN 18245

Fig. 9.10
The boom is swung out over the
edge of the rear end of the tur-
bine and the chain hoist is oper-
ated.
Rev: 13.11.2005 / ECN 18245

Use of manual cheaters
265 T2 Bonus cranes: Appendix to instructions, chapter 7.1, Use of manual cheaters.
Mounting and dismounting: • Manual crane jibs may only be mounted or dismounted, when they are sup-
ported and the crane jibs are above the floor in the machine room. Only pull
out the cheaters when the crane jibs are as close to horizontal as possible.
• When using manual cheaters, the lock bolt must always be mounted in the
crane jib and secured with the eye split (the extraction works only as an extra
safety feature).
Fig. 9.11
1. The cheater.
Fig. 9.12
1. Visible edge marking!
1
Fig. 9.13
1. Extension bolt
1
2. Lock bolt fitted! - Secured with
eye split.
The use of manual cheaters: • The cheaters may not be loaded more than what is indicated on the weight
board.
Fig. 9.14
• Short cheater: Activate EXT 1.
Rev: 13.11.2005 / ECN 18245

• Long cheater, inner position: Activate EXT 2.

• Long cheater, outer position: Activate EXT 3.
For further information, please see “Instruction book, RCI Safety system” 6.2.
Rev: 13.11.2005 / ECN 18245

Service on service crane
Service on service crane
WARNING ! Service must be performed by authorized personnel only.
Service crane span Fig. 9.15
Fundament g
kg 5k
75 13
kg
Foundation .2 a x.
ax 0m
18
m 90
.6
00 R6
ax
R5 53
0m
17 R
0
50
R2250
R3
Emne fra båd
Subject from boat
ø6
00
ma
x. 6
18
g k g
8k Servicekran
x. 61
ma Service crane
000
Bundflange ø1
Bottom flange Emne fra fundament

Subject from foundation
Rækkevidde for kran med vandret arm

Span for crane with horizontal arm
Max. hydraulisk rækkevidde: 3500 mm / 618 kg (1)
Max. hydrailic span:
Max. rækkevidde med forlænger A: 5300 mm / 275 kg (2)

Max. span w. extender A:
Max. rækkevidde m. forlænger B: 6900 mm / 135 kg (2)

Max. span w. extender B:
1) Max. kranlast - kædetalje vægt = Max. emne vægt (730 - 112 = 618 kg)
Max. crane load - hoist weight = Max. subject weight (730 - 112 = 618 kg)
2) Uden kædetalje
Without hoist
Information The following information is placed at the crane:
• Crane journal
• Safety manual
• Instruction book for “HMF Handy 265 T2-M”
Yearly service 1 Function test with load. (Test load crane at 2180kg with the crane fully in, and
at 912 kg with the crane out).
2 Checking wear of sliding shoes and bearing bushes. Replace if necessary.
3 Checking the hydraulic hoses.
4 Checking for leaks and re-tightening of connections.
5 Checking pump and transmission.
6 Crane connection to bed plate.
7 Checking for play in bolt connections and tighten if necessary.
8 Checking for damage to crane construction. Any damage must be repaired
immediately.
9 Checking bolts and locking plates.
NB: Stamp or sign instruction book after service.
Rev: 13.11.2005 / ECN 18245

Service on chain hoist
Service on chain hoist
Information The following information is placed at the chain hoist:
• Journal
• Safety manual
• Instruction book for “LIFTKET-Electric chain hoist”
Yearly service Before using the chain hoist, check that brake and end stop function.
• Maintenance and adjustment of brake

• Maintenance and adjustment of coupling
• Check of wear of the lifting chain
• Check of wear of rubber parts
• Lubrication of single / double hook
• Lubrication of thrust bearings and wheel bearings
• Check the condition of the safety lock and the lock pin in the hook.
• Check that all bolts / screws are tightened.
• Check chain guide and safety devices.
• Check the condition of the chain bag and the chain hoist covering.
• Check the electrical cables and the control strap.
• Check the suspension bracket /eye
• Lubricate the lifting chain (KEMA VET-68 sterile oil)
(The chain may be lubricated either with at wrung cloth with chain oil wich is held
on the chain while it is being unrolled or with a spray containing a lubricant that
dries so that the chain will not be left too oily.)
See Service Manual ZSM 1005840.
NB: Sign the instruction book after service.
Rev: 13.11.2005 / ECN 18245

- Chapter 16 BRAKE

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 16 BRAKE
SWT - 2.3 - 82VS/93/101
• Appendix - Installation and service manual for brake

yyyy)

- Chapter 16 BRAKE
Document history

93/101

- Chapter 16 BRAKE
Appendix - Installation and service manual for brake
See: chapter , “Installation and maintenance manual for brake BSAJ 300,”
See: chapter , “Installation and maintenance manual for brake BSAK 300,”

- Chapter 16 BRAKE

Installations- og servicemanual for bremse BSAJ 300
Date: 13.12.2005
No.: MEB-0300-063
Replace: 31.10.2005
Approved: N. Christensen
Installation and Maintenance

Manual
BSAJ 300-MSXXS-102
Siemens 2.3 MW
Siemens Wind Power A/S / Installations- og servicemanual for bremse / 391 / 408
Rev: 07.02.06 / ECN 18946
Installation and Maintenance Manual BSAJ 300-MSXXS-102
List of contents
1.General 3
1.1. General. 3
1.2. Function. 3
1.3 Connections. 3
2. Installation 3
2.1. Transport. 3
2.2. Lifting and handling. 3
2.3. Cleaning the brake disc. 3
2.4. Cleaning of the mounting surfaces. 3
2.5. Handling/mounting the brake pad. 4
2.6. Mounting the brake. 4
2.7. Inspecting the alignment of the brake. 4
2.8. Adjusting the air gap. 4
2.9 Back-stop set 4
2.10. Bleeding the hydraulic unit. 5
2.11. Bedding in of brake pads. 5
2.12. Removing the brake. 5
3. Maintenance 5
3.1. Replacing the brake pads. 5
3.2. Dismantling the hydraulic unit. 5
3.3. Lubrication. 6
3.4. Storage. 6
4. Trouble shooting. 7
Dimension drawing 8
Mounting data 9
Spare parts list for one brake half 11
Spare parts drawing - Bracket 12
Spare parts list for bracket 13
Indicator 14
Technical data 15
Recommended fluid for disc brakes 16
Recommended spare parts for one brake 17
MEB-0300-063 Page 1
392 / 408 Siemens Wind Power A/S / Installations- og servicemanual for bremse /
Rev: 07.02.06 / ECN 18946
MEB-0300-063 Page 2
Rev: 07.02.06 / ECN 18946
NEVER APPLY HIGHER HYDRAULIC

1. General PRESSURE THAN 90 BAR!!!
1.1. General.
The drainage connections (18, 21) BSP
The brake is designed to transfer a 1/8” must not be subjected to pressure
braking torque from the caliper to a brake UNDER ANY CIRCUMSTANCES. A pipe
disc in order to stop the rotation of the with a length of approx. 10-20 cm can be
brake disc. connected to the lowest drainage
Any other use of the brake should be connection. A plastic hose which
avoided!!! discharges into a vessel or similar can be
connected to the free end of the pipe
BSAJ 300 Mono-spring is a hydraulic so as to check, if any leakage occurs from
active brake. The brake can be connected the piston seals.
at max. 115 Bar which gives a clamping
force of 50.000 N. The brake is designed Check that the pressure connection which
with a self aligning system consisting of a is not used is sufficiently tight to eliminate
base plate, two shafts and a top plate. any risk of leakage and that the adjusting
screw is screwed sufficiently far into the
This Manual contains brake option BSAJ yoke. See spare parts drawing.
300-MSxxS-102.
Figures within brackets ( ) relate to
position no. on spare parts drawing of
2. Installation
brake (page 10) if not other indicated.
2.1. Transport.
1.2. Function.
When leaving the factory the brake is
The clamping force is obtained from the always packed in a way which guarantees
hydraulic pressure which presses the a maximum of security during transport.
piston (3), and the pad against the disc.
The reaction force is transferred via the 2.2. Lifting and handling.
adjusting screw (1) to the yoke (2).
The Mono-spring BSAJ 300 brake is
The braking is operated by connecting equipped with eye bolts on the caliper and
and disconnecting the hydraulic pressure. should only be lifted by means of placing
a hook through them. In any case, do not
The brake force ceases when oil pressure fit any hook or tie any rope, chain or strap
is removed. The axial play on the brake around switches, valves, accumulator,
disc will then push the pads away, gauges etc. in order to avoid damaging
allowing the disc to rotate freely. these parts. The total weight of the caliper
is approx. 72 kilos.
1.3 Connections.
2.3. Cleaning the brake disc.
The brake is provided with two pressure
connections (13) BSP 1/4”. Before the installation of the brake
callipers the disc must be washed clean
The connection at the lowest position with white spirit and thereafter with
shall always be used as pressure thinners or trichloroethylene. Any residual
connection when connecting the brake to oil or anti-corrosion preparation will
the hydraulic system. The highest reduce the friction coefficient markedly.
pressure connection can be used,
depending on the design of the hydraulic 2.4. Cleaning of the mounting surfaces.
system, if through flushing is required.
The mounting surfaces should be cleaned
Because of the brake’s self aligning in a similar way as the brake disc. See
system it is necessary to use flexible paragraph 2.3.
hoses to the brake’s pressure port.
MEB-0300-063 Page 3
Rev: 07.02.06 / ECN 18946
2.5. Handling/mounting the brake pad.

2.6.11. The hydraulic unit can now be mounted to
2.5.1 Brake pads of composite material - our the brake.
Frendo and BE pads - are delivered packed
in sealed plastic. Be careful to protect the 2.6.12. Check the position of the brake.
pads from grease and oil which would
significantly impair the friction coefficient. 2.7. Inspecting the alignment of the brake.
If any grease or oil comes in contact with
the pad, the pad must be discarded. 2.7.1 Lift the pistons by hand.
Always keep the pads in the packet for 2.7.2. Check that the pads can move freely.
as long as possible.
Important!
Brake pads of sintered metal are less The axial movement of the brake disc
sensitive to oil and can be cleaned with must not exceed 0,5 mm.
solvent and re-used.
2.8. Adjusting the air gap.
When mounting the pads, first remove the
two inside screws (19) from the end of the The air gap is the space between the
pad. brake pads and the brake disc.
Note: The pads should be inserted with
the rounded edge orientated so that it This air gap shall be adjusted when taking
follows the curvature of the disc. the brake caliper into operation.
Re-fit the two screws and tighten. Recommended air gap is 1-2 mm.
2.6. Mounting the brake. 2.8.1 Release the oil pressure.
2.6.1. When the brake is to be lifted for 2.8.2 Remove the locking device (40).
mounting, the eye bolts mounted on the
top plate are moved to the back of the 2.8.3. Turn the adjusting screw (1) clockwise
passive caliper half. using the spanner (adjusting tool) until
both pads are in contact with the
2.6.2. The brake can be lifted using these eye disc.
bolts.
2.8.4. Turn the adjusting screw a 1/4 to 1 turn
2.6.3. Ensure that the mounting flange is backwards (anti-clockwise).
cleaned of dirt and oil.
2.8.5. Turn the adjusting screw to the nearest
2.6.4 Lift the brake to the mounting flange and graduation and remount the locking
mount the lowest and innermost bolt device (40).
without tightening.
2.8.6 Check by measuring with, for example, a
2.6.5. Tip the brake backwards. 1 mm feeler gauge that the air gap
between the disc and the pad is exactly 1
2.6.6. Release the hydraulic pressure. mm.
2.6.7. Lift the piston (03) by pressing it back by 2.9 Back-stop set
hand The back-stop set is mounted to minimize
the piston movement and thereby
2.6.8. Mount the brake pads so that the curved decreasing the reaction time for the
side of the pad is placed towards the brake.
caliper and at the same time is parallel to
the periphery of the disc. 2.9.1 Apply hydraulic pressure to the brake.
2.6.9. Check the mounting flanges and disc for 2.9.2 Turn the M6 bolts until they touch the
dirt and grease. brake pad.
2.6.10. Tip the brake into its place and fit the 4 2.9.3 Unscrew the bolts until the desired air
bolts in the bottom plate. gap.
(M20, grade 8.8 - Mv = 350 Nm)
MEB-0300-063 Page 4
Rev: 07.02.06 / ECN 18946
The pitch for the bolt is 1mm.

3.1.7. It is possible to change the pads just by
2.9.4 Tighten the nuts and release the removing the 2 innermost allen screws
pressure. (19) on each pad, if there is >90 mm
space between the hub of the disc and
the Mono spring bracket.
2.10. Bleeding the hydraulic unit.
3.1.8. Otherwise disconnect the hydraulic lines
The hydraulic system of the caliper must from the brake.
ALWAYS be bled in conjunction with
assembly or when making changes in the 3.1.9. Loosen the mounting bolts in the bottom
system. This bleeding should be repeated plate of the Mono spring brake and tip the
a few times a year, since any air in the brake backwards around the lowest and
system will impair the function (see innermost bolt.
paragraph 1.3 Connections).
3.1.10. Remove the pad retraction springs, (29-
30) if fitted.
2.11. Bedding in of brake pads. Replace the worn brake pads with new
pads, and replace the pad retraction
springs if fitted.
To obtain the rated coefficient of friction
between the pads and the brake disc, it is 3.1.11. Check the mounting surfaces and the disc
essential that the pads are bedded to the for dirt, grease. oil etc.
disc surface. Instructions for this process
are packed together with the pads. 3.1.12. Tip the brake back into place and re-fix
the bottom plate using NEW bolts.
2.12. Removing the brake. Replacement should always be carried
out using new bolts. (M20-grade 8.8 and
2.12.1 Relieve the pressure greased => torque 350 Nm).
2.12.4 Remove 3 of the bolts in the ground plate 3.1.13. Re-connect the hydraulic unit to the
and loosen the 4th. brake.
NOTE: All pipes and hoses are
2.12.5 The brake can now be turned around the undamaged and thoroughly free of dirt.
4th bolt and the brake pads be removed. (See paragraph 1.3 Connections).
2.12.6 Remove hose and pipe connections. The 3.1.14. Adjust the air gap between the new brake
brake can be removed safely from the pads and the brake disc.
mounting place by removing the 4th bolt. Follow paragraph 2.8.2 - 2.8.6.
3.1.15. REMEMBER the bedding in of brake

3. Maintenance pads. See paragraph 2.10.
3.1. Replacing the brake pads. 3.2. Dismantling the hydraulic unit.
The brake pads must be replaced when General.

each pad has been worn 5 mm.
The greatest possible cleanliness must be
All brake pads for the brake consist of a observed when working on a hydraulic
steel back plate and a friction material. system of any type.
The brake pad has a total thickness of 24 Each part must be washed in solvent
mm, i.e. all brake pads must be replaced (paraffin, trichloroethylene) and dried
at the latest when the thickness of friction before being lubricated and fitted. Parts
material + back plate is minimum 19 mm. must be stored in, and assembly work
must be carried out in a clean and dust
3.1.6. Turn the adjusting screw (1) anti- free environment .Dirt shortens the
clockwise using the spanner (adjusting service life of the seals considerably and
tool), as far out as possible, i.e. until the may also damage the hydraulic unit.
adjusting screw comes into contact with
the O-ring (11).
MEB-0300-063 Page 5
Rev: 07.02.06 / ECN 18946
The surface of the piston and the yoke 3.2.13. The caliper half is now ready for mounting
which works against the seals is highly to the Mono spring bracket.
polished. Check that they are not
damaged and handle them carefully to NOTE: Mounting must ALWAYS be
avoid damaging the surface in any way. A carried out using new bolts (9).
damaged piston will immediately ruin the Tightening torque Mv = 350 Nm.
seals.
2.2.14. The Mono spring brake is ready for re-
installation and adjustment (see
ALWAYS ENSURE THERE IS NO paragraph 2. Installation).
HYDRAULIC PRESSURE IN THE
SYSTEM BEFORE STARTING WORK. 3.3. Lubrication.
Lubrication is only necessary after

3.2.1. Release the oil pressure. dismantling the pressure unit. See spare
parts drawing.
3.2.2. Dismantle and plug the hydraulic
connections.
3.4. Storage.
3.2.3. Remove the 2 allen screws (11) and the
top plate (5) see page 12
The brake is externally treated before
3.2.4. Remove the 4 mounting bolts (9) see delivery with an anti-corrosion film which
page 14, and remove the whole caliper is sufficient for indoor storage for 12
half. The caliper half must be taken to a months.
workshop prepared for hydraulic
work. If the caliper is to be stored for periods of
longer than 12 months, it must be
3.2.5. Remove the adjusting screw (1) from the pressurised 20 times at full stroke each
yoke (2). 12 months.
3.2.6. Push the piston (3) backwards.

IMPORTANT!
3.2.7. Remove the wiper (16-D) (must be The anti-corrosion protection must be
pressed out!) and the seals (12 and 15) touched up after transport and handling
and be preserved if stored for more
3.2.8. Wash the parts thoroughly, dry and than 12 months.
lubricate them (see paragraph 3.5
Lubrication).
All kinds of work carried out on the brake
3.2.9. Fit new piston seals (12 and 15) and a which are not mentioned in this manual
new wiper (16) (must be pressed in). should be regarded as repair. In such
The radial seals (12 and 15) must be cases please contact your local
fitted so that the anti-extrusion rings Svendborg Brakes A/S supplier.
are placed on the non-pressure side.
The lip on the wiper (16) must be
placed so it is facing outwards from
the yoke. Be careful with the piston seals,
even a tiny scratch can ruin the seals.
3.2.10. Push the piston (3) as far into the yoke (2)
as possible. The adjusting screw (1) can
be used as a tool.
3.2.11. Turn the adjusting screw clockwise, using

the spanner, until it is max. 18 mm out of
the yoke.
3.2.12. Fit the O-ring (11).
MEB-0300-063 Page 6
Rev: 07.02.06 / ECN 18946
4. Trouble shooting.
Fault Cause Action
The brake applies slowly. Air in the hydraulic Bleed system at highest point
system. and at brake.
Air gap between brake pad Adjust air gaps.

and disc too large.
Abnormal throttling in the Check that all valves are in the

in the hydraulic system, correct position.
valve in wrong position.
Abnormal throttling in the Clean and check pipes, hoses

hydraulic system, dirt. and valves.
Oil in lines between brake and Check that the oil is the
tank has too high viscosity (too recommended grade and not
thick). too cold.
Long braking time or Load too heavy or speed too Check the load and speed
braking distance, insuf- high. values.
ficient braking force.
Oil, paint or grease on brake Wash disc with trichlor-
disc or pad. ethylene. Replace pad. Check
that the brake does not leak.
All brakes not connected. Check valves where applicable.
Leakage. Worn seals. Replace seals. Check sealing

surfaces.
Uneven wear on pad. The brake is incorrectly Check the alignment and the
aligned. bracket.
Excessive disc throw or shaft Replace the brake disc and

deflection checks the shaft deflection.
Abnormally heavy wear on Increased brake utilisation. Check that the load, speed
pad. and frequency does not exceed
permissible values.
MEB-0300-063 Page 7
Rev: 07.02.06 / ECN 18946
Dimension drawing
MEB-0300-063 Page 8
Rev: 07.02.06 / ECN 18946
Mounting data
MEB-0300-063 Page 9
Rev: 07.02.06 / ECN 18946
Spare parts drawing
SVENDBORG BRAKES
MEB-0300-063 Page 10
Rev: 07.02.06 / ECN 18946
Spare parts list for one brake half

Pos. No Article No. Description
001 1 378-0910-003 Cylinder
002 1 490-0193-003 Yoke
003 1 378-1224-003 Piston
013 1 2522-2111-110 Plug 1/4”
017 2 2522-2111-110 Plug 1/4”
018 1 2522-2111-110 Plug 1/8”
021 1 2522-4502-109 Plast plug 1/8”
023 1 478-0815-003 Sign
024 4 4490-0676-001 Blind rivet
029 2 2192-2022-152 Spring
030 2 2121-2532-509 Bolt, M10 x 90
038 1 2151-2022-153 Washer
039 1 2121-2032-374 Bolt, M6 x 25
040 1 478-2719-001 Locking device
490-3488-801 Seal kit BSAJ 300-MS
011 1 2152-2115-524 O-Ring
012A 1 6490-0023-010 Piston seal
012B 1 6490-0028-007 O-ring
015 1 2186-2323-212 Piston seal
016 1 2186-2315-960 Wiper
MEB-0300-063 Page 11
Rev: 07.02.06 / ECN 18946
Spare parts drawing - Bracket
MEB-0300-063 Page 12
Rev: 07.02.06 / ECN 18946
Spare parts list for bracket

Pos. No Article No. Description
001 1 490-0280-801 Passive caliper
002 1 490-0419-002 Base plate
003 2 490-0553-001 Shaft
004 4 487-8784-006 Washer, t=10 mm (30 mm disc thickness)
4 487-8784-002 Washer, t=5 mm (25 mm disc thickness)
005 1 490-0307-002 Top plate
009 4 4490-0600-006 Bolt, M20x120 (28 to 32 mm disc thickness)
4 4490-0600-006 Bolt, M20x110 (20 to 25 mm disc thickness)
010 4 2151-2022-191 Washer, t=3
011 2 2121-2532-493 Bolt, M10x25
012 2 4490-0610-001 Lifting eye
013 4 2151-2022-173 Washer
014 2 6490-0013-001 O-ring
MEB-0300-063 Page 13
Rev: 07.02.06 / ECN 18946
Indicator
Date: 30.08.2005
DATA SHEET No.:

Replace:
Approved:
DEB-INDI-002
27.06.2005
NCH
Page 1 of 2
BRAKE SWITCH – 30 VDC / AC
Brake “Pad Worn” - Hydraulic applied (active) brakes and brakes with
Automatic Wear Adjustment (AWA)
Function
Two micro-switches are mounted inside the housing of
the switch. The explorer triggers these switches at two C
different positions.
NOTE - The indication for “Pre Pad Worn” and “Pad
B
Worn” is only active during braking and disappears
when the brake is lifted - therefore a holding circuit may
be ideal.
Fail Safe operation
96
For fail-safe operations the switch should be wired to Connections
have a signal/connection when everything is ok (i.e.
closing a normally open switch (NO)). The connection
should disappear when switching i.e. applying the
brake, having wear or in case of faults like broken
cable, poor connections etc.
“Pad Worn”
The switch measures the brake pad movement. A
The “Pad Worn” switch triggers, when the brake pad is
worn and needs to be replaced.
On active brakes the signal is given by measuring Functions for Fail Safe operations
directly on the pad. This is done through the threaded
holes in the yoke - next to the pad holders or through a
hole in the adjusting screw.
On AWA brakes this is done through the push-rod in
the centre of the adjusting screw.
The switch has two switch points with 1.5mm in

between.
The first switch point (1-4) is used for the “Pre Pad
Worn” signal. This indicates 1mm left on the pad before
it must be replaced.
The second switch point (2-3) is used for the “Pad
Worn” signal. This indicates that the pad needs to be
replaced.
Mounting
1. Adjust the airgap on the brake. (Refer to manual)
2. Remove the plugs from the adjusting screw.
3. Screw the indicator tread (A) into the adjusting screw
4. Electrical connection. (See connection diagram)
Technical data
0 0
Operating temperature : -40 C to +85 C
Max. Voltage : 30 VDC / AC
Max. Current : 10 mA
Switching tolerance : +/- 0.3mm
Max. Stroke : 16mm
Protection grade : IP 65 (mounted)
Max. Tightening torque Ø21 mm : 20 Nm - A)
Max. Tightening torque Ø12 mm : finger tight - B)
Min. no. of operations : 1 million
Cable length - C) : 5, 10 or 15meters
Cable type/material - C) : PUR *) = Brake “ON” = NO hydraulic pressure
2
Cable dimension - C) : 5 * 0.34mm = brake released / activated
Thread size - A) : 1/2” BSP **) = Brake “OFF” = MAX. hydraulic pressure
Spanner size (SW) - A) : 24mm = brake “lifted”
MEB-0300-063 Page 14
Rev: 07.02.06 / ECN 18946
Technical data
Date: 13.12.2005
DATA SHEET No.:

Replace:
DEB-0300-046
TECHNICAL DATA AND CALCULATION FUNDAMENTALS FOR

DISC BRAKE BSAJ 300
BRAKING TORQUE
The braking torque MB is calculated from following formulas:
Where:
(D ȅ 0,13) a is the number of callipers acting on the disc
ȂǺ a FǺ [Nm]
2 FB is the braking force according to table above [N]
DO is the disc outer diameter [m]
FǺ FC 2 P [N] FC A P 10 [N] FC is the clamping force [N]
A [cm2], P [bar] and µ see values below
The actual braking torque may vary, depending on friction coefficient.
CALCULATION FUNDAMENTALS Standard Monospring

Weight of caliper with bracket: 70 kg 75 kg
Weight of caliper without bracket: 52 kg
Overall dimensions (20mm disc) 326 x 316 x 353 mm 420 x 278 x 284 mm
Pad width: 130 mm 130 mm
Pad area: (organic) 29.000 mm2 (*) 2
29.000 mm (*)
Max. wear of pad: (organic) 10 mm (*) 5 mm (*)
Pad area: (sintered) 20.000 mm2 (*) 20.000 mm2 (*)
Max. wear of pad: (sintered) 7 mm (*) 5 mm (*)
Nominal coefficient of friction: P= 0.4 P= 0.4
2 2
Total piston area - each caliper half: A=44,2 cm A=44,2 cm
Total piston area - each caliper: 88,4 cm2 44,2 cm
2
Volume for each caliper at 1 mm stroke: 8,8 cm3 4,4 cm3

Volume for each caliper at 3 mm stroke: 24,6 cm3 13,2 cm
3
Actuating time (guide value for calculation): 0.3 sec. 0.3 sec.
Pressure connection/port: 1/4" BSP 1/4" BSP
Drain connection port R: 1/4" BSP 1/4" BSP
Max. operating pressure: P=115bar P=115bar
Recommended pipe size: 10/8 mm 10/8 mm
Operating temperature range from -20 to +70 qC from -20 to +70 qC
(For temperatures outside this range contact Svendborg Brakes)
(*) On each brake pad
MEB-0300-063 Page 15
Rev: 07.02.06 / ECN 18946
Recommended fluid for disc brakes

Date: 16.01.2004
DATA SHEET No.:

Replace:
Approved:
DEB-DIVE-005
19.12.2003
N. Christensen
RECOMMENDED FLUID FOR DISC BRAKES & HYDRAULICS

Pressure fluids / Oil types
The following oil types are recommended by Svendborg Brakes – other types corresponding to these can be used.
The minimum and maximum temperatures for standard components are, -20°C - +60°C / -14°F - +140°F.
Extreme temperature applications may require special options. Please contact Svendborg Brakes.
Special option Standard Special option

-30°C - +20°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Mineral Oil
-22°F - +68°F -14°F - +104°F +50°F - +140°F +86°F - +158°F
Shell Tellus Artic Tellus TX32 Tellus TX46 Tellus TX68
Mobil - DTE 13M DTE 15M DTE 16M
Hydro Texaco Rando Ashless 8401 Rando HDZ32 Rando HDZ46 Rando HDZ68
Valvoline - Ultramax HVLP32 Ultramax HVLP46 Ultramax HVLP68
-30°C - +20°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Syntethic Oil
-22°F - +68°F -14°F - +104°F +50°F - +140°F +86°F - +158°F
Mobil - SHC 524 SHC 525 SHC 526
(1)
Bio Oil -30°C - +20°C -20°C - +30°C +10°C - +60°C +30°C - +70°C
(Ester or Colza oil)
-22°F - +68°F -14°F - +86°F +50°F - +140°F +86°F - +158°F
Shell - Naturelle HF-E15 Naturelle HF-E32 Naturelle HF-E46
General: Mineral Pressure Fluids according to DIN 51524 Part 3
(1) There must be less than <200PPM water in the oil, due to the seals.
Viscosity
Recommended viscosity range: 20-200 cSt at working temperature.
Filtration
The oil in a hydraulic system and the oil added to the hydraulic system must always be filtered. The level of cleanliness
in a hydraulic system is an important factor to the lifetime of the system.
When refilling the hydraulic tank, it is recommended that the oil added to the system is filtered through an off-line filter
unit.
The hydraulic system, supplied by Svendborg Brakes, has a build-in oil filter with a standard 10-micron purity filter. To
maintain a reliable system it is recommend that only hydraulic oil of the following classes of purity is used: NAS 1638,
Class 8, or ISO 4406, Class 19/17/14.
It is recommended that the filter be changed at a minimum, once every six months or more often depending on the level
of exposure to contamination.
Service life of pressure fluids

Mineral oil: 8.000 Hours or at least once a year.
Other fluids: 2.000 Hours or at least once a year.
Change of pressure fluid

Note: The mixing or blending of different brands or types of pressure fluid can cause unintended chemical reactions,
such as sludging, gumming etc. The complete hydraulic system should be thoroughly flushed prior to changing from one
oil type to another.
The respective manufactures should be contacted prior to changing from one pressure fluid to another.
Seal material
Brakes from Svendborg Brakes A/S are normally supplied with PUR-seals (PolyURethane)
PTFE (PolyTetraFlourEthylene) seals can be delivered on request for most of the brake types.
Note: the BSFG 400 brake series are supplied with NBR rubber fabric seals (acrylNitrile Butadiene Rubber).
MEB-0300-063 Page 16
Rev: 07.02.06 / ECN 18946
Recommended spare parts for one brake
1 off Seal kit 490-3488-801
1 off brake pad set 490 0402-803 Incl. 2 pads of sintered metal
1 off indicator pad worn 490-3476-829 5m cable and straight plug
1 off adaptor for indicator 490-3447-001
1 off pad retraction spring set 490-0666-811
1 off back stop set 490-3481-801
For purchasing and further information, please contact your local Svendborg Brakes supplier.
MEB-0300-063 Page 17
Rev: 07.02.06 / ECN 18946
Installations- og servicemanual for brake BSAK 300
Date: 13.12.2005
No.: MEB-0300-062
Replace: 05.12.2005
Installation and Maintenance

Manual
HYDRAULIC ACTIVE
MONO SPRING
DISC BRAKE
BSAK 300-MS30S-200
Siemens 2.3 MW
Rev: 07.07.06 / ECN 21618
Installation and Maintenance Manual - BSAK 300-MS30S-200
Table of contents
TABLE OF CONTENTS ............................................................................................................ 1
1. GENERAL...................................................................................................................... 3
1.1 Who to contact ............................................................................................................... 3
1.2 Safety ............................................................................................................................. 3
1.3 Conventions used in this manual ................................................................................... 4
1.4 Disclaimer....................................................................................................................... 4
1.5 Conversion factors ......................................................................................................... 4
1.6 Nameplate / Serial-numbers........................................................................................... 5
1.7 How the brake works...................................................................................................... 6
1.8 Function.......................................................................................................................... 6
1.9 Transport ........................................................................................................................ 7
1.10 Connections ................................................................................................................... 7
1.11 Lubrication...................................................................................................................... 8
1.12 Storage........................................................................................................................... 8
1.13 Disposal.......................................................................................................................... 8
1.14 How to order spare parts................................................................................................ 9
2. INSTALLATION ............................................................................................................. 10
2.1 Lifting and handling ........................................................................................................ 10
2.2 Cleaning the brake disc.................................................................................................. 10
2.3 Cleaning of the mounting surfaces................................................................................. 10
2.4 Handling / mounting the brake pads............................................................................... 10
2.5 Mounting the brake......................................................................................................... 12
2.6 Inspecting the alignment of the brake ............................................................................ 14
2.7 Back-stop set.................................................................................................................. 14
2.8 Positioning system ......................................................................................................... 14
2.9 Adjusting the positioning system .................................................................................... 15
2.10 Bleeding the calliper ....................................................................................................... 15
2.11 Installing the Indicator .................................................................................................... 15
2.12 Bedding in ...................................................................................................................... 16
2.13 Removing the brake ....................................................................................................... 16
3. MAINTENANCE ............................................................................................................. 16
3.1 Pad worn signal.............................................................................................................. 16
3.2 Replacing the brake pads............................................................................................... 16
3.3 Replacing other components.......................................................................................... 17
3.4 Dismantling the active calliper........................................................................................ 18
3.5 Replacing the seals ........................................................................................................ 18
3.6 Lubrication of the brake.................................................................................................. 19
4. TROUBLE SHOOTING .................................................................................................. 20
APPENDIX A - DIMENSION DRAWING, BRAKE .................................................................... 21
APPENDIX B - ASSEMBLY DRAWING, BRAKE EXPLODED ................................................ 22
APPENDIX B - ASSEMBLY PARTS LIST, BRAKE ................................................................. 23
APPENDIX C - SPARE PARTS DRAWING, CALLIPER HALF EXPLODED........................... 25
APPENDIX C - SPARE PARTS DRAWING, CALLIPER HALF ............................................... 26
APPENDIX C - SPARE PARTS LIST, CALLIPER HALF ......................................................... 27
APPENDIX D - MOUNTING DRAWING.................................................................................... 28
APPENDIX E - SPARE PARTS DRAWING, PASSIVE CALIPER............................................ 29
APPENDIX E - SPARE PARTS LIST, PASSIVE CALIPER ..................................................... 29
APPENDIX F - SPARE PARTS DRAWING, BASE PLATE ..................................................... 30
APPENDIX F - SPARE PARTS LIST, BASE PLATE ............................................................... 30
MEB-0300-062.doc Page 1
Rev: 07.07.06 / ECN 21618
APPENDIX G – POSITIONING SYSTEM.................................................................................. 31

APPENDIX H - BRAKE SWITCH / INDICATOR ....................................................................... 32
APPENDIX I - TECHNICAL DATA............................................................................................ 33
APPENDIX J - RECOMMENDED FLUID .................................................................................. 34
APPENDIX K - RECOMMENDED SPARE PARTS .................................................................. 35
Rev: 07.07.06 / ECN 21618
1. General x In order to maintain the guarantee always

use original spare parts from Svendborg
Svendborg Brakes’ range of high-integrity Brakes A/S
brakes offers a brake designer a system of x It is the customer’s responsibility that the
braking that meets the highest requirements brake and hydraulic aggregate are always
for safety and reliability for large braking clean, and free from dirt, grease or oil
applications and multifunctional service x It is the customer’s responsibility that the air
braking. gap between brake pads and brake disc
Svendborg Brakes is able to deliver to you never exceeds the air gap recommended
complete solutions including brakes, x Always use a torque wrench when refitting
hydraulic power units and electronic SOBO® mounting bolts or valves in order to ensure
brake-controls. the torque obtained is the torque described
in this manual
1.1 Who to contact x There should be one manual available for
In case you have any questions to this the service/maintenance crew as a minimum
manual please contact your local
representative or nearest Svendborg Brakes Hydraulic power unit:
Office: x Do not operate the hydraulic power unit
before correctly filling the reservoir / oil tank
Svendborg Brakes offices: with oil
x Do not adjust valves or pressure switches to
Denmark: higher operating pressure than specified in
Jernbanevej 9, DK-5882 Vejstrup the manual
Phone: +45 63 255 255 x Do not change the size or type of
e-mail: sb@svendborg-brakes.dk components
x Do not use hydraulic fluids not
Germany: recommended in this manual
Kirchnerstrasse 42, DE-32257 Bünde
Phone: +49 522 368 5400 Brakes:
e-mail: sb@svendborg-brakes.de x Do not operate the brake before removing
the air from the hydraulic system by
Spain: bleeding and then re-filling with oil
C/ San Benito 24, 1ºB, ES-42001 Soria x Do not use higher operating pressures than
Phone: +34 97 523 3655 specified on the nameplate of the brake / or
e-mail: sb@svendborg-brakes.es in the manual
x Do not change the size or type of spring
USA: pack
. P.O.Box 1948, Denver, CO 80201-1948 x Do not use the brake pads when they are
Phone: +1 303 285 1271 worn to the minimum thickness as shown in
e-mail: sb@svendborg-brakes.us the manual
x Do not operate the brake if there is dirt or
or visit us at: corrosion protection on disc or brake pads
www.svendborg-brakes.com
Personal safety
1.2 Safety Do not work on the brake/ system before:
The Svendborg Brakes brake line of x The manual has been read and understood
products are designed to be mounted on a x The brake disc is locked and not able to
rotating brake disc for use in conjunction rotate before adjusting the brake and / or air
with parking brake applications, service gap
brake applications or emergency brake x Locking / securing the brake piston by using
applications only. the air gap bolt / air gap nut if working on a
spring applied brake
Note: x Being sure there is no pressure on the
x Always make sure that you consult hydraulic power unit or circuit
Svendborg Brakes A/S before using tools or x Being sure the oil pressure in the
any other equipment not recommended / accumulator(s) has been relieved / removed
specified in this manual x The control signals has been shut off and
blocked before working on the system
x The electrical power has been shut off
Rev: 07.07.06 / ECN 21618
Heavy equipment Figures within brackets ( ) relate to

Be careful when lifting the brake or brake position number and appendix number
components - it is heavy equipment and is i.e. (15-C) refers to position number 15 in
not made for manually lifting appendix C on both drawing and bill of
material (parts list).
1.4 Disclaimer
Svendborg Brakes A/S reserves the right to
revise this document without prior
notification. These documents have been
proofread for errors in translation and
accuracy. Despite this, technical and
Use proper lifting equipment in order to typographical deviations can sometimes
prevent personal injuries occur.
Fingers warning This document is updated on a regular

Never place your fingers between the brake basis; changes will be published in future
pad and the brake disc without having the printings. Improvements and/or changes to
brake piston properly secured the described products or manual can be
implemented at any time without preceding
notice.
In no event shall Svendborg Brakes A/S be

liable for any special, incidental,
consequential or punitive damages. This
includes, but is not limited to: damage to
other property or person, inconvenience,
loss of goodwill, lost profits or revenue, loss
of use of this product or any associated
x Avoid prolonged skin contact with hydraulic equipment, cost of substitutive equipment,
fluids – read the manufacturer’s instructions downtime costs or claims of any party such
before using hydraulic fluids damages, resulting from any misspellings or
x If using solvent cleaners you must read the inaccurate information in this users guide.
manufacturer’s instructions before using a
solvent cleaner, and then carefully follow This document or parts hereof may in no
these instructions. event be copied, reproduced, changed or
translated to other languages without explicit
1.3 Conventions used in this manual written permission from Svendborg Brakes
A/S.
To make sure that you perform certain tasks
properly, please take note on the following
symbols used throughout this manual. 1.5 Conversion factors
All units in this manual are in metric units
WARNING: Information to prevent personal If you have needs for conversion between
injury when trying to complete a task metric and imperial units the following
figures can be used.
CAUTION: Information to prevent damage Table 1.1

to the components when trying to complete Conversion factors
a task
Length:
1 inch = 25.4 mm (millimetre)
IMPORTANT: Information that you MUST 1 mm = 0.0394 inch
follow to complete a task (millimetre)
Mass:
1 kg (kilogram) = 2.2046 lb (pound)
NOTE: Tips and additional information to aid 1 lb (pound) = 0.4536 kg (kilogram)
in completing a task
Rev: 07.07.06 / ECN 21618
Force: NAMEPLATE FIGURE 1.2

/ SIGN
1 N = 0.2248 lbf.
(Newton) (pound force)
1 kN = 224.8089 lbf.
(kiloNewton) (pound force)
Pressure:
1 Bar = 0.1 MPa
(Mega Pascal)
1 Bar = 14.5038 PSI (pound per
square inch)
1 MPa (Mega 1 N/mm²
Pascal)
1 N/mm² 145.038 PSI (pound per
square inch)
Torque:
1 Nm (Newton = 0.7376 lbf.ft.
meter) (pound foot) Naming of the brake:
1 lbf.ft. = 1.3557 Nm “TYPE”
(pound foot) (Newton meter) The type is the description (name) of the
brake. Our brakes are named after following
Examples: nomenclature:
125 bar = 12.5 MPa = 1812.98 PSI
320 N/mm² = 46412.00 PSI BSAK 300-MS30S-200
305 Nm = 224.96 lbf.ft
BS = Brake system
A = Active applied
1.6 Nameplate / Serial-numbers K = Brake version
Before contacting Svendborg Brakes A/S or
your local reseller please record the serial
number of the product. MS = MonoSpring
This will ease the process of identifying the 30 = Disc thickness in mm
actual product supplied and will help in S = Standard finish
locating eventual problems. -200 = Option (version) number of the
brake
Brakes - reading the sign / nameplate
The sign is located on the brake and should Serial number:
look like this The serial number is located on the
FIGURE 1.1 nameplate / sign at the label named
“SERIAL NO.”
The serial number is a unique number,

which identifies the brake by the origin of the
brake, the date produced (year month date)
BSAK 300-MS30S-200 and the number in the series.
0 - 55.000 0 – 12,5 Example:

DK 040317 / 02 indicates this is brake
DK 040317 / 02 490-3443-801
number 02 produced in Denmark on March
th
17 in 2004.
For tracking purposes the serial number is
The nameplate / sign is positioned on the also written on the delivery note / invoice.
brake as per figure 1.2
Other information on the nameplate /
sign
Do not apply higher pressure than “ITEM NO”
This is the item number of the brake.
125 bar!.
“CLAMPING FORCE” and “OPERATING
PRESSURE”
The performance of the brake is shown by
the clamping force provided.
Rev: 07.07.06 / ECN 21618
The operating pressure has to ensure

correct use of the brake. Only limited movement of the brake disc and
brake is allowed. The sliding capabilities of
the brake are limited in both directions of the
1.7 How the brake works
mounting surface – forward and backwards.
The brake is designed to transfer a clamping When moving too close towards the
force into a braking torque from the brake mounting surface, the brake will touch the
calliper to a brake disc - either in order to base plate preventing it from sliding freely.
stop the rotation of the brake disc or for In worst case this may cause damages to
preventing it in rotating when stopped the brake / brake disc / hub / coupling and or
(parking brake). mounting structure.
When moving backwards from the mounting
The BSAK 300 Mono Spring is designed as surface the forces / torque on the shafts and
a hydraulically applied disc brake. base plate will increase resulting in reduced
The clamping force increases when the lifetime.
hydraulic pressure increases.
Check the mounting and dimension drawing
The Mono Spring brake contains one piston for exact dimensions, tolerances and
only - this is located inside the active allowed movement.
calliper.
In order to prevent the passive calliper from
FIGURE 1.3 sliding correctly on the shafts it is necessary
to use flexible hydraulic hoses as a final part
/section of the connection when connecting
the pressure ports on the brake to the
hydraulic power unit.
This Manual is valid for the brake option

BSAK 300-MS30S-200.
1.8 Function
The BSAK 300 brake is designed as a
hydraulically applied disc brake.
The clamping force is obtained from the

hydraulic pressure applying force to the
piston and to the brake pad against the
The active calliper is mounted / joined
brake disc.
together with the passive calliper using bolts
The reaction force is transferred via the
and spacers (spacers only where
yoke.
applicable).
The assembled / joined unit is floating on the
base plate via the two shafts and bearings
FIGURE 1.4
inside the passive calliper.
When braking - the piston inside the active

calliper (and brake pad no. 1) will move
towards the brake disc.
The brake pad no. 2 and the passive calliper
will then lift towards the brake disc and
provide a braking force on both sides of the
disc because the active and passive calliper
are assembled / joined and is floating on the
shafts.
Connecting and disconnecting hydraulic
Please notice that the brake pad (no. 2) in pressure to the pressure ports operates the
the passive calliper does not move. brake.
Only the brake pad in the active calliper The brake applies the clamping force when
moves – therefore the pad holder in passive the hydraulic oil pressure is applied /
calliper is lower than in the active calliper. supplied to the hydraulic chamber / unit
Rev: 07.07.06 / ECN 21618
causing the piston to execute movement

towards brake disc.
c FIGURE 1.6
The braking force decreases when hydraulic

oil pressure is removed from the hydraulic
chamber / unit causing the piston to execute
a short stroke towards the yoke - away from
the brake disc.
The pad retraction springs (mounted in the

brake pads) will then pull the pads away,
allowing the disc to rotate freely.
A pad worn indicator can be used for

indication of wear of the brake pads and
when to replace the brake pads.
These bolts (if mounted) will have to be
1.9 Transport removed during mounting of the brake and
refitted during the adjustment process.
When leaving the factory the brake is always
packed / wrapped to ensure maximum
security for the product during transport. 1.10 Connections
The weight of the brake is approx. 75kg The brake is as standard provided with two
excluding brake pads. pressure connections 1/4” BSP (8-C) and
one drain connection 1/8” BSP (7-C) – see
figure 1.7 and 1.8
IMPORTANT
The brake has one O-ring (8-B) mounted on PRESSURE DRAIN PORT
each shaft between the base-plate and the FIGURE 1.7
PORT 1/4” 1/8” BSP
passive calliper. The O-rings are split / open BSP (2x)
and are mounted with a piece of yellow tape
and – they are for transportation only and
must be removed before usage of the brake
FIGURE 1.5
Pressure ports
O-RING & YELLOW TAPE
The pressure ports are used to operate the
brake. The connection at the lowest position
shall always be used as a pressure
connection when connecting the brake to
IMPORTANT the hydraulic system.
If the brake is supplied with a positioning The brake should always be bled from the
system (optional) the bolts and springs (pos highest port when mounted.
c on fig. 1.6) may already be mounted from The highest pressure connection can be
the factory. This will be done to prevent the used if flushing is required.
calliper to slide on the shafts during Flushing is depending on the design of the
transport. hydraulic system and may not be an option.
Rev: 07.07.06 / ECN 21618
Drain ports wiper and will blow off the wiper and most
The drain connection (7-C) provides access likely destroy the seal.
to the chamber between the outer seal (12-
C) and the wiper (13-C) through a hole in
the yoke. IMPORTANT
In order to prevent the passive calliper from
sliding correctly on the shafts it is necessary
to use flexible hydraulic hoses as a final part
NOTE / section of the connection when connecting
It is recommended to use / connect the drain the pressure ports on the brake to the
connection because this can prevent leaking hydraulic power unit
oil from reaching the brake disc resulting in
reduced braking force.
1.11 Lubrication
A pipe with a length of approximately 10 to Different types of lubrication are used in
20cm can be connected to the lowest drain different situations.
port connection (1/8” BSP). This can be either for lubrication of the seals
A plastic hose (preferably clear) can be or disc springs during servicing or when
connected to the free end of the pipe (from tightening bolts of a diameter above 16mm.
before) and then connected to a container,
bottle or similar. Some symbols are used on the drawings to
Using a clear hose makes it easy to see if indicate where lubrication is needed during
leaking occurs from the seals. service.
The brake can optionally be supplied with an
air-breather in the drain port (7-C). Ì Grease – Molykote P74
Grease – Molykote B20
{ Hydraulic oil
MoS2 Molybdenum Disulfide
IMPORTANT
To prevent misty air to enter the interior of Molykote is produced by Dow Corning
the brake causing possible damage, fill the Hydraulic oil can be synthetic or mineral oil
container only partly with hydraulic oil and as per recommended oil types.
let the free air pass through this oil. Molybdenum Disulfide (MoS2) can be in
various forms; either spray, fluid or solid
FIGURE 1.8 state
1.12 Storage
The brake / calliper is externally treated at
the factory with an anti-corrosion film which
is sufficient for indoor storage for up to 12
months.
If the brake / calliper is to be stored for

periods longer than 12 months the active
calliper / piston be "worked" / operated at full
stroke, at least 20 times every 12 months to
When using this brake in salty and / or prevent the seals from ‘sticking to the piston.
aggressive environments please replace this
breather with a drain connection as
described previously in order to prevent the IMPORTANT
aggressive air to enter the interior of the The anti-corrosion protection should be
brake. reapplied if necessary after transporting or
handling.
CAUTION
Never apply any pressure to the drain 1.13 Disposal
connection (7-C). General
Applying pressure could damage the seals The operator and / or user are responsible
because the hydraulic oil / pressure then for the proper disposal of the brake and the
enter the chamber between the seal and the associated components.
Rev: 07.07.06 / ECN 21618
If any doubts about the correct disposal

please do not hesitate to contact Svendborg
Brakes or your local dealer or regional
disposal enterprises for further information.
Brake pads
The brake pads are made of a steel back
plate and some brake pad material / lining.
The brake pad material is either made of an
organic compound or of the sinter metal
type.
Either type is asbestos free and free of lead
The brake pads can be treated as steel

waste/scrap.
Hydraulic oil
Hydraulic oil may not enter the environment
and must be professionally treated when
disposed.
The oil must be removed from the brake and
from the hydraulic system / unit and stored
in proper containers until delivery to local
disposal enterprises.
Brake
The brake is in general made of cast iron or
machined steel.
Once the hydraulic oil has been removed
from the brake, and the seals have been
removed the brake can be treated as steel
waste/scrap.
Seals
The seals and o-rings used in the brake are
made of either Polyurethane (PUR), PTFE
(Teflon) or rubber (NBR).
They can all be treated as normal waste.
Electronics
If equipped with any
electronic equipment like
sensors, indicators or similar
- this equipment should be
treated as electronic waste
1.14 How to order spare parts

When ordering spare parts for your brake
please refer to the specific item number in
the parts list / bill of material – see
appendices or the recommended spare
parts list.
For full identification of the brake please
note the serial number and preferably the
item number and type stated on the name
plate / sign – see Section 1.6 – “Nameplate /
Serial-numbers”.
Rev: 07.07.06 / ECN 21618
2. Installation
2.3 Cleaning of the mounting surfaces
2.1 Lifting and handling The mounting surface of the bracket or
The BSAK 300 Mono spring brake is customer post / gearbox must comply with
equipped with eyebolts on the calliper and the relevant arrangement drawings and
should only be lifted by means of placing a mounting data drawings.
hook through them.
The eyebolts mounted on the brake can be If the mounting surface is not within the
moved to the back of the passive calliper specification this can cause the base plate
half or they can be mounted in the brake to permanently distort and prevent the
pad holders for lifting. calliper from sliding on the shafts / axles.
If the eye bolts are mounted in brake pad
holders please remove eyebolts again be for It is critical that the base plate is bolted to
use of the brake. the mounting surface in compliance with the
In order not to damage any parts on the tolerance specified on the calliper dimension
brake do not fit any hook or tie any rope, drawing.
chain or strap around indicators, hoses,
positioning system, etc.
When lifting please note that the total weight IMPORTANT
of the complete brake is approx. 75 kg. The joint between the base plate and the
customer post / gearbox is classified as a
friction joint.
2.2 Cleaning the brake disc
Before installing the brake callipers the Therefore NO lubricant or other compound
brake disc must be cleaned from any dirt or shall be applied between the calliper and
anti corrosive protection. mounting surfaces.
The anti corrosive protection can normally The mounting of the calliper does NOT rely
easily be removed in two steps: on the shear capacity of the mounting bolts
but of the friction joint. This friction joint is
1) by using petroleum or diesel fuel for the created by the clean, dry, lubricant free
initial cleaning surface machined to the correct surface
2) using solvent cleaners to remove the finish and of the tension created by the
remaining dirt completely mounting bolts.
Use a cleaning solvent for the final cleaning. The mounting surfaces for the base plate
Solvent cleaners could be clear methylated should be cleaned in the same way as the
or white spirits or isopropyl alcohol. brake disc - see section 2.2 – ‘Cleaning the
brake disc’.
Any residual oil or anti-corrosion preparation
will reduce the coefficient of friction greatly.
WARNING
Solvent cleaners can be flammable,
WARNING poisonous and can cause burns.
Solvent cleaners can be flammable, Please follow the manufacturer’s instructions
poisonous and can cause burns. and see section 2.2 – ‘Cleaning the brake
disc’.
To avoid serious personal injury when you
use solvent cleaners, you must read the
2.4 Handling / mounting the brake
manufacturer’s instructions before using a
solvent cleaner, and then carefully follow pads
these instructions. Friction material is a very essential part of
the brake system and the brake pads should
Also follow these procedures: be handled carefully to avoid damages to
x Wear protective eye protection the brake pads / friction material.
x Wear clothing that protects your skin The brake pads should be kept as clean as
x Work in a well-ventilated areas possible - be careful to protect the pads from
grease and oil. Even a small amount of oil
Always follow local rules and regulations for can reduce the friction coefficient
/ when working with solvents considerably.
Rev: 07.07.06 / ECN 21618
It is possible, when assuming that the space

is available for the hub, to change the pads
NOTE just by removing the 2 innermost bolts
All brake pads supplied by Svendborg (M10x35) and pad holders on each pad and
Brakes are asbestos free and free of lead. thereafter by sliding the brake pad towards
Certificate is available on request. the centre of the main shaft.
Brake pads can be supplied in several types Mounting is done in reverse order.
and with different brake pad materials
depending on the actual needs in the For information on the tightening torque for
application. the loose pad-holders please refer to Table
In general there are two types of brake 2.2 – “Bolts for brake pad holders / pads”
pads:
x Brake pads with organic / composite If the hub is too large the brake pad can be
linings removed by removing the 2 bolts (M12x50)
x Brake pads with sintered metal pucks / (5-C) and the pad holder (4-C).
material The brake pad can be removed by sliding
the brake pads sideways out of the brake.
2.4.1 Brake pads with organic brake pad material Mounting is done in reverse order.
is quite sensitive to dirt, grease and oil and
they are normally packed / sealed in plastic FIGURE 2.2
to protect them from contamination – please
keep the pads in the packet for as long as
possible.
Organic materials are very sensitive to
grease and oil and can not be cleaned. They
must in most cases be discarded and must
be replaced if exposed to this.
2.4.2 Brake pads with sinter metal brake pad

material is less sensitive to dirt, grease and
oil and can in some cases - where not fully
soaked up with oil - be cleaned with solvent
and re-used.
Since they are not that sensitive the brake
pads of sintered metal are not necessarily
wrapped in plastic.
CAUTION
It is essential that sinter metal brake pads
WARNING are oriented correctly before usage.
Solvent cleaners can be flammable,
poisonous and can cause burns. On some brake pads the sinter metal pucks
Please follow the manufacturer’s instructions are oriented to absorb the heat as effectively
and see section 2.2 – ‘Cleaning the brake as possible.
disc’. If using sinter metal brake pads with pucks
(round or rectangular shape) oriented in a
2.4.3 The brake pads are mounted with loose pad curved pattern the brake pad should be
holders on the pad (bolts). oriented with the curve towards the
perimeter of the brake disc.
FIGURE 2.1
LOOSE PAD HOLDER / GUIDE
Rev: 07.07.06 / ECN 21618
FIGURE 2.3 These O-rings are split and are marked with
a piece of yellow tape.
FIGURE 2.5
NOTE
The pad holder on the active calliper is
higher / larger than the one on the passive O-RING & YELLOW TAPE
calliper. This is because the brake pad on
the passive calliper does not move whereas
2.5.2 Check that the mounting surface of the
the brake pad in the active calliper moves
bracket or customer post / gearbox does
the full distance.
comply with the relevant arrangement
drawings and mounting data drawings i.e. is
2.4.4 After mounting the pad holders the pad
flat and at right angles to the brake disc,
retraction springs should be mounted into
before mounting the base plate.
the brake pads
2.5.4 Ensure that the mounting surfaces are clean
FIGURE 2.4 of dirt and oil – otherwise clean as per
Pad retraction
spring & bolt section 2.3 – ‘Cleaning of the mounting
surfaces’
2.5.5 Position the brake on the mounting flange

and mount the lowest bolt – without fully
tightening it.
2.5.6 If possible tip the brake backwards using the

lower bolt (M20) as pivot. Doing this will
ease the mounting of the brake pads on
initial installation.
FIGURE 2.6
Pad retraction
spring & bolt
2.5 Mounting the brake

2.5.1 Remove the indicator (if fitted) to prevent it
from being damaged.
2.5.2 The brake has one O-ring (8-B) mounted on If this is not possible mount the brake with
each shaft between the base plate and the both bolts and tight them according to
passive calliper. They are only mounted for section 2.5.11 / Table 2.4
avoiding damages during transport and must
be removed before usage of the brake. 2.5.7 Align the brake on the shafts to the disc
(slightly in the middle).
Rev: 07.07.06 / ECN 21618
GENERAL FIGURE FIGURE 2.8

2.5.8 Unpack the brake pads from the plastic
sealing / bag. Be careful and protect the
pads from grease and oil, see section 2.4 -
‘Handling / mounting the brake pads’
NOTE
If the brake has been tipped backwards /
pivoted it may be possible to mount the
brake pads and pad retraction springs
without having to remove the brake pad
holders.
Please note that the piston has to be fully
lifted in order to mount the pads.
2.5.9 Slide the brake pads into position and mount

the brake pad holder (4-C) and the two bolts FIGURE 2.9
Pad retraction
(M12x50) (5-C) again. spring & bolt
Use the tightening torque specified on the

Pad retraction
spare parts drawing or from Table 2.2 – spring & bolt
“Bolts for brake pad holders”
Table 2.2
2.5.11 If the brake was pivoted, please check the
Bolts for brake pad holders / pads mounting surfaces and the brake disc for dirt
Bolt size Torque and grease before rotating into place and
Lubricated MoS2 Dry & Oiled mount the brake with 4 x M20 bolts grade
M10 8.8 37 Nm 45 Nm 8.8.
M12 91 Nm 108 Nm
Use the tightening torques from the spare-
10.9
parts drawing or Table 2.4 – ‘Mounting bolts
“Lubricated” is based on Molykote – MoS2
for base plate’
2.5.10 Fit the pad retraction springs and bolts and Table 2.4
mount these - tighten firmly according to
Mounting bolts for base plate
Table 2.3 – ‘Bolts for pad retractions springs’
Torque
Bolt size
Lubricated MoS2 Dry & Oiled
Table 2.3 M20 8.8 305 Nm 365 Nm
Bolts for pad retraction springs “Lubricated” is based on Molykote – MoS2
Torque
Bolt size 2.5.12 Check that the brake disc can rotate freely,
M10 8.8 20 Nm 27 Nm without touching the brake and that the
brake is aligned parallel to the brake disc
Rev: 07.07.06 / ECN 21618
2.6 Inspecting the alignment of the

brake FIGURE 2.11
2.7.1. Check that the brake pads can move freely

within the brake pad holders. The pad
retraction springs will reduce the movement
somewhat, but the brake pad must not be
stuck to the brake.
IMPORTANT
The axial movement of the brake disc must
not exceed 0.3mm – see mounting drawing
2.7 Back-stop set

The back-stop set is mounted to minimize If the brake is mounted in horizontal position
the piston movement and thereby even higher gravitational forces will occur. In
decreasing the reaction time for the brake. this situation a special positioning system is
recommended needed.
2.7.1 Apply hydraulic pressure to the brake.
FIGURE 2.12
2.7.2 Turn the M6 bolts until they touch the brake
pad.
2.7.3 Unscrew the bolts until the desired air gap.

The pitch for the bolt is 1mm.
2.7.4 Tighten the nuts and release the pressure.
2.8 Positioning system

If the mono spring brake is mounted in
perfect vertical position the brake pads on
the passive side of the brake will just slightly Please note that in this situation wear will be
touch the brake disc. on the active side.
If axial movement of the disc is present and
wear becomes a problem - a positioning To prevent the gravitational forces from
system can be mounted on the brake. wearing the pads off - the mono spring can
be equipped with a positioning system.
FIGURE 2.10
In general the positioning system has two
functions:
1) adding forces to absorb/minimize the
gravitational forces – using springs in
either direction
2) to align the brake within the air gap i.e. to
position the brake with equal amount of
space between the brake disc and the
brake pads on both sides
The positioning system on the BSAK 300

mono spring consists of:
If the brake is not mounted at level i.e. it is 2 bolts, 2 springs, 2 guides and 2
mounted downwards like in a wind turbine, nuts
the gravity will provide a force on the brake,
making the brake pads on the passive side The springs are placed on the shafts. See
touch the disc – this will result in wear on the Appendix G
pads and a positioning system is highly
recommended.
Rev: 07.07.06 / ECN 21618
FIGURE 2.16
(Equal air gap)

FIGURE 2.14
2.10 Bleeding the calliper
2.10.1 The calliper’s hydraulic system must always
Remember to mount / fit the nuts before be bled in conjunction with assembly,
entering the thread in the passive caliper. repairs or when making changes in the
system.
2.9 Adjusting the positioning system Failure to bleed the brakes will allow air to
remain in the brake system.
This section is only valid if the brake is
This will / could prevent the hydraulic
equipped with a positioning system
pressure in the brake system from rising /
For exact location of the positioning system
increasing enough to lift the brakes
check Appendix B - position 11
correctly. This could cause that the brake
pads will still touch the brake disc and
After initial installation the positioning
heating of the brake pads and brake disc
system shall be adjusted i.e. the distance
could occur.
between the brake pad and the brake disc
Air in the system could also destroy / blow
should be adjusted to be equal
the seals (diesel effect) within the brake /
calliper.
2.9.1 Measure the air gap
The air gap is the space between the brake
2.10.2 The calliper must be bled at the highest
pads and the brake disc, when the piston is
point on the brake through the pressure port
completely.
(8-C).
A special bleeding plug (Mini mess / test
Measure the air gap using a feeler gauge
point) ¼” BSP and a hose can be supplied
from Svendborg Brakes.
FIGURE 2.15
2.11 Installing the Indicator

The BSAK 300-MS30S-200 brake can be
mounted with a pad worn indicator.
The mechanical switch is tamper-proof and

is preset from the factory
2.11.1 The indicator for ‘Pad worn must be

mounted in the yoke.
If the positioning system is mounted the
springs will push the passive calliper Remove the plug (1/2” BSP) and fit the
towards the base plate and the air gap will indicator.
be located on the passive side only
2.9.2 Adjust the air gap to be symmetrical by

lifting the passive calliper by turning the bolt
(1-G)
Check the air gap again before locking the

nut (2-G)
Rev: 07.07.06 / ECN 21618
2.12.4 Apply the hydraulic pressure to the correct

c pressure level. Run until bedded in
Example:
25% of clamping force needed
25% of the operating pressure of 11.5MPa =
2.88MPa (29 bar)
The hydraulic pressure of 29 bar should be
applied during bedding in.
FIGURE 2.17 2.13 Removing the brake
2.13.1 Remove the pad retractions springs (and

2.12 Bedding in bolts) from the active calliper
To obtain the rated coefficient of friction
between the brake pad and the brake disc, 2.13.2 Remove the brake pad holder (4-C) and the
and to ensure the pad surface is aligned to brake pad (12-B) from the active calliper
the disc, it is essential that the pads are
bedded to the disc surface. 2.13.3 The brake can now be removed safely by
removing the 4 mounting bolts going through
The coefficient of friction may drop by the base plate (M20)
approx. 20% when not bedded in.
This can be done by making a series of

load-tests with increasing load or speed until
3. Maintenance
sufficient coefficient of friction is achieved. 3.1 Pad worn signal
If the brake disc is new the time of bedding
in will be longer because the disc also has to During usage the brake pads will wear.
be bedded in. Always use new pads with a
new disc. Never use used pads with a new When the signal for Pad Worn switches it is
disc. an indication that the brake pads should be
replaced.
Organic pads:
Organic pads can normally be bedded in by 3.2 Replacing the brake pads
driving the disc through the pads with a The brake pads must be replaced when
minimum of 25% of the rated clamping force each pad has been worn 5mm.
applied, or if that is not possible by making a
series of activations with increased load or The brake pad thickness can always be
increased speed. checked with a gauge:
All brake pads for the brake consist of a
Sinter-metal pads: steel back plate and a friction material. The
The bedding in process for sinter-metal pads brake pad has a total thickness of 24mm,
is the same as for organic pads, but with a i.e. all brake pads must be replaced when
slightly higher clamping force when bedding the thickness of friction material + back plate
in – approx. 40% of the rated clamping force is minimum 19mm.
applied.
The brake pads are packed in sealed plastic
During the process of “bedding in”, the disc to protect them from contamination – please
temperature should be monitored to ensure keep the pads in the packet for as long as
that the disc does not overheat. possible.
Be careful to protect the pads from grease
Instruction for the bedding in process is and oil. Even a small amount of oil can
packed together with the brake pads. reduce the friction coefficient considerably.
2.12.1 Connect a hand pump and a pressure See section 2.4 -‘Handling / mounting the
gauge into one of the pressure ports (8-C). brake pads’ for proper handling of the brake
pads
2.12.3 Start the application / rotating of the brake
disc 3.2.1 Remove the indicator if fitted
Rev: 07.07.06 / ECN 21618

3.2.2 Remove the pad retraction springs and bolts
from the active calliper and passive calliper.
WARNING
Under no circumstance place your fingers
between the brake pad and the brake disc.
FIGURE 3.1
Pad retraction
spring & bolt
Use the tightening torque specified on the

spare parts drawing or from the table 2.2 –
‘Pad holders’.
3.2.12 Fit the pad retraction springs and bolts. The

tightening torque as specified in section 2.5
– ‘Mounting the brake’ / Table 2.3
3.2.14 Readjust the positioning system if equipped

– see section 2.7 Back-stop set
The back-stop set is mounted to minimize
the piston movement and thereby
decreasing the reaction time for the brake.
Pad retraction
spring & bolt 2.7.1 Apply hydraulic pressure to the brake.
2.7.2 Turn the M6 bolts until they touch the brake

pad.
3.2.3 Remove the brake pad holders (4-C) and
the 2 bolts (M12x50) (5-C) from both the 2.7.3 Unscrew the bolts until the desired air gap.
active and passive calliper. The pitch for the bolt is 1mm.
2.7.4 Tighten the nuts and release the pressure.

FIGURE 3.2
2.8 – ‘Positioning system’
3.2.15 Remember to bed in the brake pads before

taking the brake into full load situations –
see section 2.12– ‘Bedding in of the brake
pads’
3.3 Replacing other components

Some minor components can be replaced
with the brake mounted on site, but it is
highly recommended to take the brake to a
workshop for repairs.
3.2.10 Remove the brake pads by sliding them NOTE

sideways out of the brake Depending on the work that needs to be
done on the brake it might be worth
3.2.11 Slide the brake pads into position and mount considering only taking the active calliper to
the brake pad holders (4-C) and the two the workshop.
bolts (M12x50) (5-C) in each again.
CAUTION
Rev: 07.07.06 / ECN 21618
When lifting please note that the total weight The surface of the internal components i.e.
of the complete brake is approx. 75kg - the piston (2-C) and the yoke (1-C) that are in
active calliper itself weighs approx. 20kg. contact with the seals are all ground or
polished.
FIGURE 3.4
Please check that these surfaces are not
damaged or scratched in any way and
handle them with care to avoid damaging
the surfaces.
A damaged piston will immediately ruin the
seals resulting in leakage.
3.5 Replacing the seals

If the brake has been leaking it is
recommended to replace all seals not only
single seals.
IMPORTANT
Please note that the sealing solution /
design can vary over time. The actual seals
of a brake can therefore vary from the
3.3.1 Either remove the brake completely replacement seal kit supplied.
according to section 2.13 – ‘Removing the All sealing solutions used are fully
brake’ by removing the M20 mounting bolts interchangeable and backwards compatible.
(4pcs) or remove the active calliper only by For specific details on the different seal
removing the M20 (9-B) mounting bolts types and how they should be mounted -
instead. please see Fejl! Henvisningskilde ikke
fundet. – ‘U-Cup Information’
WARNING
Always ensure there is no hydraulic
IMPORTANT
pressure in the brake before starting work.
Ensure that there is no pressure on the
calliper.
3.4 Dismantling the active calliper
General 3.5.5 Remove the piston by hand.
The greatest possible cleanliness must be
observed when working on a hydraulic
system of any type. IMPORTANT
Each part must be cleaned thoroughly Handle the piston carefully. A scratched
washed in solvent cleaners piston can immediately destroy the new
Solvent cleaners could be clear methylated seals.
or white spirits, isopropyl alcohol or
trichloroethylene. 3.5.6 Place the piston at a safe location while
replacing the seals.
WARNING 3.5.7 Remove the wiper (13-C) and the seal (12-C
Solvent cleaners can be flammable, & 11-C).
poisonous and can cause burns.
See section 2.2 – ‘Cleaning the brake disc’
for additional information
Parts must be stored in a clean and dust

free environment. All assembly work must
also be carried out in clean and dust free
environment.
Dirt shortens the lifetime of the seals

considerably and may also damage the
calliper / hydraulic unit.
Rev: 07.07.06 / ECN 21618
FIGURE 3.5 3.5.11 Lubricate the seals and yoke according to

the lubrication note in the Appendix C –
‘Spare parts drawing’
3.5.12 Place the piston (2-C) in the yoke (1-C)
3.5.13 Push the piston down as far as possible.
3.5.14 Depending on how the brake / active calliper

has been brought to the workshop it is now
ready for being mounted again. Refer to
section 2.5 – ‘Mounting the brake’
3.5.15 If the calliper half was removed from the

complete brake the mounting bolts must be
fitted again using the tightening torques from
the spare-parts drawing or from Table 3.1 –
‘Mounting bolts for calliper half’
Use a screwdriver to lever the seal, and the
wiper out of the grooving (a hammer be
become handy to remove the wiper) Table 3.1
Be careful not to damage the edges on the Mounting bolts for calliper half
grooves Bolt size Torque
3.5.8 Clean and dry the involved parts, see M20 10.9 430 Nm 510 Nm
section 2.2 - ‘Cleaning the brake disc’ for
details.
3.5.9 Open the seal kit and place the seals on the
NOTE
table in correct order.
Mounting must in general ALWAYS be
carried out using new bolts, nuts and
3.5.10 Mount the new seals (11-C, 12-C) and the
washers, otherwise the clamping force of the
wiper (13-C). The dust lip of the wiper must
bolt connection may not be present
be facing outwards.
For easing the mounting of the wiper it

should squeeze in a kidney style. 3.6 Lubrication of the brake
Lubrication is only necessary after
FIGURE 3.6 dismantling the active calliper for internal
maintenance / replacement of the spring
package.
When replacing the spring package, every
single cup spring must be greased.
For details on where to lubricate internally

see appendix C - ‘Spare parts drawing’.
CAUTION
Only use your fingers to squeeze out any
kinks. Be very careful with the edges on the
piston rod seals as they are quite sensitive.
Rev: 07.07.06 / ECN 21618
4. Trouble shooting
Fault Cause Action
The brake applies slowly. Air in the hydraulic system Bleed system at highest point
and at brake
Abnormal throttling in the Check that all valves are in the
hydraulic system or correct position.
valve in wrong position
Abnormal throttling in the Clean and check pipes, hoses
hydraulic system caused by dirt and valves.
The hydraulic oil in pressure lines Check that the oil is the
between brake and tank has too recommended grade and the
high viscosity (too thick) temperature is not too cold.
Long braking time or long Load too heavy or speed too high Check the load and speed values.
braking distance or
insufficient braking force.
Oil, paint or grease on brake disc Clean the brake disk - see section
or brake pad. 2.2
Replace or clean the brake pad –
see section
Check the hydraulic system does

not leak.
Not all brakes are braking / Check valves where applicable –

connected. check that the individual brake is
working.
Leakage Worn seals Replace seals
Uneven wear on pad. The brake is incorrectly aligned Check the alignment and that the
passive calliper can float on the
shafts
Positioning system not adjusted Adjust positioning system
correctly (if mounted)
Excessive disc throw or shaft Replace the brake disc and check
deflection the shaft deflection.
Abnormally heavy wear on Increased brake utilisation Check that the load speed and
pad. frequency do values.
Rev: 07.07.06 / ECN 21618
Appendix A - Dimension drawing, Brake
SVENDBORG BRAKES
Rev: 07.07.06 / ECN 21618
Appendix B - Assembly drawing, Brake exploded
SVENDBORG BRAKES
Rev: 07.07.06 / ECN 21618
Appendix B - Assembly parts list, Brake
BSAK 300-MS30S-200
490-3453-801 BSAK 300 MS30S-200
POS. QTY ITEM NUMBER ITEM NAME

1 1 PCS 490-3421-801 BSAK 300-S-100 ½
2 1 PCS 490-1899-801 PASSSIVE CALIPER
3 1 PCS 490-0419-801 BASE PLATE COMPLETE
4 1 PCS 490-0307-002 TOP PLATE
5 2 PCS 2121-2532-493 BOLT
6 2 PCS 2151-2022-173 WASHER
8 2 PCS 6490-0013-001 O-RING Ø48X4,0
O-RINGS HAS TO BE REMOVED BEFORE FIRST USAGE
9 1 PCS 490-1922-805 BOLT SET FOR 30MM BRAKE DISC

10 2 PCS 4490-0610-001 EYE BOLT M10
11 1 PCS 490-2122-801 POSITIONING SYSTEM
12 1 PCS 490-3481-802 BACK—STOP SET
THE FOLLOWING PARTS ARE NOT INCLUDED IN 490-490-3453-801 AND MUST BE ORDERED
SEPERATELY
7 1 PCS 490-0666-804 PAD RETRACTION SPRING SET
13 1 PCS 490-0402-803 BRAKE PAD SET MD 550 (SINTER METAL)
14 1 PCS 490-3476-828 INDICATOR “ON/OFF” & “PAD WEAR” 10MM WITH 5M CABLE
WITH STRAIGHT PLUG
Rev: 07.07.06 / ECN 21618
This page is supposed to be empty
Rev: 07.07.06 / ECN 21618
Appendix C - Spare parts drawing, Calliper half exploded
SVENDBORG BRAKES
Rev: 07.07.06 / ECN 21618
Appendix C - Spare parts drawing, calliper half
SVENDBORG BRAKES
Rev: 07.07.06 / ECN 21618
Appendix C - Spare parts list, calliper half

BSAK 300-MS30S-200
490-3421-801 Calliper half BSAK 300 – S – 100 ½
POS. QTY ITEM NUMBER ITEM NAME

1 1 PCS 490-3220-002 YOKE BSAK300
2 1 PCS 490-0544-002 PISTON BSAK 300
3 1 PCS 2522-2111-113 HYDRAULIC PLUG 1/2” BSP WITH SEAL
4 2 PCS 490-1925-001 PAD HOLDER
5 4 PCS 4490-0633-009 BOLT M12 X 50 10.9
6 4 PCS 478-0870-001 WASHER
9 1 PCS 478-0815-003 SIGN
10 4 PCS 4490-0676-001 BLIND RIVET
490-3427-801 SEAL KIT
11 1 PCS 6490-0028-007 O-RING

12 1 PCS 6490-0023-010 ROD SEAL
13 2 PCS 6490-0015-003 WIPER
Rev: 07.07.06 / ECN 21618
Appendix D - Mounting Drawing
Rev: 07.07.06 / ECN 21618
Appendix E - Spare parts drawing, Passive Caliper
SVENDBORG BRAKES
Appendix E - Spare parts list, Passive Caliper

Passive caliper – 490-1899-802
Pos. Qty Item number Item name

pc
1 1 s 490-1899-001 PAS. CALIPER GGG50 W/BEAR.
pc
2 4 s 7490-0001-004 SLIDE BEARING Ø55X50X40
pc
3 2 s 490-1926-001 PAD HOLDER BSFI300-MS
pc
4 4 s 4490-0633-009 BOLT M12X50 10.9
pc
5 4 s 4490-0632-002 WASHER Ø13X24X2,5
Rev: 07.07.06 / ECN 21618
Appendix F - Spare parts drawing, Base plate
SVENDBORG BRAKES
Appendix F - Spare parts list, Base plate

Base plate – 490-0419-802
Pos. Qty Item number Item name

pc
1 2 s 490-1072-001 SHAFT Ø50
pc
2 2 s 4490-0607-006 SPRING PIN SLOTTED Ø6X20
pc
3 2 s 4490-0607-007 SPRING PIN SLOTTED Ø4X20
pc
4 1 s 490-0419-002 BASE PLATE
Rev: 07.07.06 / ECN 21618
Appendix G – Positioning system

Date: 05.01.2004
DATA SHEET No.:

Replace:
Approved:
DEB-0300-027
03.03.2003
NCH
Positioning system for BSFI 300-MSXXX

Standard (S) and offshore (R) versions
Spareparts
490 2122-801 (Standard version)
Item Qt Parts no. Description

1 2 4490 0613-013 Bolt M10x160
2 2 4490 0614-001 Nut, M10
3 2 2151 2022-173 Washer
4 2 3490 0032-001 Spring
5 2 490 0515-001 Spacer
490 2122-803 (Offshore version)
Item Qt Parts no. Description

1 2 4490 0641-015 Bolt M10x160 A4
2 2 4490 0650-004 Nut, M10 A4
3 2 2151 2022-172 Washer A4
4 2 3490 0032-001 Spring
5 2 490 0515-001 Spacer
Rev: 07.07.06 / ECN 21618
Appendix H - Brake switch / Indicator

Date: 30.08.2005
DATA SHEET No.:

Replace:
Approved:
DEB-INDI-002
27.06.2005
NCH
Page 1 of 2
BRAKE SWITCH – 30 VDC / AC
Brake “Pad Worn” - Hydraulic applied (active) brakes and brakes with
Automatic Wear Adjustment (AWA)
Function
Two micro-switches are mounted inside the housing of
the switch. The explorer triggers these switches at two C
different positions.
NOTE - The indication for “Pre Pad Worn” and “Pad
B
Worn” is only active during braking and disappears
when the brake is lifted - therefore a holding circuit may
be ideal.
Fail Safe operation
96
For fail-safe operations the switch should be wired to Connections
have a signal/connection when everything is ok (i.e.
closing a normally open switch (NO)). The connection
should disappear when switching i.e. applying the
brake, having wear or in case of faults like broken
cable, poor connections etc.
“Pad Worn”
The switch measures the brake pad movement. A
The “Pad Worn” switch triggers, when the brake pad is
worn and needs to be replaced.
On active brakes the signal is given by measuring Functions for Fail Safe operations
directly on the pad. This is done through the threaded
holes in the yoke - next to the pad holders or through a
hole in the adjusting screw.
On AWA brakes this is done through the push-rod in
the centre of the adjusting screw.
The switch has two switch points with 1.5mm in

between.
The first switch point (1-4) is used for the “Pre Pad
Worn” signal. This indicates 1mm left on the pad before
it must be replaced.
The second switch point (2-3) is used for the “Pad
Worn” signal. This indicates that the pad needs to be
replaced.
Mounting
1. Adjust the airgap on the brake. (Refer to manual)
2. Remove the plugs from the adjusting screw.
3. Screw the indicator tread (A) into the adjusting screw
4. Electrical connection. (See connection diagram)
Technical data
0 0
Operating temperature : -40 C to +85 C
Max. Voltage : 30 VDC / AC
Max. Current : 10 mA
Switching tolerance : +/- 0.3mm
Max. Stroke : 16mm
Protection grade : IP 65 (mounted)
Max. Tightening torque Ø21 mm : 20 Nm - A)
Max. Tightening torque Ø12 mm : finger tight - B)
Min. no. of operations : 1 million
Cable length - C) : 5, 10 or 15meters
Cable type/material - C) : PUR *) = Brake “ON” = NO hydraulic pressure
2
Cable dimension - C) : 5 * 0.34mm = brake released / activated
Thread size - A) : 1/2” BSP **) = Brake “OFF” = MAX. hydraulic pressure
Spanner size (SW) - A) : 24mm = brake “lifted”
Rev: 07.07.06 / ECN 21618
Appendix I - Technical data

Date: 07.12.2005
DATA SHEET No.:

Replace:
Approved:
DEB-0300-043
05.12.2005
NCH
TECHNICAL DATA AND CALCULATION FUNDAMENTALS FOR

DISC BRAKE BSAK 300
BRAKING TORQUE
The braking torque MB is calculated from following formulas:
Where:
(D ȅ 0,13) a is the number of callipers acting on the disc
ȂǺ a FǺ [Nm]
2 FB is the braking force according to table above [N]
DO is the disc outer diameter [m]
FǺ FC 2 P [N] FC A P 10 [N] FC is the clamping force [N]
2
A [cm ], P [bar] and µ see values below
The actual braking torque may vary, depending on friction coefficient.
CALCULATION FUNDAMENTALS Standard Monospring

Weight of caliper with bracket: 56 kg 73 kg
Weight of caliper without bracket: 40 kg
Overall dimensions (20mm disc) 331 x 320 x 321 mm 260 x 420 x 300 mm
Pad width: 130 mm 130 mm
2 2
Pad area: (organic) 29.000 mm (*) 29.000 mm (*)
Max. wear of pad: (organic) 10 mm (*) 7 mm (*)
2 2
Pad area: (sintered) 20.000 mm (*) 20.000 mm (*)
Max. wear of pad: (sintered) 7 mm (*) 7 mm (*)
Nominal coefficient of friction: P= 0.4 P= 0.4
2 2
Total piston area - each caliper half: A=44,2 cm A=44,2 cm
2 2
Total piston area - each caliper: 88,4 cm 44,2 cm
3 3
Volume for each caliper at 1 mm stroke: 8,8 cm 4,4 cm
3 3
Volume for each caliper at 3 mm stroke: 24,6 cm 13,2 cm
Actuating time (guide value for calculation): 0.3 sec. 0.3 sec.
Pressure connection/port: 1/4" BSP 1/4" BSP
Drain connection port R: 1/8" BSP 1/8" BSP
Max. operating pressure: P=125bar P=125bar
Recommended pipe size: 10/8 mm 10/8 mm
Operating temperature range -20 to +70 °C -20 to +70 °C
(For temperatures outside this range contact Svendborg Brakes)
(*) On each brake pad
Rev: 07.07.06 / ECN 21618
Appendix J - Recommended fluid
Date: 16.01.2004
DATA SHEET No.:

Replace:
Approved:
DEB-DIVE-005
19.12.2003
N. Christensen
RECOMMENDED FLUID FOR DISC BRAKES & HYDRAULICS

Pressure fluids / Oil types
The following oil types are recommended by Svendborg Brakes – other types corresponding to these can be used.
The minimum and maximum temperatures for standard components are, -20°C - +60°C / -14°F - +140°F.
Extreme temperature applications may require special options. Please contact Svendborg Brakes.
Special option Standard Special option

-30°C - +20°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Mineral Oil
-22°F - +68°F -14°F - +104°F +50°F - +140°F +86°F - +158°F
Shell Tellus Artic Tellus TX32 Tellus TX46 Tellus TX68
Mobil - DTE 13M DTE 15M DTE 16M
Hydro Texaco Rando Ashless 8401 Rando HDZ32 Rando HDZ46 Rando HDZ68
Valvoline - Ultramax HVLP32 Ultramax HVLP46 Ultramax HVLP68
-30°C - +20°C -20°C - +40°C +10°C - +60°C +30°C - +70°C
Syntethic Oil
-22°F - +68°F -14°F - +104°F +50°F - +140°F +86°F - +158°F
Mobil - SHC 524 SHC 525 SHC 526
(1)
Bio Oil -30°C - +20°C -20°C - +30°C +10°C - +60°C +30°C - +70°C
(Ester or Colza oil)
-22°F - +68°F -14°F - +86°F +50°F - +140°F +86°F - +158°F
Shell - Naturelle HF-E15 Naturelle HF-E32 Naturelle HF-E46
General: Mineral Pressure Fluids according to DIN 51524 Part 3
(1) There must be less than <200PPM water in the oil, due to the seals.
Viscosity
Recommended viscosity range: 20-200 cSt at working temperature.
Filtration
The oil in a hydraulic system and the oil added to the hydraulic system must always be filtered. The level of cleanliness
in a hydraulic system is an important factor to the lifetime of the system.
When refilling the hydraulic tank, it is recommended that the oil added to the system is filtered through an off-line filter
unit.
The hydraulic system, supplied by Svendborg Brakes, has a build-in oil filter with a standard 10-micron purity filter. To
maintain a reliable system it is recommend that only hydraulic oil of the following classes of purity is used: NAS 1638,
Class 8, or ISO 4406, Class 19/17/14.
It is recommended that the filter be changed at a minimum, once every six months or more often depending on the level
of exposure to contamination.
Service life of pressure fluids

Mineral oil: 8.000 Hours or at least once a year.
Other fluids: 2.000 Hours or at least once a year.
Change of pressure fluid

Note: The mixing or blending of different brands or types of pressure fluid can cause unintended chemical reactions,
such as sludging, gumming etc. The complete hydraulic system should be thoroughly flushed prior to changing from one
oil type to another.
The respective manufactures should be contacted prior to changing from one pressure fluid to another.
Seal material
Brakes from Svendborg Brakes A/S are normally supplied with PUR-seals (PolyURethane)
PTFE (PolyTetraFlourEthylene) seals can be delivered on request for most of the brake types.
Note: the BSFG 400 brake series are supplied with NBR rubber fabric seals (acrylNitrile Butadiene Rubber).
Rev: 07.07.06 / ECN 21618
Appendix K - Recommended spare parts

Recommended spare parts for one brake
Brake pad set

Sinter metal MD550 490-0402-803
Seal kit 490-3427-801
Brake pad retraction springs

Pad retraction spring set 490-0666-804
Back-stop set 490-3481-802
Positioning system
Positioning system - standard
490-2122-801
Indicators
Mechanical indicators
Pad Worn 10 mm Indicator (straight 490-3476-828

cable)
For purchasing and further information, please contact your local Svendborg Brakes supplier.
Rev: 07.07.06 / ECN 21618
-

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 17 TENSION
SWT - 2.3 - 82VS/93/101
• Appendix - Bolt tightening with tensions

yyyy)

-
Document history

93/101

-
Appendix - Bolt tightening with tensions
See: chapter Description:, “Bolt tightening with tensioner,”

-

Arbejdsinstruktion
AI-WI544243
Work instruction
Designer: SPE Beskrivelse: Tilspænding med tensioner
Description: Bolt tightening with tensioner
Dato/Date: 18-05-04 Operation: Retrofit
ECN nr.: 21927 Værktøj/Tools: 1008351 / 90178 /1008359
Suppl. Dele/Parts:
ECN Dato / Date: 04-09-06 Mølle/Turbine type: Standard
DK: Der henvises i øvrigt til sikkerhedsinstruktionerne i møllemanualerne.
Vigtigt!
Tensioners må kun anvendes af personer der har deltaget i et boltekursus,
herunder en grundig instruktion i brugen af tensioner.

Som alternativ må der arbejdes sammen med en kollega, der har deltaget i kuset.
Husk at bruge det korrekte diagram for tensioner, da ikke alle tensionere behøver lige stort tryk.
For at løsne møtrikker med tensioner se Fig 82.
INT: Also refer to the safety regulations in the turbine manuals.
Important!
Tensioners must be used only by persons who have passed a bolt course with detailed instruction in the use
of tensioners.
Alternatively a person without specialist training can work together with a colleague who has passed the
course.
Remember to use the correct diagram for the tensioner as not all tensioners need the same pressure.
To loosen nuts with the tensioner, see Fig 82.
AI-WI544243 - 21927 Siemens Wind Power 449 / 472

Tilspænding ved brug af ITH Tensioner /
Tightening bolts with the ITH Tensioner
DK- Vigtigt:
Kontroller at slanger ikke har knæk,
mærker eller andre tegn på svaghed.
Kontroller at pumpestation og ten-
sioner ikke er beskadiget eller defekt.
Tag dig god tid og efterse udstyret
grundigt, da utætheder kan få fatale
følger.
INT- Important:
Check for sharp bends, bruises and
other signs of weakness of the hoses.
Check that the pumping station and
the tensioner are not damaged or
defective. Take your time checking the
Fig 45
equipment properly as leaks may have
fatal consequences.
DK- Det kontrolleres, at det er den korrekte

slange godkendt til tensioner pumpen.
Slange og koblinger er specielt armeret
til 2500 bar. Slangen kobles til pumpen
men ikke til tensioner.
INT- Check that the hose is the correct type

approved for the tensioner pump. Hose
and fittings are designed for 2500 bar.
Connect the hose to the pump but not to
the tensioner.
Fig 46
450 / 472 AI-WI544243 - 21927 Siemens Wind Power

DK- Der tilsluttes strøm til pumpestationen.
Normalt anvendes der 230V men hvis
der anvendes 400V skal man kontrollere
at pumpen køre den rigtige vej. Ellers
vendes faser.
INT- Connect the pumping station to electric-

ity. Normal voltage is 230 V, but if 400 V
is used, check that the direction of rota-
tion on the pump is correct. If not, switch
the phases.
Fig 47
DK- NB: Alle, der opholder sig i nærheden

af udstyret mens der er tryk på syste-
met, skal benytte sikkerhedsbriller og
hjelm.
INT- Note: All personnel who are near the

equipment while it is pressurized must
wear goggles and helmet.
Fig 48

DK- Det kontrolleres at der kan opbygges tryk
Opbygge tryk / og at trykket kan løsnes igen. Derefter
indstilles trykket. Slangen er fortsat
Build pressure monteret på pumpen men ikke på ten-
sioner. Gå ikke længere op i tryk end 500
bar ved funktionstest.
INT- Check that the system can build pressure

and relieve pressure. Then set the correct
pressure. The hose is still connected to
Løsne tryk /
the pump but not to the tensioner. Do not
exceed 500 bar during the functional test.
Relieve pressu-
re
Fig 49
DK- Pumpen indstilles til det forud bestemte

tryk iht. skema eller manualer. Pumpe,
slange og koblinger observeres for
utætheder. Trykket løsnes igen.
INT- Set the pump to the pressure specified in

the table or manuals. Pump, hose and fit-
tings must be checked for leaks. Relieve
the pressure.
Fig 50

DK- Det kontrolleres at stemplet i tensioner er
kørt helt i bund så overfladen er helt
plan.
INT- Check that the piston in the tensioner is

fully down and the top surface com-
pletely flush.
Fig 51
DK- Vigtigt:
Det kontrolleres, at der er min. 0,8 x
boltdiameter afstand mellem tensioner
og flange. F.eks. 36mm x 0,8 = 28,8
Så for at man må benytte tensioner på
en 36mm bolt skal der være min
28,8mm gevind fri når tensioner står
løst på bolt.
Dette måles kun på den laveste bolt i
Min. 0.8 x boltdiameter flangen.
Min. 0.8 x bolt diameter
INT- Important:
Check that the bolt distance between
tensioner and flange must be mini-
mum 0.8 x bolt diameter. E.g. 36 mm x
Fig 52
0.8 = 28.8 - which means that to use the
tensioner on a 36 mm bolt you need
min. 28.8 mm free threading when the
tensioner is positioned loosely on the
bolt.
This is only measured for the lowest
bolt in the flange.

DK- Anlægsflader kontrolleres for ujævnhe-
der og rengøres.
Gevind rengøres. Smøres hvis tensioner
går sejt.
INT- Check for irregularities on contact sur-

faces and clean them.
Clean the threading. Lubricate if the ten-
sioner does not work smoothly.
Fig 53
DK- Kontroller at tensioner er ren og fri for

skader. Kontroller at fjeder for møtrik-
medbringer virker.
INT- Check that the tensioner is clean and free

of damage. Check that the spring for the
nut catch works.
Fig 54

DK- Tensioner sættes ned over bolten, det er
meget vigtigt at tensioner står plan på
underlag, og ikke trykker på svejsninger
eller kanter.
INT- Place the tensioner on the bolt. It is very

important that the tensioner is level on
the surface and not pressing on welds or
edges.
Fig 55
DK- Stemplet i tensioneren skrues ned over

bolten med skraldenøgle. Gevindet skal
gå let og stemplet skal være nemt at
holde og må ikke vride. Mens der
spændes, roteres stemplet lidt frem og til-
bage, så møtrikmedbringer inde i ten-
sioner falder ned over møtrikken.
INT- Screw the piston in the tensioner onto the

bolt with the ratchet wrench. The thread-
ing must work smoothly and the piston
must be easy to hold and must not twist.
While tightening, rotate the piston
slightly back and forth until the nut catch
inside the tensioner drops down over the
Fig 56
nut.

DK- Tensioner spændes helt ned mod flangen
og løsnes derefter, så der er ca. 1 mm
spillerum mellem tensioner og flange.
Det kontrolleres, at tensioner virker fast
på bolten, og at der ikke er slør mellem
tensioner og bolt. Tensioneren må maxi-
malt kunne rykkes 2 mm frem og tilbage.
INT- Tighten the tensioner fully down towards

the flange and then loosen it to allow
approx. 1 mm gap between tensioner and
flange. Check that the tensioner feels
firm on the bolt and that no slack is felt
between tensioner and bolt. You should
be able to move the tensioner no more
Fig 57
than 2 mm back and forth.
DK- Slangen monteres nu på tensioner.

Husk at løsne evt. tryk i systemet
inden.
INT- Now connect the hose to the tensioner.

First remember to release any pres-
sure in the system.
Fig 58
For at løsne møtrikker med tensioner, se Fig 82

To loosen nuts with the tensioner, see Fig 82

DK- Vigtigt: Monter beskyttelsesbøjle over
tensioner.
INT- Important: Fit the protective brace

over the tensioner.
Fig 59
DK- Der opbygges nu tryk på systemet.

Hold afstand til tensioner når der
opbygges tryk første gang.
Stå ALDRIG med hovedet over tensio-
neren eller beskyttelsesbøjle når der er
tryk på systemet.
Kontroller for utætheder og fejlfunktion.
Trykket løsnes igen.
Se Fig 63
INT- Now pressurize the system.

Stay clear of the tensioner when build-
ing pressure the first time.
NEVER place your head over the ten-
sioner or protective brace when the
Fig 60
system is pressurized.
Check for leaks and malfunctioning.
Relieve the pressure.
See Fig 63

DK- Der opbygges tryk igen og møtrikken
spændes løbende med 50Nm med
momentnøgle, mens der opbygges tryk.
Se Fig 63
INT- Build pressure again and continuously

tighten at 50 Nm with the torque wrench
while the pressure is building.
Fig 61
DK- Hold øje gennem inspektionshullet med,

Inspektionshul at møtrikken bliver spændt ned til under-
laget. Vær opmærksom på, at stempel-
Inspection hole vandringen ikke overstiger det
tilladelige. Dette punkt er markeret med
en rød ring på den opadgående stempel.
INT- Keep an eye on the nut through the

Max. tilladelige inspection hole to ensure that it is
stempelvandring screwed fully down to the base. Make
sure that the piston does not travel further
Max. allowed pi- than allowed. This point is indicated by a
ston movement red ring on the upward moving piston.
Fig 62

DK- Træk bolt med trykket som angivet i dia-
gram for tensioner.
Spænd møtrik 50Nm
Løsn tryk.
Træk samme bolt igen.
Spænd møtrik 50Nm igen.
Det er vigtigt at hver bolt bliver trukket
og spændt to gange.
Fortsæt med næste bolt, og gentag arbe-
jdsgangen.
Trækkes der f.eks bolte i tårn, hvor der

skal trækkes hele vejen rundt, er der
vigtigt at sikre, at tilspændingen af de
efterfølgende bolte ikke har reduceret
Fig 63
forspændingen af de første bolte.
Mærk derfor startbolten, og når alle bolte
er trukket og man kommer til startbolten
igen, trækkes og spændes yderligere ca.
en 10-20% af boltene (indtil boltene ikke
kan efterspændes mere).
INT- Tension the bolt to the pressure indicated

in the tensioner diagram.
Tighten the nut to 50 Nm.
Tension the same bolt again.
It is important that each bolt is tensioned
and tightened twice.
Continue with the next bolt and repeat
the procedure.
If bolts are tensioned in tower where all

bolts in the circle need to be tensioned it
is important to ensure that the tightening
of the following bolts has not reduced the
initial tension of the first bolts.
To prevent this, mark the first bolt, and
when returning to this bolt after tighten-
ing the others, retension and retighten
approx. 10-20% of the first bolts (until
the bolts can not be retightened any fur-
ther.)

Tilspænding ved brug af Tentec / Hydretight Tensioner
Tightening bolts with the Tentec /Hydretight Tensioner
DK- Vigtigt:
Kontroller at slanger ikke har knæk,
mærker eller andre tegn på svaghed.
Kontroller at pumpestation og ten-
sioner ikke er beskadigede eller
defekte.
Tag dig god tid og efterse udstyret
grundigt, da utætheder kan få fatale
følger.
INT- Important:
Check for sharp bends, bruises and
other signs of weakness of the hoses.
Check that the pumping station and
the tensioner are not damaged or
Fig 64
defective. Take your time checking the
equipment properly as leaks may have
fatal consequences.
DK- Det kontrolleres, at det er den korrekte

slange godkendt til tensioner pumpen.
Slange og koblinger er specielt armeret
til 2500 Bar. Slangen kobles til pumpen
men ikke til tensioner.
INT- Check that the hose is the correct type

approved for the tensioner pump. Hose
and fittings are designed for 2500 bar.
Connect the hose to the pump but not to
the tensioner.
Fig 65

DK- Der tilsluttes strøm til pumpestationen.
Normalt anvendes der 230V men hvis
der anvendes 400V skal man kontrollere
at pumpen køre den rigtige vej. Ellers
vendes faser.
INT- Connect the pumping station to electric-

ity. Normal voltage is 230 V, but if 400 V
is used, check that the direction of rota-
tion on the pump is correct. If not, switch
the phases.
Fig 66
DK- NB: Alle, der opholder sig i nærheden

af udstyret mens der er tryk på syste-
met, skal benytte sikkerhedsbriller og
hjelm.
Pumpen startes op uden tryk.
INT- Note: All personnel who are near the

equipment while it is pressurized must
wear goggles and helmet.
Start the pump without pressure.
Fig 67

DK- Det kontrolleres, at der kan op bygges
tryk, og at trykket kan løsnes igen.
Opbygge tryk / Derefter indstilles trykket. Slangen er
fortsat monteret på pumpen men ikke på
Build pressure tensioner. Gå ikke længere op i tryk end
500 bar ved funktionstest.
Løsne tryk /
INT- Check that the system can build pressure
and relieve pressure. Then set the correct
Relieve pressu-
re
pressure. The hose is still connected to
the pump but not to the tensioner. Do not
exceed 500 bar during the functional test.
Fig 68
DK- Pumpen indstilles til det forud bestemte

tryk iht. skema eller manualer. Pumpe,
slange og koblinger observeres for
utætheder. Trykket løsnes igen.
INT- Set the pump to the pressure specified in

the table or manuals. Pump, hose and fit-
tings must be checked for leaks. Relieve
the pressure.
Fig 69

DK- Der kontrolleres at stemplet i tensioner er
kørt helt i bund så overfladen er helt
plan.
INT- Check that the piston in the tensioner is

fully down and the top surface com-
pletely flush.
Fig 70
DK- Vigtigt:
Det kontrolleres, at der er min. 0,8 x
boltdiameter afstand mellem tensioner
og flange. F.eks. 36mm x 0,8 = 28,8
Så for at man må benytte tensioner.på
en 36mm bolt skal der være min
28,8mm gevind fri. når tensioner står
løst på bolt.
Min. 0,8 X boltediameter Dette måles kun på den laveste bolt i
Min. 0.8 x bolt diameter flangen.
INT- Important:
Check that the bolt distance between
tensioner and flange must be mini-
mum 0.8 x bolt diameter. E.g. 36 mm x
Fig 71
0.8 = 28.8 - which means that to use the
tensioner on a 36 mm bolt you need
min. 28.8 mm free threading when the
tensioner is positioned loosely on the
bolt.
This is only measured for the lowest
bolt in the flange.

DK- Anlægsflader kontrolleres for ujævnhe-
der og rengøres. Gevindene rengøres og
smøres.
INT- Check that the contact surfaces are com-

pletely even and clean them. Clean and
lubricate the threads.
Fig 72
DK- Kontroller at tensioner er ren og fri for

skader. Kontroller at fjeder for møtrik
medbringer virker.
INT- Check that the tensioner is clean and free

of damage. Check that the spring for the
nut catch works.
Fig 73

DK- Tensioner sættes ned over bolten, det er
meget vigtigt at tensioner står plan med
på underlag, og ikke trykker på svejs-
ninger eller kanter.
INT- Place the tensioner over the bolt. It is

very important that the tensioner is level
on the surface and that it does not press
down on welds or edges.
Fig 74
DK- Stemplet i tensioneren skrues ned over

bolten med skraldenøgle. Gevindet skal
gå let og stemplet skal være nemt at
holde og må ikke vride. Mens der
spændes, roteres stemplet lidt frem og til-
bage, så møtrik medbringer falder ned
over møtrikken.
INT- Screw the tensioner piston onto the bolt

with the ratchet wrench. This must be
easy, the piston must be easy to hold and
must not jerk. While tightening, the pis-
ton must be rotated slightly back and
forth to make the bushing inside fall
down over the nut.
Fig 75

DK- Tensioner spændes helt ned mod flangen
og løsnes derefter, så der er ca. 1 mm
spillerum mellem tensioner og flange.
INT- Tighten the tensioner fully down towards

1 mm the flange and then loosen it to allow
approx. 1 mm gap between tensioner and
flange. Check that the tensioner feels
firm on the bolt and that no slack is felt
between tensioner and bolt. You should
be able to move the tensioner no more
Fig 76
than 2 mm back and forth.
DK- Slangen monteres nu på tensioner. Husk

at løsne evt. tryk i systemet inden.
INT- Now connect the hose to the tensioner.

First remember to relieve the system of
pressure.
Fig 77

DK- Der opbygges nu tryk på systemet. Hold
afstand til tensioner når der opbygges
tryk første gang. Stå ALDRIG med
hovedet over tensioneren når der er
tryk på systemet. Kontroller for utæthe-
der og fejlfunktion. Trykket løsnes igen.
INT- Build pressure on the system. Stand

back when pressurizing the tensioner
the first time. NEVER stand with your
head above the tensioner when the sys-
tem is pressurized. Check for leaks and
malfunctioning. Relieve the pressure.
Fig 78
DK- Der opbygges tryk igen og møtrikken

spændes løbende med 50 Nm med
momentnøgle mens der opbygges tryk.
INT- Build pressure again and continuously

tighten to 50 Nm with the torque wrench
while the pressure is building.
Fig 79

DK- Hold øje gennem inspektionshullet med,
Inspektionshul at møtrikken bliver spændt ned til under-
laget. Vær opmærksom på, at stempel-
Inspection hole vandringen ikke overstiger det
tilladelige. Dette punkt er markeret med
en rød ring på den udskiftelige bøsning.
INT- Keep an eye on the inspection hole to

Max. tilladelige check that the nut is tightened fully down
stempelvandring onto the base. Make sure that the piston
does not travel further than the allowed
Max. allowed pi- distance. This point is marked by a red
ston movement ring on the interchangeable bushing.
Fig 80

DK- Træk bolt med trykket som angivet i dia-
gram for tensioner.
Spænd møtrik 50Nm
Løsen tryk.
Træk samme bolt igen.
Spænd møtrik 50Nm igen.
Det er vigtigt at hver bolt bliver trukket
og spændt to gange.
Fortsæt med næste bolt, og gentag arbe-
jdsgangen.
Trækkes der f.eks bolte i tårn, hvor der

skal trækkes hele vejen rundt, er der
vigtigt at sikre, at tilspændingen af de
efterfølgende bolte ikke har reduceret
Fig 81
forspændingen af de første bolte.
Mærk derfor startbolten, og når alle bolte
er trukket og man kommer til startbolten
igen, trækkes og spændes yderligere ca.
en 10-20% af boltene. (indtil boltene
ikke kan efterspændes mere)
INT- Tension the bolt to the pressure indicated

in the tensioner diagram.
Tension the same bolt again.
It is important that each bolt is tensioned
and tightened twice.
Continue with the next bolt and repeat
the procedure.
If bolts are tensioned in tower where all

bolts in the circle need to be tensioned it
is important to ensure that the tightening
of the following bolts has not reduced the
initial tension of the first bolts.
To prevent this, mark the first bolt, and
when returning to this bolt after tighten-
ing the others, retension and retighten
approx. 10-20% of the first bolts (until
the bolts can not be retightened any fur-
ther.).

DK- Løsne bolte med tensioner
INT- Loosening bolts with the ten-

sioner
Fig 82
DK- Efterse værktøj. Se Fig 45 til Fig 56

Stemplet spændes helt ned mod flangen
og løsnes derefter, så der er 2 mm spill-
erum mellem anlægsflade og stempel.
2 mm
INT- Tighten the piston fully down on the
flange and then loosen until there is a gap
of 2 mm between base and piston.
Check that the tensioner fits tightly on
the bolt and that there is no play between
tensioner and bolt. The tensioner is
Fig 83
allowed to move max. 2 mm back and
forth.

DK- Træk bolt som vist i Fig 58 til Fig 60.
INT- Tension the bolt as shown in Fig 58 to

Fig 60.
Fig 84

DK- Drej momentnøgle 4-5 gange for at løsne
møtrikken.
Når man aflaster tensioneren og
møtrikken stadig ikke er løs, opbygger
man atter tryk og løsner møtrikken lidt
mere. Hvis ikke man kan dreje
møtrikken, når trykket er fjernet og man
ved, at møtrikken er helt løs, er det fordi
tensioneren fra starten har været for tæt
på flangen og derfor nu er kommet til at
virke som møtrik. Sker dette trækkes bolt
igen, og møtrik spændes igen til ten-
sioner kan løsnes en anelse, hvor efter
man starter forfra.
Vær opmærksom på, at stempel-
Fig 85
vandringen ikke overstiger det tillade-
lige.
Se Fig 62
Tensioner løsnes og trækkes til igen
imens møtrik løsnes.
Gentag dette til der ikke er mere for-
spænding i bolt.
INT- Turn the torque wrench 4-5 times to

loosen the nut.
If the nut is still not loose when relieving
the tensioner, build pressure again and
loosen the nut a bit more. If you can not
turn the nut when the pressure is relieved
and you know that the nut is fully loos-
ened, it is because the tensioner was too
close to the flange at the outset and for
that reason has begun to function as a nut
itself. If this happens, tension the bolt
again and tighten the nut until the ten-
sioner can be loosened slightly, and start
over.
Make sure that the piston does not
travel further than allowed, see Fig 62.
Loosen the tensioner and retension while
loosening the nut. Repeat this procedure
until the bolt is no longer preloaded.

- Chapter 18 PAINT REPAIR

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 18 PAINT REPAIR

SWT - 2.3 - 82VS/93/101
• Appendix - Paint repair procedure for tower and nacelle

yyyy)

Document history

93/101

Appendix - Paint repair procedure for tower and nacelle
See: chapter , “Repair painting, service & production,”


Repair painting, service & production
Repair painting, service & production
This work instruction covers towers painted with an epoxide paint system e.g.
PS6004. For required layer thickness and paint system, see the relevant PS.
• Always check site specifications
Personal safety equipment: • Filter mask for organic solutions. (A2). If the paint repair work exceeds one
hour per day, a mask connected to fresh air must be used.
• Nitrile gloves. Change gloves after max. half an hour if paint is spilled on them.
Discard the used gloves.
• Eye protection.
For further information, please see the product safety health sheets.
Pre-treatment of the surface: • The surface must be clean and dry before it is painted.
• Open the surface with sandpaper before it is painted.
• If the scratches go through to the bare steel, grind off the paint leaving a clean
steel surface.
If uneven areas or scratches have already been painted and need to be repaired
to improve the visual appearance, it is not necessary to grind off the paint. Filler
can be used to repair the area.
Assembly Instruction 169 / 176

Rev: 04.09.2009 / ECN 32393

Used by the service department:
Used by the service department:
Paint type for white US towers Outside: RAL 9010
Paint type for white UK towers Outside: RAL 7038 / RAL 7035 - (Always check site specifications)
Towers Inside: RAL 7035
Tower outside and nacelle in-

side and outside.
Base coat Only used when scratches go through to the steel.

Paint type: Kema Juul Zn 595 Zinc spray (BONUS item no. 35030)
OAR code: 3:1
Color: Metal grey
Thickness per layer: 15- 20 my dry film
Total layers: 2 layers
Dry to re-coat: 15- 30 minutes at 20 C (must be surface dry)
Intermediate coat Paint type: Hempatex Hi-build 4641 (BONUS item no. 35195)
OAR code: 4:3
Color: Hempel 1217 (pale grey)
Dry to re-coat: 1 hr. at 20 C
Top layer Paint type: Hempatex Enamel 5636 (BONUS item no. 35191)
OAR code: 4:3
Color: Hempel 0105 (old) / Ral 7035 (new)
Thickness per layer: 20 - 30 my dry film
Total layers: 1 layer
Tower inside
Base coat Only when the scratches go through to the bare steel.
Paint type: Kema Juul Zn 595 Zinc spray(BONUS item no. 35030)
OAR code: 3:1
Color: Metal grey
Thickness per layer: 15- 20 my Dry film thickness
Dry to re-coat: 15- 30 minutes at 20 C (must be surface dry)
Intermediate coat and top Paint type: Hempatex Hi-build 4641 (BONUS item no. 35195)
coat OAR code: 4:3
Color: Hempel 1217 (pale grey)
Dry to re-coat: 1 hr. at 20 C
170 / 176 Assembly Instruction

Rev: 04.09.2009 / ECN 32393

Used by the Production Department:
Nacelle inside V.No.DescriptionPaint codeThickness [µ]
35182 Paint, pale grey, anti-rust.3-1 80µ
35030 Zinc spray3-1 80µ
35167 Paint blue: bearing/ oil filter4-3120µ
35177 Paint, black non-gloss spray:
covers/ hyd.station.3-1120µ
35178 Paint black glossy: brake disc/
shafts/flange for Svendborg brakes/
turning union 2-1120µ
35179 Paint, black glossy spray:
Round sling/bolts at/brake disc/
turning union3-1120µ
35180 Paint, black non-gloss: covers.2-1120µ
35183 Paint, grey: Yaw gear2-1120µ
35184 Paint, grey: yaw gear2-1120µ
35185 Paint, orange: Svendborg brakes 2-1120µ
35188 Paint, blue: Flender gear.2-1120µ
35201 Paint, blue: Generator.2-1120µ
35206 Paint, green: Oil pump.2-1120µ
35209 Paint, red: Service crane.2-1120µ
35213 paint, yellow: Anchorage points 4-5cover
35262 Paint, pale grey top coat.4-3cover
35225 Hardener for top coat.5-3-
Components inside C3: Zinc primer, anti-rust. Acc. to list. 80 µ
Paint, Color acc. to list.120 µ
Total thickness of dry film min.200 µ
Thickness of layer must be measured and must comply with 80 : 20 in principle

cf. DS/R 454.

Rev: 04.09.2009 / ECN 32393

Nacelle outside 35213 Paint, yellow anchorage points.4-5cover
35223 Paint, grey hi-build.4-5220µ
35222 Hardener for hi-build.4-3-
35224 Paint, red zinc primer.4-580
35221 Hardener for zinc primer.4-3-
35262 Paint, pale grey top coat.4-350
35225 Hardener for top coat.5-3-
Component outside C5-M Paint, red zinc primer, acc. to list. 80 µ

(damage repair)
Paint, grey hi-build, acc. to list.220 µ
Paint, pale grey top coat, acc. to list.50 µ
Total thickness of dry filmmin.350 µ
Thickness of layer must be measured and must comply with 80 : 20 in principle

cf. DS/R 454.

Rev: 04.09.2009 / ECN 32393

Nacelle damage
Nacelle damage
• Contact site manager before work starts.
Fig. 10.1
Clean the nacelle with cleaning
fluid and after that with water.
1
Do not repair visual damage (where the surface is not damaged) unless it is visi-
ble within 4 meters of the turbine. Start by polishing the damaged area.
Fig. 10.2
Damage on the metal or zinc
primer must be ground. After re-
1 pair, the damage is painted,
starting with zinc primer (base
coat), Hi-build (intermediate
2 coat) and finally top coat.
Fig. 10.3
1. The damaged area must be
1 ground.
2
2. Limit the repair area.

Rev: 04.09.2009 / ECN 32393

Nacelle damage
Fig. 10.4
Prime with Zinc primer.
2 1
Fig. 10.5
Prime with Hi-build.
2 1
Fig. 10.6
Prime with topcoat.
2 1

Rev: 04.09.2009 / ECN 32393

Damage on the fiberglass
Damage on the fiberglass

Fig. 10.7
Clean the surface with cleaning
1 fluid and after that with water.
2
Fig. 10.8
Paint with grey Hempathane
1 paint.
2
Limit the repair area.

Rev: 04.09.2009 / ECN 32393

Damage on machine parts
Damage on machine parts
Fig. 10.9
Clean the shaft with cleaning flu-
1 id and after that with water.
2
Limit the repair area.
Fig. 10.10
If the paint is damaged (through
1 to bare steel), the damage must
2
be primed with anti-rust.
Fig. 10.11
The shaft is painted black.
2 1

Rev: 04.09.2009 / ECN 32393

- Chapter 19 TURNING GEAR

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 19 TURNING GEAR

SWT - 2.3 - 82VS/93/101
• Appendix - Turning gear (option)

yyyy)

Document history

93/101

Appendix - Turning gear (option)
IMPORTANT !! Always yaw the turbine out of the wind when using the turning gear
Always ensure that the brake can be activated by activating the emergency
stop or by using the hand pump on all callipers.
Also see ZWI 549498” .
Lift the parts for the turning gear into the nacelle in the following order:
1 pumping station + hoses

2 assembled gear unit
3 Torque support


SIEMENS
Aktivitet/Operation: Montage af turning gear ZWI549498
Mounting of turning gear Designer: SPE
Designer dato/date: 30-05-05
Mølle type / Turbine: SWT-2.0-76 / SWT-2.3-82/93/101 ECN nr./no.: 28990
DK- Vigtigt:
INT- Note:
DK- Kun ved opstilling: Kabel med multistik
for styreboks monteres i A3 skab iht. dia-
gram, inden der tilsluttes 690V til
møllen.
Blå = Nul
Brun-Rød = Hydraulikpumpe vinge pitch
Sort = Krøjemotor med urets retning
Hvid-Grå = Krøjemotor mod urets ret-
ning
Grøn = Hydraulikpumpe bremsekaliber
1.3MW (Hvis ikke ibrug skal denne isol-
eres)
Gul-Grøn = Jord
Bemærk at ved demontering af kablet
i A3 skab, SKAL generator med 690V
Fig.1
spænding afbrydes imens, så systemet
er spændingsløst.
UK- Only installation: Fit the multi-plug

cable for the control box in the A3 box
according to the diagram before connect-
ing 690V to the turbine.
Blue = Zero
Brown-Red = Hydraulic pump blade
pitch
Black = Yaw motor clockwise
White-Grey = Yaw motor counterclock-
wise
Green = Hydraulic pump disc brake
1.3MW (If not used it shall be insulated)
Yellow-Green = Ground
Note that while disconnecting the cable
in the A3 box, the generator for 690V
must be OFF to ensure that the system
is dead.
for styreboks monteres i A3 skab iht. dia-
gram, inden der tilsluttes 690V til
møllen. Bemærk at ved demontering af
kablet i A3 skab, SKAL generator med
690V spænding afbrydes imens, så sys-
temet er spændingsløst.
UK- Only installation: Connect the multi-

plug cable for the control box in the A3
box according to the diagram before con-
necting 690V to the turbine. Note that
while disconnecting the cable in the A3
box, the generator for 690V must be
OFF to ensure that the system is dead.
Fig. 2
DK- Kun ved opstilling: Div. ledninger, der

afmonteres i A3 skab, skal blændes af
med samlemuffer. Bemærk at ved
demontering af kablet i A3 skab,
SKAL generator med 690V spænding
afbrydes imens så systemet er spænd-
ingsløst.
UK- Only installation: The var. cables which

are disconnected from the A3 box must
be terminated with connectors. Note that
while disconnecting the cable in the A3
box, the generator for 690V must be
OFF to ensure that the system is dead.
Fig. 3
DK- Rotorlås monteres.
UK- Mount the rotor lock.
Fig. 4
DK- Afskærmning afmonteres.
UK- Remove the cover.
Fig. 5
DK- Kobling afmonteres.
UK- Remove the coupling.
Fig. 6
DK- Turning gear hejses forsigtigt ned

mellem bremseskive og generatorflange.
UK- Carefully hoist the turning gear down

between the brake disc and the generator
flange.
Fig. 7
DK- Turning gearet monteres på brem-
seskiven med 8 stk. M20 X 55mm
unbrako bolte. Husk brug af hærdede
skiver. Boltene spændes 500Nm.
UK- Mount the turning gear on the brake disc

with 8 pcs. M20 x 55mm Allen bolts.
Remember to use hardened washers.
Tighten the bolts 500Nm.
Fig. 8
DK- Turning motor løsnes og trækkes fri, så

der bliver plads til modhold.
UK- Loosen the turner motor and pull it free

to make room for the backstop.
Fig. 9
DK- Modhold hejses ned på plads. Vær
opmærksom på at modholdsarm på turn-
ing gear går i indgreb i modholdet inden
denne monteres.
UK- Hoist the backstop into place. Make sure

that the backstop arm on the turning gear
engages with the backstop before it is
mounted.
Fig. 10
DK- Modhold monteres med 4 stk. gevind-

stænger, møtrikker og hærdet skiver.
Spænd gevindstængerne 450Nm
UK- Mount the backstop with 4 pcs. threaded

bars, nuts and hardened washers. Tighten
the threaded bars 450Nm.
Fig. 11
DK- Modholdsbolte spændes godt til mod kal-
iberbeslag.
UK- Tighten the backstop bolts well onto the

caliber bracket.
Fig. 12
DK- Bolten og kontramøtrikken for modhold

justeres, så der er ca. 2mm spillerum
mellem bolten og anlægsfladen på
momentarmen.
UK- Adjust the bolt and counternut for the

backstop with only 2mm gap between the
bolt and the contact surface of the torque
arm.
Fig. 13
DK- Pumpestationen placeres på generatoren
og olieslangerne monteres.
UK- Place the pumping station on the genera-

tor and connect the oil hoses.
Fig. 14
DK- Olieslangerne monteres på turning gear.

Kabel fra pumpestationen monteres i stik
ved siden af nødstop. Vær opmærksom
på at indstille håndtaget til at aktivere
turning gear i neutral stilling. Vinkel-
ret op fra ventilblokken.
UK- Connect the oil hoses to the turning gear.

Connect the cable from the pumping sta-
tion in the plug next to the emergency
stop. Note that the handle for activat-
ing the turning gear must be in neutral
position. Perpendicular to the valve
block.
Fig. 15
DK- Kun ved opstilling: Stik fra styreboks
monteres på ventiler på hydraulikstation.
UK- Only installation: Connect the plugs

from the controller box on the valves on
Fig. 16
DK- Kun ved opstilling: Multistik for styre-

Tænd og sluk
boks samles med betjeningsboks. Betjen-
for hyd.pumpe/
ingsboksen benyttes til at krøje med
On/off switch for Krøjekontakt/
møllen og starte hyd. pumpen.
for hyd. pump Yaw switch
UK- Only installation: Assemble the multi-
plug and control box. The control box is
used for yawing the turbine and starting
the hydraulic pump.
Fig. 17
DK- Kun ved opstilling: Styreboksen
tilsluttes A9 skab
UK- Only installation: Connect the control-

ler box to the A9 box.
Fig. 18
DK- Kun ved opstilling: Pumpestationen

tilsluttes stikket på styreboksen. Pumpe-
motoren kontrolleres for korrekt omløb-
sretning, med uret set fra oven.
UK- Only installation: Connect the pumping

station to the plug on the controller box.
Check the direction of rotation on the
pump motor, clockwise seen from the
above.
Fig. 19
DK- Pumpestationen frakobles på A9 skabet.
Pumpemotoren kontrolleres for korrekt
omløbsretning, med uret set fra oven.
UK- Connect the pumping station to the A9

box. Check that the flow direction in the
pumping motor is correct, clockwise
seen from above.
Fig. 20
DK- Pumpestationen startes, og pumpen kører

et par minutter for at sikre udluftning af
systemet inden brug. Nødstoppet kon-
trolleres inden brug. Vær opmærksom
på, at rotorlåse afmonteres igen, inden
der køres med turning gear.
Bemærk: Max. hydraulisk arbe-
jdstryk er 155 bar.
Vær opmærksom på at rotorlåse skal
fjernes inden der køres med turning
gear.
UK- Start the pumping station and run the

pump for a few minutes to ensure bleed-
ing of the system before use. Check the
Fig. 21
emergency stop before use. Make sure
that the rotor locks are dismounted
again before running the turning gear.
Note: Max. hydraulic operating pres-
sure is 155 bar.
Be aware op removing the rotor locks
before using the turning gear.
Demontage af hydraulisk turning gear

Dismounting of hydraulic turning gear
DK- Rotorlås monteres.
UK- Mount the rotor lock.
Fig. 22
DK- Pumpestationen frakobles på A9 skabet.
UK- Disconnect the pumping station at the A9

box.
Fig. 23
DK- Kun ved opstilling: Styreboksen fra-
kobles A9 skab
UK- Only installation: Disconnect the con-

troller box to the A9 box.
Fig. 24
DK- Kun ved opstilling: Stik fra styreboks

frakobles ventiler på hydraulikstation.
UK- Only installation: Disconnect the plugs

from the controller box on the valves on
Fig. 25
DK- Olieslangerne frakobles på turning gear.
Kabel fra pumpestationen frakobles
stikket ved siden af nødstop. Vær
opmærksom på at indstille håndtaget
til at aktivere turning gear i neutral
stilling. Vinkelret op fra ventilblokken.
UK- Disconnect the oil hoses to the turning

gear. Disconnect the cable from the
pumping station to the plug next to the
emergency stop. Note that the handle
for activating the turning gear must be
in neutral position. Perpendicular to
the valve block.
Fig. 26
DK- Afmonter olieslanger på pumpestationen.
UK- Disconnect oil hoses for the pumping sta-

tion.
Fig. 27
DK- Løsn bolten og kontramøtrikken for
modhold og afmonter modhold.
UK- Loosen the bolt and counternut for the

backstop and dismount the backstop.
Fig. 28
DK- Hug an i turning gear med kran.

Afmonter bolte for turning gear. Turning
gear hejses forsigtigt op mellem brem-
seskive og generatorflange.
UK- Hook the crane on to the turning gear.

Remove bolts for the turning gear. Care-
fully hoist the turning gear down
between the brake disc and the generator
flange.
Fig. 29
DK- Kobling monteres. Spænd moment iht.
servicemanualen.
UK- Fit the coupling. Torque tighten accord-

ing to the servicemanual.
Fig. 30
DK- Afskærmning monteres.
UK- Fit the cover.
Fig. 31
for styreboks afmonteres i A3 skab iht.
diagram.
spænding afbrydes imens, så systemet
er spændingsløst.
UK- Only installation: Disconnect the multi-

plug cable for the control box in the A3
box according to the diagram.
Note that while disconnecting the cable
in the A3 box, the generator for 690V
must be OFF to ensure that the system
is dead.
Fig. 32
DK- Kun ved opstilling: Afmonter samle-

muffer på ledningerne der er afmonteret
på Fig.1 og Fig. 2 og monter ledninger
igen iht. diagram.
spænding afbrydes imens så systemet
er spændingsløst.
UK- Only installation: Remove connectors at

the cables which were disconnected at
Fig.1 and Fig. 2. Connect the cables
again according to the diagram.
Note that while disconnecting the
cable in the A3 box, the generator for
Fig. 33
690V must be OFF to ensure that the
system is dead.
Fig. 34
DK- 2.3MW med ABB dele: Diagram for montage af kabel med multistik for styreboks i A3.
UK- 2.3MW with ABB parts: Diagram for mounting the multi-plug cable for the control box in the A3
box.
Fig. 35
DK- 2.3MW med ABB dele: Diagram for montage af kabel med multistik for styreboks i A3.
UK- 2.3MW with ABB parts: Diagram for mounting the multi-plug cable for the control box in the A3
box.
Fig. 36
DK- 2.3MW med Telemecanique dele: Diagram for montage af kabel med multistik for styreboks i
A3.
UK- 2.3MW with Telemecanique parts: Diagram for mounting the multi-plug cable for the control
box in the A3 box.
Fig. 37
DK- 2.3MW med Telemecanique dele: Diagram for montage af kabel med multistik for styreboks i
A3.
UK- 2.3MW with Telemecanique parts: Diagram for mounting the multi-plug cable for the control
box in the A3 box.
- Chapter 20 FIRE DETECTING

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 20 FIRE DETECTING

SWT - 2.3 - 82VS/93/101
• Appendix - Data sheet - fire / smoke detector (option)

yyyy)

Document history

93/101

Appendix - Data sheet - fire / smoke detector (option)
See: chapter , “Data sheet for series 600 (option),”
See: chapter , “Data sheet for M600/M900 fire detection range (option),”
See: chapter , “Data sheet for M600/M900 low profile detector (option),”
See: chapter , “Smoke and heat detectors 65 series,”
See: chapter , “Data sheet for MXC panel (option),”
See: chapter , “Data sheet for H-series heat detectors (option),”


Data sheet for series 600 (option)
Series 600 Series 600

Key Features
Conventional Fire
•
Detection Range
Designed for approval to EN54, LPCB, Vds,
SSL, ANPI, UL and ULC
Low operational voltage (10.5V to 33V)
Backward compatible with M600 Series
Compatible with new 5B and 5BD 5" Bases
Aesthetically discreet
Superior performance and reliability
Designed for rapid installation
Locking kit included as part of 5" Base
May be used in systems that meet BS5839 pt1
Integral and remote alarm LED
Wiring polarity independent
Tyco Safety Products conventional detector design evolution has resulted in the creation of a new Series 600 range of
unobtrusively styled detectors, incorporating a number of unique design features enabling improved operation, installation and
ease of servicing.
Through innovative design Series 600 detectors have the ability to reduce installation and servicing time to a minimum, needing
only one visit to the ceiling to complete the installation and having a park position for the detector to simplify servicing.
Siemens Wind Power A/S /Data sheet for series 600 (option) 221 / 230
Rev: 16.10.06 / ECN 22349

Series 600 Conventional Fire Detection Range
General
Included within the Series 600 range is the new conventional enhanced The complete range has been designed to meet the requirements of BS
carbon monoxide fire detector (601CH). The incorporation of a reliable (British standards) and EN (European Standards) for fire detectors. All
electrochemical CO detection cell and high specification low thermal detectors also carry a mandatory CE mark.
mass thermistor for accurate temperature detection has enabled the
introduction of an enhanced CO detector suitable for fast, reliable
detection of both slow and fast developing fires.
Series 600 Conventional Detectors
Series 600 provides the detector part of an automatic fire detection The detectors along with call points are grouped into fire zones, with each
system. The Series 600 conventional or two state detector is one that zone being connected to the control panel; by a separate two wire circuit
provides two output states to the controller, either "normal" or a "fire and having a separate zone indicator on the panel.
alarm" condition.
Application
As each type of fire detector responds to a particular "fire product", the In situations where the installation of smoke detectors would cause an
relative speed of response of the detector is therefore dependent upon unacceptable level of false alarms, heat detectors or the enhanced CO
the type of fire being detected. The range of Series 600 fire detectors fire detector may be installed.
have been designed to provide the earliest possible warning of a fire
condition, with a minimum possibility of false/unwanted alarms. Because of the wide variety of applications that fire
detectors are expected to cover, it is recommended that
As smoke is normally present at an early stage in most fires, smoke type a fire risk assessment should be undertaken to
detectors (optical, high performance optical and ion chamber) are determine the most suitable detector for any application.
therefore considered the most useful. When considering the type of
smoke detector for the application, the probable type of fuel for the fire
should be considered, in general terms, fast developing fires are
detected quicker with ion-chamber detectors, whereas with a slow
developing fire an optical type smoke detector will respond quickest. But
for general fire detection, where there is an equal possibility of either a
"fast" or "slow" fire developing the intelligent high performance optical
detector provides an excellent detection response.
Fire Test Response
Test Fire Heat Smoke Aerosol Visible High Ion Optical

Developed Portion Performance Chamber
Optical
TF1 Open Cellulosic fire (wood) STRONG YES INVISIBLE DARK C A N
TF2 Smoldering Pyrolysis fire (wood) NEGLIGIBLE YES VISIBLE LIGHT B C A
TF3 Glowing Smoldering fire (cotton) NEGLIGIBLE YES INVISIBLE LIGHT B B A
TF4 Open Plastics fire (polyurethane) STRONG YES INVISIBLE VERY DARK B A C
TF5 Liquid fire (n-heptane) STRONG YES INVISIBLE VERY DARK B B C
TF6 Liquid fire (methylated spirits) STRONG NO NONE NONE N N N
222 / 230 Siemens Wind Power A/S / Data sheet for series 600 (option)
Rev: 16.10.06 / ECN 22349

Series 600 Conventional Fire Detection Range
Optical Smoke 601P Enhanced Carbon Monoxide Fire 601CH
601P detectors are capable of detecting the visible smoke produced by 601CH detectors are generally faster than ion-chamber and optical
materials which smoulder or burn slowly, i.e. soft furnishings, plastic foam detectors in responding to fires that start by smoldering. They are also
etc; or "smoke" produced by overheated but unburnt PVC. These detectors more tolerant of positioning and can be mounted in locations where there
are particularly suitable for general applications and areas where cable are likely to be obstacles to free smoke plume movement.
overheating may occur, e.g. electrical services areas. Optical only These detectors are particularly well suited to sleeping risks, storage areas
detectors are not suitable for detecting fast burning fires producing little and applications where smoke detectors are prone to false alarm.
visible smoke or very black smoke. Incorporation of a A1R rate of rise heat detector within the 601CH provides
The novel design of the asymmetrical sampling chamber and signal extra non-selectable detection modes which allows the detector to operate
processing techniques stop unwanted alarms caused by very small in a wide variety of applications where combined risks mean that CO
insects, i.e. thrips. Smoke entering the sampling chamber scatters the detection alone would be insufficient.
infra-red light pulses onto a photodiode. These pulses are converted to an The integrated rate-of-rise heat detector acts as a normal heat detector,
electrical signal which is compared against a preset alarm level or additionally enhancing the sensitivity of the carbon monoxide detector if a
transmitted as an analogue value. rapid change of temperature is detected by the detectors thermistor.
High Performance Optical Smoke 601PH Ion Chamber Smoke 601I
601PH detectors react to the complete range of fire products, from slow 601I detectors are offered for old specifications which still call for ionisation
smoldering fires, producing visible particles to open flaming fires smoke detectors. The 601CH and 601PH detectors offer improved
producing large numbers of very hot smaller sized aerosols. The performance, significantly lower false alarms and environmental
combination of optical and heat technology allows detection of clear compatibility for smoke detection applications.
burning fire products which hitherto could only be easily detected by ion- The 601I nevertheless offers detection of visible and invisible fire aerosols
chamber detectors. (products of combustion) and are therefore capable of detecting the early
For normal ambient conditions the HPO behaves as a normal detector. presence of hot smoldering and flaming fires, such as wood, paper etc.
Only when a rapid rise in temperature is detected does the sensitivity of the They use a dual ionisation chamber in which the air is ionised by a single
detector increase and the presence of smoke will confirm a fire condition radioactive source. The presence of smoke in the sampling chamber
which will be transmitted as an alarm level. causes a change in the balance voltage, between the two chambers. This
The 601PH design incorporates a unique "mousehole" optical chamber is then compared against an alarm level.
with an unrivaled signal to noise ratio providing high resilience to dust and
dirt which means reduced servicing costs. In addition a unique chamber Technical Publications
cover actually draws slow moving smoke into the chamber to provide a
more responsive detector. Customers are advised that a full range of product application and design
information documents are available for this range via our website at
Heat, Rate-of-Rise 601H-R, Fixed Temperature 601H-F www.tycosafetyproducts-europe.com.
Heat detectors offer an acceptable, but less sensitive alternative to smoke Document Numbers
detectors if environmental conditions rule out their use. 601H-R (rate-of- Series 600 01C-02-D1
rise) and 601H-F (fixed temperature) detectors detect abnormally high 601PH 01C-02-D2
rates of rise of temperature and abnormally high (static) temperatures 601CH 01C-02-D3
respectively. 601I 01C-02-D4
For general use and particularly where the ambient temperature may be 601H-R/601H-F 01C-02-D5
low, a rate-of-rise heat detector 601H-R is to be preferred. A fixed 601P 01C-02-D6
temperature limit is also incorporated in these detectors.
In many environments, e.g. kitchens, canteens and boiler rooms, sudden,
large changes in temperature are considered normal therefore rate-of-rise
detectors are generally not suitable in these cases and a slower response
fixed temperature detector 601H-F should be used.
Rev: 16.10.06 / ECN 22349

S200 PLUS
Series Series
600 Conventional Fire Detection Range
Technical Information
Mechanical
Detector Material FR110 “Bayblend” Fire Resistant
Dimensions See diagram below
Weight See Specification Summary
Colour White
109mm
43mm
Environmental & Electrical

Reset Time 2 - 5 seconds
Relative Humidity 0 - 95% non-condensing
Wiring Connections SEM Terminal 2 x 1.5 mm2
Note: Ion chamber radiation source - americium 241< 33.3kBq
Electromagnetic Compatibility
The detector complies with the following:
Product family standard EN50130-4 in respect of Conducted Disturbances, Radiated Immunity, Electrostatic Discharge, Fast
Transients and Slow High Energy
EN50081-1 for Emissions
Average Quiescent Current (μA)
(1K1 internal resistor fitted)

Remote Current (mA) @ 24V
Operating Temperature
(no condensation or icing)
(no condensation or icing)

Storage Temperature
Detector Weight (Kg)
Alarm Current (mA)

Supply Voltage d.c.
Specification Summary
Type Detector Description 10.5V 24V 10.5V 24V
601CH Enhanced CO Fire 0.09 10.5 - 33V 60 68 14 53 -10oC to +55oC -20oC to +55oC 21
601H-R Heat Rate of Rise 0.08 10.5 - 33V 57 65 14 53 -20oC to +70oC -25oC to +80oC 21
601H-F Heat 60oC Fixed Temp 0.08 10.5 - 33V 58 61 14 53 -20oC to +70oC -25oC to +80oC 21
601I Ion Smoke 0.01 10.5 - 33V 52 62 15 53 -20oC to +70oC -40oC to +80oC 21
601P Optical Smoke 0.093 10.5 - 33V 63 67 12 45 -20oC to +70oC -25oC to +80oC 21
601PH High Performance Optical Smoke 0.093 10.5 - 33V 63 67 12 45 -20oC to +70oC -25oC to +80oC 21
The right is reserved to modify or withdraw any product or service without notice
Technical Information Sheet PSF123U Issue 1 www.tycosafetyproducts-europe.com ©Thorn Security Ltd. 2000
Rev: 16.10.06 / ECN 22349

EQUIPMENT: M600 SERIES

PUBLICATION: 01B-04-D15
ISSUE No. & DATE: 1 11/02
DOCUMENT CONTROL NUMBER /

5B 5" UNIVERSAL BASE AND ACCESSORIES
AS USED WITH THE M600 SERIES DETECTORS
PRODUCT APPLICATION AND DESIGN INFORMATION
1. INTRODUCTION 2.1 DETECTOR BASE
The 5B 5" Universal Base is common to the M600 Detector T h e d e tec to r b a se is m a d e o f f i r e r e s is ta n t F R11 0
R ange, the M9 00 Detector R ange and 800 Detector ‘BAYBLEND’.
Range. This document describes the base and accessories as The base may be fixed directly to the ceiling, to either a British
used with the M600 Series Detectors. The Base is common to or European conduit box. For ease of fixing, there are
all types of plug-in ceiling-mounted detectors in the M600 enlarged holes on the fixing slots, which allows the first fixing
series. Thus, a ceiling-mounted detector will comprise a specific screw to be inserted loosely, the base is then fitted to the screw.
detector type, plus a 5B 5" Universal Base. The range is
intended for two-wire operation. The base also has four electrical contacts which align with the
contacts on the detector once the latter is fitted and fully
latched into position.
2. MECHANICAL CONSTRUCTION An external rib moulded into the base indicates the position
which will be assumed by the detector alarm LEDs once the
See Figs 1 and 2. detector is fitted. The rib must be aligned so that it is visible
from the search route. This is to satisfy the BS5839 Part 1
definition of a zone.
Cabling may be connected to the base terminals L1 (line A IN),
L2 (line A OUT) and L (line B IN/OUT) in any order as the
detector bridge circuit makes it polarity independent.
A drive is provided for a remote indicator connected between
loop positive and terminal R, therefore, at a detector where a
remote indicator is connected, the polarity of the loop must be
known.
Fig. 1 Overall Base Dimensions
LED APERTURE
LOCKING DEVICE
FITTED HERE
LOCKING DEVICE
LED APERTURE PLUG
EXTERNAL RIB
TEMPORARY PARK
PLUNGER
Fig. 2 Detector Base
© 2002 Tyco Safety Products PAGE 1 of 5

Registered Office: First Floor North Building Walden Court Parsonage Lane Bishop’s Stortford Herts CM23 5DB
Rev: 16.10.06 / ECN 22349

M600 SERIES
01B-04-D5
1 11/02
The detector may be locked in position by inserting a

locking key which is part of the detector moulding. This is
broken from the sprue and inserted in the locking key slot.
The base may be fixed directly to:
• British or European conduit box
• directly to the ceiling.
The 5B 5" Universal Base cannot be used with:

• MP69/SMP69 Duct Probe Units
• 800EM Euro Box
• DHM69 Deckhead Mounting
2.2 TEMPORARY PARK PLUNGER

A temporary park plunger is fitted to all bases and enables
the detector to be mounted in a park position once mounted
on the base. This allows the detector to be turned
anticlockwise past the location position to break electrical
contact with the base. This means that the cabling of the
loop may be tested with the detector mounted to the base
(Fig. 1).
Fig. 3 Detector Changer
2.3 DETECTOR CHANGER

The detector changer (Fig. 3) is used to remove/replace
detectors from/to a detector base. Extension poles are
available which permit the detector to be inserted or
removed from high sitings.
The metal slides are retained by wing nuts and are used in
two positions, fully up and fully down. In the fully up
position it is used to remove/replace a detector. In the fully
down position it is used to remove the dust cover and to
engage the temporary park plunger.
2.4 CONTINUITY ADAPTOR

The continuity adaptor (Fig. 4) is used to short terminals L1
and L2 to provide cable continuity through the base.
Fig. 4 Continuity Adaptor
PAGE 2 of 5
Rev: 16.10.06 / ECN 22349


2.5 SHORTING ADAPTOR 2.7 LOCALLY MANUFACTURED LOCK

RELEASE TOOL
A lock release tool for the detector can be locally
manufactured (Fig.7), gives the dimensions for the
tool. The exam ple shown is an R.S. Components
screwdriver part number 544-689.
Fig. 5 Shorting Adaptor
The Shorting Adaptor (Fig. 5) is used to short terminals L,

L1 and L2 to allow cable resistance checks to be carried out.
2.6 DUST COVER

The dust cover (Fig.6) forms part of the detector
packaging. When the detector is removed from the
packaging the top of the packaging is also removed.
Fig. 7 Locally Manufactured Unlocking Tool
Fig. 6 Dust Cover

Rev: 16.10.06 / ECN 22349

M600 SERIES
01B-04-D5
1 11/02
3. TECHNICAL SPECIFICATION 4. CABLING

3.1 MECHANICAL CHARACTERISTICS Cabling is to be selected in accordance with Publication
05A-02-D1. A maximum of two 1.5mm2 cables may be
DIMENSIONS connected at any one terminal.
Fig. 1 refers.
Material
5. ASSOCIATED EQUIPMENT
Base: FR110 ‘BAYBLEND’ The base is compatible with the complete range of M600
Flame Retardant plug-in detectors.
Base Contacts: Stainless steel/Nickel plated The base is used in conjunction with the following
Base screws: Steel/Zinc plated mountings:
Weight
• British conduit box.
Base: 0.064kg
• European conduit box.
Environmental
Operating Temperature: -25°C to +70°C (+90°C for 6. ORDERING INFORMATION
short periods)
5B 5" Universal Base: 517.050.017
Storage Temperature: -40°C to +80°C
Relative Humidity: 95% non-condensing Head Removal Tool: 517.050.004
Lock Release Tool: Local Manufacture
Shorting Adaptor: 517.050.002*
3.2 ELECTRICAL CHARACTERISTICS
Continuity Adaptor: 517.050.003*
Through supply voltage: 28V d.c. max (not polarity
conscious) * Apend Part Number with A or T.
The Base has four cable terminals:

R Remote LED connector
L Line B IN/OUT JM/jm
L1 Line A IN 11th November 2002
L2 Line A OUT
Fig. 8 Terminal Designation
PAGE 4 of 5
Rev: 16.10.06 / ECN 22349


Fig. 9 Simplified Circuit Diagram

Rev: 16.10.06 / ECN 22349

Rev: 16.10.06 / ECN 22349

Data sheet for M600/M900 fire detection range (option)
MINERVA M600/M900
K e y Fe a t u r e s
Fire Detection
• Range
Intelligent Universal Smoke Detector
Low profile, discreet and unobtrusive
Superior performance and reliability
Attractive new design
Smart Card Addressing Technology
Designed for fast easy installation
Optional Locking Kit
May be used in systems that meet BS5839 Pt1
Integral and remote alarm LED
Wiring polarity independent
LPCB approved to EN54
Our sophisticated new low profile range of fire detectors introduces to the market a range of both conventional fire detectors
(M600) and analogue addressable type fire detectors (M900). In addition to the unobtrusive size and styled shape of the new
range, the M900 analogue addresable series has a number of new design features, including smart card technology for setting
the detector address, single visit to the ceiling installation and a service and maintenance detector park position.
Siemens Wind Power A/S / Data sheet for M600/M900 fire detection range (option) 197 / 202
Rev: 16.10.06 / ECN 22349

Ge n e r a l
Included within the range in both M600 and M900 formats is the intelligent high performance optical smoke (H.P.O)
detector. The use of the patented optical sensing chamber, together with refined signal processing, has enabled the
introduction of a smoke detector suitable for fast, reliable smoke detection of both slow and fast developing fires.
The complete range has been designed to meet the requirements of BS (British Standards) and EN (European
Standards) for fire detectors. The detectors also carry the new CE mark.
M 6 0 0 Se r i e s Co n ve n t i o n a l De t e c t o r s M 9 0 0 Se r i e s An a l o g u e Ad d r e s s a b l e
The M600 Series provides the detector part of an auto- Unlike conventional style detectors where the detector
matic fire detection system, as defined in BS5839 carries out the “normal” or “ fire alarm” decision with the
pt1:1988. The M600 Series Conventional or two state M900 Series Analogue addressable fire detector, the
detector is one that provides two output states to the detectors are acting as transducers relaying an output
controller, either “normal” or a “fire alarm” condition. signal of the sensed phenomenon to the fire controller.
The control unit then processes this information either in
The detectors along with callpoints are grouped into fire isolation, or in conjunction with information from other
zones, with each zone being connected to the control detectors to determine the appropriate response and ulti-
panel, by a separate two wire circuit and having a sepa- mately make the decision whether or not to raise an
rate zone indicator on the panel. alarm.
Ap p l i c a t i o n
As each type of fire detector responds to a particular “ fire prod- “ slow ” fire developing, the intelligent high performance optical
uct” the relative speed of response of the detector is therefore detector provides an excellent detection response.
dependant upon the type of fire being detected. The range of
M 600 and M 900 fire detectors have been designed to provide In situations w here the installation of smoke detectors w ould
the earliest possible w arning of a fire condition, w ith a minimum cause an unacceptable level of false alarms (i.e. Kitchens, laundry
possibility of false/unw anted alarms. areas) heat detectors may be installed. The M 600 and M 900
series provide a comprehensive selection of heat detectors, from
As smoke is normally present at an early stage in most fires, Rate of Rise types to various fixed temperature.
smoke type detectors (high performance optical, optical and ion-
chamber) are therefore considered the most useful. When con- Because of the w ide variety of applications that fire detectors are
sidering the type of smoke detector for the application, the prob- expected to cover, it is recommended that reference to BS5839
able type of fuel for the fire should be considered, in general Pt 1:1988 is made to aid selection.
terms, fast developing fires are detected quicker w ith ion-cham-
ber detectors, w hereas w ith a slow developing fire an optical
type smoke detector w ill respond quickest. But for general fire
detection, w here there is an equal possibility of either a “ fast” or
Fi r e Te s t Re s p o n s e
Test Fire Heat Sm oke Aerosol Visible High Opt ical Ion-
Developed Port ion Perform ance Cham ber
Opt ical
TF1 Open Cellulosic fire (w ood) STRONG YES INVISIBLE DARK C N A
TF2 Smouldering Pyrolysis fire (w ood) NEGLIGIBLE YES VISIBLE LIGHT B A C
TF3 Glow ing Smouldering fire (cotton) NEGLIGIBLE YES INVISIBLE LIGHT B A B
TF4 Open Plastics fire (polyurethane) STRONG YES INVISIBLE VERY DARK B C A
TF5 Liquid fire (n-heptane) STRONG YES INVISIBLE VERY DARK B C B
. TF6 Liquid fire (methylated spirits) STRONG NO NONE NONE N N N
198 / 202 Siemens Wind Power A/S / Data sheet for M600/M900 fire detection range (option)
Rev: 16.10.06 / ECN 22349

M600/M900 Fire Detector Range
High Performance Optical Smoke MR601T and MR901T
These detectors react to the whole range of fire products from slow
smouldering fires, producing visible particles to open flaming fires pro-
ducing large numbers of very hot smaller sized aerosols. It combines
optical and heat detector technology to detect clear burning fire prod-
ucts which hitherto could only be easily detected by ion-chamber
detectors.
For normal ambient conditions, the high performance optical detector

behaves as a normal optical detector. Only when a rapid rise in tem-
perature is detected does the sensitivity of the detector increase and
the presence of smoke will confirm a fire condition which will be trans-
mitted as an alarm level.
Optical Smoke MR601 and MR901

These detectors are capable of detecting the visible smoke produced
by materials which smoulder or burn slowly, i.e. soft furnishings, plas-
tic foam etc;. or ‘smoke’ produced by overheated but unburnt PVC.
These detectors are particularly suitable for general applications and
areas where cable overheating may occur e.g. electrical services
areas.
The novel design of the asymmetrical sampling chamber and signal
processing techniques stop unwanted alarms caused by very small
insects. i.e. thrips. Smoke entering the sampling chamber scatters the
infra-red light pulses onto a photodiode These pulses are converted to
an electrical signal which is compared against a preset alarm level or
transmitted as an analogue value.
Ion Chamber Smoke. MF601 and MF901

These detectors react to the visible and invisible fire aerosols (prod-
ucts of combustion) and are therefore capable of detecting the early
presence of hot smouldering and flaming fires, such as wood, paper
etc.
They are particularly suitable for general applications in all areas and
use a dual ionisation chamber in which the air is ionised by a single
radioactive source (33k Bq Americium 241) The presence of smoke in
the sampling chamber causes a change in the balance voltage,
between the two chambers. This is then compared against an alarm
level or converted to a current level and transmitted as an analogue
value.
Heat MD601, MD611 and MD901

These detectors use two networked thermistors in a bridge
configuration to provide a fast response, that depends both on
absolute temperature and notes the change of temperature.
The rate of rise/fixed temperature heat detectors can be used in areas

where smoke sensors are unsuitable due to environmental conditions
(smoke, dust etc,). Such areas include kitchens, locker rooms,
canteens, garages, loading bays etc.
The integral electronics emulate conventional fire detector’s response

curves and transmit the state to a controller as an alarm condition or
as an analogue representation of the ambient temperature conditions.
Rev: 16.10.06 / ECN 22349

M600/M900
S200 PLUSFire Detector Range
Series
Mechanical
Detector M aterial: FR110 “ Bayblend” Fire resistant

Dimensions: See diagram below
Weight (kg): 0.2 detector and base approx
Colour: White
109mm
53mm
Environmental
Operating Temperature Range -20°C to +70°C

Storage Temperature: -25°C to + 80°C
Relative Humidity: 95% non-condensing
Note: Ion chamber radiation source - americum 241< 33.3 KBq
Electrical
M 600 Series M 900 Series
Supply Voltage: 16 to 32 V d.c. Determined by

Quiescent Current: 60 µA typ. controller
Alarm Current: 48 mA typ.
Reset time: 2 - 5 seconds
Wing Connections: SEM Terminal SEM Terminal
2 x 1.5mm 2 2 x 1.5 mm 2
Electromagnetic Compatibility
ESD: to IEC 801-2-1991, level 3

Radiated: to ENV50140 1993
M agnetic: 10v/m @ 20 -1000 M Hz
Fields: 80% modulation @ 1KHz AM
1 Hz Pulse modulation
Fast transient: to IEC801 - 4, level 3
Slow High energy: to ENV50142 1994 @ +/_1KV
Technical Information Sheet PSF084U Issue 5 www.tepg.com ©Thorn Security Ltd. 2000
Rev: 16.10.06 / ECN 22349

Rev: 16.10.06 / ECN 22349

Rev: 16.10.06 / ECN 22349

Data sheet for M600/M900 low profile detector (option)
MINERVA M600/M900
Key Features Low Profile
•
4” and 6” Universal Detector Bases
Detector Bases
Low profile sounder bases
Conventional and addressable sounders
Up to 48 sounders per addressable loop
Uniform sound output
Line isolator base with indicator LED
Conventional or addressable relay output base
Double pole relay outputs with status LED
Automatic functions base lock
Up to 99 detectors plus 99 relay bases per loop
Detector anti-tamper lock
CE marked
Comply with BS5839 and EN54
The M600 and M900 Series of low profile detectors provide a comprehensive range of cost effective and aesthetically pleasing fire
and smoke detectors with worldwide approvals from UL, VdS, LPCB, SSL, NSTC, ULC and a comprehensive range of maritime
approvals. As well as standard heat, optical and ionisation detectors, the low profile detectors include the worlds first High
Performance Optical (HPO) Detector. The HPO combines heat and optical detection with intelligent algorithms to provide a
detector with an optimum flat response to fire tests such as those in EN54 Pt.9. The product range also includes the unique Tyco
Carbon Monoxide fire detector which opens new possibilities for the early detection of fires and saving lives.
Siemens Wind Power A/S / Data sheet for M600/M900 low profile detector (option) 193 / 196
Rev: 16.10.06 / ECN 22349

M600/900 Low Profile Detector Bases
Introduction
The unique design and leading edge technology of the low profile detectors goes beyond the detection technology itself. The
range of detector bases are designed to make low profile detector installations cost effective, aesthetically pleasing and easy
to install and maintain, thus minimising disruption.
The detector bases include standard universal bases which have no integral electronics, thus making them low cost and low
maintenance. Alternatively, a range of functional bases incorporate sounders, relays and line isolators to provide a cost effec-
tive method of adding flexibility to the fire detection installation.
Standard Universal Bases

The standard universal detector bases are compatible with both conventional and analogue addressable detectors. The
bases have no electronics and even when the detectors are connected to the bases, they can be electrically disconnected and
left in a “park” position. This enables wiring integrity tests to take place without any damage to electronics. When used with
addressable detectors, the smart card address key automatically transfers to the base, thus the address remains with the base
even if the detector is changed or replaced. An optional, tool removable locking pin allows the detector to be fixed in place to
prevent tampering.
4” Universal Base
The 4” base designed to fix directly to the ceiling
or various common backboxes. This base allows
a detector to be fitted in directly or a functional
base to be plugged in between the base and
detector.
.. Variety of fixing options
...
Remote LED connections
Available with continuity diode fitted
Anti-tamper facility
. LPCB, Vds, Marine approved (M600/900)

UL approved (4B)
6” Universal Base
The 6” base is specially designed for applica-
tions using the US style single gang backbox.
The 6” base provides an attractive alternative to
the 4” base in most applications.
... Variety of fixing options

Sealed back and cable entry
.. Remote LED connections

Anti-tamper facility
UL approved (6B)
Functional Detector Bases
Functional detector bases use a common moulding which incorporates a double sided circuit board which enables electrical
connections to be made on the top and bottom of the functional base. This allows the functional bases to be retrofitted into
new and existing universal bases or alternatively the depth and cost of the installed detector can be reduced by using the
functional base instead of the universal base. This feature enables additional line isolators and sounders to be easily added
during commissioning. In addition, changes to the building during it’s life can be easily adapted to, by retrofitting sounders
and relay outputs to existing detection points.
194 / 196 Siemens Wind Power A/S / Data sheet for M600/M900 low profile detector (option)
Rev: 16.10.06 / ECN 22349

M600/900 Low Profile Detector Bases
When functional bases are fitted to universal bases, they automatically lock into position. Removal is then achieved using
the detector removal tool. This feature ensures that the detector and functional bases are removable separately.
When used on addressable systems, the MC6/900 and MB900 take the same address as the detector. This increases the
number of devices on a loop and significantly improves fault monitoring. Any attempt to remove the functional base will
generate a fault on the system.
MB600 Conventional Sounder Base

The MB600 sounder provides a conventional sounder which blends
easily with the detector, providing the same tone as the rest of the
range of MINERVA electronic sounders. A unique design single point
sound source is used to provide complete audio coverage without
obtrusive holes in the moulding.
.. 3 selectable tones (slow, fast and continuous)
.. 3 volume settings (90, 80 and 70dB @ 1m)

Power consumption from 10mA
...
Single point sound source
Frequency compatible with all other MINERVA banshees
Can be used in place of a standard base
. Complies with pr EN54 pt3

Available with continuity diode fitted
MB900 Loop Powered Addressable Sounder Base
The MB900 sounder includes the same features as the MB600 with the
added benefit of being powered from the two wire MINERVA addressable
loop. The MB900 is controlled by the powerful event action of the address-
able MINERVA fire panel. This allows the MB900 to sound when its own
detector is in alarm or as a zonal sounder. By using the same address as
the detector, the sounder significantly increases the number of devices per
loop.
.. From 24 (90dbA) to 48 (70dbA) sounders per loop (plus 99 detectors)
...
3 selectable tones (slow, fast and continuous)
3 volume settings (90, 80 and 70dB @ 1m)
Single point sound source
...
Frequency compatible with other MINERVA banshees
Easily retrofitted
Complies with pr EN 54 pt 3
MC6/900 Functional Relay Base

The MC600 & MC900 provide dual relay contacts for signalling external
devices on conventional and addressable systems. Very low operating cur-
rent even when the relay is energised, enables the relay base to be used
without any additional power. When used with conventional detectors, the
MC600 triggers when the detector goes into alarm. On addressable sys-
tems, the dual contacts of the MC900 operate when the detector is in alarm
OR when commanded to do so by the panel.
.. Dual pole 24V DC relay contacts (60VA)
...
Status indication LED
Very low power consumption (<20μA except start-up)
Latching operation on conventional detectors
.. Easily retrofitted
. Complies with BS5839

MC600 available with continuity diode fitted.
Siemens Wind Power A/S / Data sheet for M600/M900 low profile detector (option) 195 / 196
Rev: 16.10.06 / ECN 22349

M600/900
S200 PLUSLow Profile Detector Base
Series
MI900 Analogue Addressable Loop Line Isolator

The MI900 incorporates the same circuitry as the LI520 MkII line isolator to pro-
vide a flexible and easily installed line isolation protection on MINERVA analogue
addressable systems. As the line isolator is easily inserted or removed, future
systems changes can be implemented to suit changes in building use with mini-
mum disruption.
.. Up to 12 isolators per loop Environmental (Functional Bases)
..
Status indication LED
Operating temperature -25 to 70oC
Easily retrofitted Humidity Up to 96% RH (non-condensing)
Complies with BS5839 Vibration Exceeds requirements of prEN54-3
Marine & UL268
Corrosion Hydrogen Sulphide - UL 464
Salt Mist - Marine
Technical Specification EMC BS-EN 50130-4 Exceeds pr EN54-3
IP Rating IP21-2-(EN 60529)
Mechanical
MB600† MB900 MI900 MC600 & 900 M600/900(4B) 6B
Height: (mm) 36.6mm 10mm 21mm

Weight: (kg) 0.166 0.166 0.147 0.152 0.07 0.12
Diameter:(mm) 107.8mm(4”) 152mm(6”)
No. per loop (max) NA *24/36/48 12 32 99 - -
Frequency (Hz) 850 850 - - - -
Power Supply 28Vdc Loop Loop Loop/Circuit - -
Volume Setting 1 70dbA 70dbA - - - -
Tones: 3 3 - - - -
Material FR110 Bayblend
* Some limitations apply when fitting MB900 units to existing installations and when using certain configuration options.
† Also available as MB600D and MC600D with integral continuity diode. This allows the functional base to be used with an
additional continuity diode base on conventional circuits.
mA MB600 mA MB900
48
25 50
20
20 40 36
15
15 30
24
10
10 20
5 10
70dBA 80dBA 90dBA 70dBA 80dBA 90dBA
196 / 196 Siemens Wind Power A/S / Data sheet for M600/M900 low profile detector (option)
Rev: 16.10.06 / ECN 22349

Smoke and heat detectors 65 series

Fig. 12.1
Siemens Wind Power A/S / Data sheet for Smoke and heat detectors 205 / 220
Rev: 13.11.2007 / ECN 26195

Fig. 12.2
206 / 220 Siemens Wind Power A/S / Data sheet for Smoke and heat detectors
Rev: 13.11.2007 / ECN 26195

Fig. 12.3
Rev: 13.11.2007 / ECN 26195

Fig. 12.4
Rev: 13.11.2007 / ECN 26195

Fig. 12.5
Rev: 13.11.2007 / ECN 26195

Fig. 12.6
Rev: 13.11.2007 / ECN 26195

Fig. 12.7
Rev: 13.11.2007 / ECN 26195

Fig. 12.8
Rev: 13.11.2007 / ECN 26195

Fig. 12.9
Rev: 13.11.2007 / ECN 26195

Fig. 12.10
Rev: 13.11.2007 / ECN 26195

Fig. 12.11
Rev: 13.11.2007 / ECN 26195

Fig. 12.12
Rev: 13.11.2007 / ECN 26195

Fig. 12.13
Rev: 13.11.2007 / ECN 26195

Fig. 12.14
Rev: 13.11.2007 / ECN 26195

Fig. 12.15
Rev: 13.11.2007 / ECN 26195

Rev: 13.11.2007 / ECN 26195

Type: Honeywell (option)
Siemens Wind Power A/S / Flylys type: Honeywell / 555 / 564

Rev: 16.10.06 - ECN 22349
556 / 564 Siemens Wind Power A/S / Flylys type: Honeywell /
Rev: 16.10.06 - ECN 22349
Rev: 16.10.06 - ECN 22349
Rev: 16.10.06 - ECN 22349
Rev: 16.10.06 - ECN 22349
Rev: 16.10.06 - ECN 22349
Rev: 16.10.06 - ECN 22349
Rev: 16.10.06 - ECN 22349
Rev: 16.10.06 - ECN 22349
Rev: 16.10.06 - ECN 22349
Data sheet for MXC panel (option)
MINERVA MINERVA
Key features
• MXC
Approved to EN54
2, 4 and 8 zone variants
Operates with Tyco M601 LPCB and M613

VdS approved detector ranges
Tyco 2-Wire sounders on the first

4 detection zones
Supports a plug-in Alarm Receiving

Centre Communicator
Programmable mapping of detection circuits

to sounder circuits
Capable of supporting repeater panels
Compatible with the standard

RedCARE STU
An Exceptional New Conventional Fire Panel Family

The New Minerva MXC Panel Range characterises the first in a fresh generation of highly featured low cost conventional fire panel.
The exceptional 2, 4 and 8 zone panels are the first in an entirely new family of fire detection and extinguishing controllers.
New Panel design has specifically targeted the high volume, small system segment of the fire detection market. Focused design
at conceptual stage, has ensured incorporated features, aimed to reduce installation costs, simplify connection to central alarm
monitoring stations and allow service upgrades of old installations. The MXC offers a robust self-contained control panel,
providing all required monitoring, and control functions needed to install a complete fire detection alarm system.
Siemens Wind Power A/S /Data sheet for MXC panel (option) 183 / 192
Rev: 16.10.06 / ECN 22349

MINERVA - MINERVA MXC

Operation overview Detection Zones
Minerva MXC provides reliable, independent, isolated control of the The MXC can support up to 8 detection zones. Zones 1-4 support
sounders and detectors on the same 2-wire circuit, and hence 2-wire sounders. Zones 5-8 are detection inputs, provided on a plug
achieves significant cost and installation savings without in expansion card. Zones 5-8 do not support 2-wire sounders.
compromising performance. Two-four or eight zone panels are
available with up to four of the zones driving sounders.
Panel functions
For normal operation, the MXC requires no configuration. Other

typical options can be easily selected on links inside the controller.
An optional advanced programming mode changes the function of
the standard user interface to allow powerful bell mapping and
sounder delay options.
..
Detection zones support Conventional 600 Series Detectors, up
One man weekly test option to a total load of 3mA - typically 32 devices.
.. One man zone and sounder walk test

Zone Disable (Isolate) functions
Sounders
Zones 1-4 can each support up to 16 Tyco 2-wire sounders.
. Cross zoning/coincidence on zones 1 & 2

Optional reset on auxiliary 24V
Sounders can be wall-mounted or integrated within the detector
base - 602SB or 602SB 2-Wire Line Powered Sounder Bases.
Installation Features Callpoints
The MXC offers flexible-mounting arrangements, with an easily Alert type callpoints and the CP211 Evacuate callpoint can be used
removable door, multiple conduit entries and a large terminations on the detection zones but CP210 must not be used.
designed for ease of installation.
... Surface or semi-flush mount Inputs and Outputs
Reversible back-box for top or bottom conduit or cable entry The detection circuits support 2-stage alarms, Alert and Evacuate,
. Customised zone text inserts

Terminations that suit up to 2.5mm^ CSA Cable
which can be used for different sounders responses. Auxiliary inputs
allow school class change to be configured to existing installations,
signalling faults to be monitored and non-latching alarms from
Power Supply landlord systems to be implemented.
... Designed to comply with EN54 Pt 4 .. Detection circuits monitored for detection removal
Up to 72hr plus 30 minutes alarm
. Non-latching alarm input
. .
Space for x 7Ah batteries internally Non-latching fault input
2A PSU/charger with 1.5A available for detectors, sounders Signalling fire and fault outputs (with optional
(2x500mA) and auxiliary devices (24V 250mA). monitoring/supervision of the connection
Stockcode Description
508.030.102 UK 4-Zone EN54 Panel (non -line powered)
508.030.201 UK 2-Zone Line Powered Panel (2-wire on 2-zones)
508.030.202 UK 4-Zone Line Powered Panel (2-wire on 4-zones)
507.030.203 UK 8-Zone Line Powered Panel (2-wire on 4-zones) c/w MXC IOP expander
3072 12V 7Ah Battery
509.030.001 MXC IOP input/output expander card
509.030.005 MXC-DIGI plug-in Scantronic Microcom communicator c/w mounting kit
573.013.300 24V RedCARE STU (requires box)
573.013.103 Fire Test Buzzer and Keyswitch (for RedCARE)
184 / 192 Siemens Wind Power A/S / Data sheet for MXC panel (option)
Rev: 16.10.06 / ECN 22349

185 / 192
MX CONVENTIONAL FIRE CONTROLLER Product Application and System Design 120.415.754 Issue 5
- INTRODUCTION - Fault Signalling Output: 30mA sink to 0V (EOL: controller can ‘learn’ the quiescent zone voltage Class Change/Non-latching Alarm
10kΩ to 12V or 20kΩ to 24V) level. This shared input is monitored for short circuit faults
The MX Conventional Controller (MXC) is a 2, 4, or
8 zone fire panel. It is designed to comply with BS OPTIONS: On the 2-wire sounder versions of the controllers, only. The input is operated by switching a resistor
EN54 parts 2 & 4 and can be used to fit installations zones 1-4 each support up to 16 Tyco 2-wire across the input; 47kΩ for class change or 27kΩ for
EXPANSION CARD sounders. The zones are protected by an electronic
designed to meet BS5839 part 1. the non-latching alarm. Both options can be activated
Zone voltage: 22V DC nominal fuse reset by the controller when the fault is cleared. together. The resistor should be switched using a volt-
The MXC is a self-contained panel providing all
required monitoring and control functions to install a Zone detector load: 3mA (typically 32 devices) When using Tyco 2-wire sounders the zone must be free contact.
complete fire detection and alarm system. This sheet Zone EOL device: 18V zener diode in series with wired in 1.5mm cable (or thicker) and must be less
than 500m long. Non-latching Fault/Line Fault Input
provides the technical details and features of the 150Ω resistor
MXC to design a fire system. Only CP11 evacuate callpoints can be used on This shared input is monitored for short circuit faults
Zone Outputs: 50mA sink to 0v (Darlington) only. The input is operated by switching a resistor
The fire detection system should be designed in detection zones. The CP210 MUST NOT be used.
accordance with BS5839 part 1 or Local National Disabled Output: 50mA sink to 0v across the input; 27kΩ for the non-latching fault or
(Darlington) Note: There is a delay of up to 0.5s between the 47kΩ for line fault. Both inputs can be activated
Fire Code. The choice of cables is dependent on the zones to turn 2-wire sounders on or off.
installation and should comply to this standard or Fire/Fault Relays: Volt-free N/O and N/C contacts - together. The resistor should be switched using a volt-
code. (Note: Where 2-wire sounders are used on the 1A at 24v DC End-of-line device free contact.
detection zone the wiring must conform to the Silence/Reset Input: No EOL. Silence 47kΩ and The line fault input is always enabled, regardless of
relevant requirements of the standard). The end-of-line device for detection zones is a 18V signalling options.
Reset 27kΩ to activate. 1W zener diode with a 150Ω 2W series resistor. This
The controller and all cables should be installed Evacuate/Resound Input: No EOL. Evacuate 47kΩ MUST be used on all zones to provide correct
Siemens Wind Power A/S /Data sheet for MXC panel (option)
Fire and Fault Signalling Outputs
according to the current edition of the IEE Wiring and Resound 27kΩ to activate. monitoring for faults and detector removal.
Regulations or Local National Wiring Regulations. The fire and fault signalling outputs provide a
RELAY CARD Sounder Circuits 1 and 2 monitored link to external remote signalling
Note: A local fused spur should be provided to
connect the controller to the mains supply. Fire/Fault Relays: Volt-free N/O and N/C contacts - The MXC provides two standard, line reversal equipment. The auxiliary output can be used to power
1A at 24v DC sounder outputs each capable of 500mA load. The an external communicator.
TECHNICAL SUMMARY INTERNAL COMMUNICATOR outputs are monitored for short and open circuit The fire output should be wired with a 20kΩ resistor
Scantronics Microcom 08300 EUR-01 faults. Each output is separately protected using an to 0V at the signalling equipment and is monitored for
Dim: 332 (W) x 240 (H) x 100 (D) mm electronic fuse reset by the controller when the fault open and short circuit faults. It is driven to 24V when
Rev: 16.10.06 / ECN 22349

Weight: 6.8kg (inc. 7Ah batteries) MECHANICAL SPECIFICATION is cleared. The circuits must be fitted with a 27kΩ the controller is in alarm.
Enclosure: Moulded Polycarbonate end-of-line resistor. The fault output should be wired with a 20kΩ resistor
The plastic enclosure is shown in Figure 1. It can be
Cable Entries: 20 off, 20mm top or bottom entry mounted either way up to provide top or bottom cable Power Supply and Batteries to 24V or a 10kΩ resistor to 12V at the signalling
entry using the holes provided. The door is easily The MXC has an internal mains PSU that provides equipment. It is monitored for open and short circuit
Standards: BS EN54 parts 2 and 4 faults. It is normally held at 0V and switches off when
rotated by removing the hinge pins and refitting using all power. It charges and monitors two 12 volt lead
Temperature range: 0 to +40oC the hinges on the other side. Note: The door may only the controller is in fault (or looses power).
acid batteries (up to 7Ah) which are fitted inside the
Mains voltage: 230V AC +10% -15% 50Hz be used opening to the left. enclosure. The battery charge is current-limited to A fault on the fault output itself is latched and is
Operating voltage: 24V DC nominal 450mA. cleared by a reset.
TECHNICAL SPECIFICATION
Current: 1.5A available for external use; for The PSU provides a maximum of 1.5A for external If external signalling is not required, the fire and fault
detectors, sounders and external loads. The MXC General Wiring Diagram and the link table use: for detectors, sounders and external loads which outputs can be configured to be used as unmonitored
on the other side summarise the capabilities of the must not be exceeded. External PSUs MUST NOT outputs to drive external loads. This option is selected
Battery voltage: 24V DC nominal controller. These are described in more detail below. by configuration links. The fire output can source up
be used to operate the MXC.
Battery charge current: limited to 450mA to 30mA and is protected by current-limiting. The

Zone voltage: 22V DC nominal FEATURES Power Supply Calculations fault output sinks 30mA and is current-limited.
Zone detector load: 3mA (typically 32 devices) Detection Zones The battery size, to meet the required standby period Repeaters
Zone sounder load (1 to 4): 16 sounders per zone The MXC can support up to 8 detection zones. Zones for the MXC, should be calculated using the figures An opto-isolated communication bus is provided to
with an active fuse 1-4 are on the main power supply board and support in the battery calculation table. A spreadsheet is support up to 4 repeater controllers. The cable should
2-wire sounders. Zones 5-8 are detection inputs a v a i l a b l e o n t h e Ty c o w e b s i t e a t be suitable for 1200 baud communication Belden or
Max. zone wiring resistance: 24Ω www.tycosafetyproducts-europe.com.
provided on a plug-in expansion card. Zones 5-8 do similar. Only ONE unit, normally the main controller,
Zone EOL device: 18V zener diode in series with not support 2-wire sounders. provides power to the bus by fitting links on the power
150Ω resistor Auxiliary Output supply board.
The detection zones are monitored for both open and
Sounder load (1 & 2): 500mA each with an active short circuit faults. They support the M600 range of The auxiliary output provides up to 250mA at 24V The repeater controllers are mains powered. The
fuse detectors up to a total load of 3mA; typically 32 for external devices. This is reduced to 150mA on an repeater PSU charges and monitors batteries, like the
Sounder EOL resistor: 27kΩ devices. The zones must be fitted with an end-of-line 8-zone controller, or when the expander card is main panel. A charger fault will be reported if the
device. fitted. It is protected by an electronic fuse reset by the mains or the batteries fail. Earth faults are detected by
Auxiliary 24V supply: 250mA with an active fuse controller when the fault is cleared. This output is
Detector removal is monitored by a change in voltage the main panel.
Fire Signalling Output: 24V at 30mA (EOL: 20kΩ normally switched off when the controller is reset.
to 0V) on the zone. It is important that all detectors are On repeaters, Earth faults are monitored by the main
connected in circuit during commissioning so that the panel not by the repeater. But link 5 must not be fitted
on repeaters.
© 2003 Tyco Safety Products Page 1 of 4
LINK NO LINK
OPTION LABEL LINK FITTED NOTE
No. (DEFAULT)
PANEL SIZE 1 SIZE 2 ZONE 4 ZONE SELECTS WHETHER THE CONTROLLER IS 2 OR 4 ZONES
TB1
EXPANSION CARD 2 EXPC NOT FITTED FITTED SELECTS THAT THE OPTIONAL EXPANSION CARD IS FITTED
TO PROVIDE MORE I/O
N
N
E
L
FS1
MICROCOM 3 UCOM NOT FITTED FITTED SELECTS THAT MICROCOM IS FITTED FOR FIRE AND FAULT
E
SIGNALLING
WARNING:
L
HIGH VOLTAGE AREA
FIRE AND FAULT 4 FFOP GENERAL SIGNALLING SELECTS WHETHER OUTPUTS ARE USED FOR EXTERNAL
C2
Siemens Wind Power A/S / Data sheet for MXC panel (option)
MXC PSU PCB
OUTPUTS (UNMONITORED) (MONITORED) SIGNALLING OR GENERAL RELAYS
C2
EARTH FAULT 5 EFLT ENABLED DISABLED SELECTS EARTH FAULT MONITORING
DISABLEMENT 6 DACS DISABLEMENT DISABLEMENT SELECTS ACCESS TO DISABLE FACILITY USING FRONT
ACCESS AVAILABLE NOT AVAILABLE PANEL CONTROLS TRANSFORMER
TB3
B B
TEPG c 2001
SOUNDER 7 SAA CONTINUOUS PULSING/ SELECTS PULSED SOUNDERS FOR ALERT EVENTS. OR
ACTION BELL MAP ENABLES BELL MAP IF PROGRAMMED. N/O
FIRE COM
REPEATER 8 RPTR PANEL REPEATER SELECTS THAT UNIT IS A REPEATER. ASSUMES IT IS
AUX AUX BAT BAT
Rev: 16.10.06 / ECN 22349

RESET
+ N/C
SW2
REPEATER NUMBER 1
N/O
-
A
RED
+
A FAULT COM
BLACK
Table 1: Configuration Links
-
N/C
Note: 1
TB2
2
Link 2 must be fitted in an 8 zone controller or repeater.
SD1 SD1 SD2SD2 Z1 Z1 Z2 Z2 Z3 Z3 Z4 Z4 0V FIRE FLT ALM 0V FLT

+ SD1+ 3
SD1-
-
Link 5 must not be fitted on repeaters. 4 ZONE
+ SD2+
SD2- 5 OUTPUT
For repeaters, addresses other than 1 are selected using the configuration overlay.
-
+ Z1+ 6
1- Standard Zone Circuits Z1- 7
-
+ Z2+ 8
2- Tyco 2-wire Zone Circuits
MX CONVENTIONAL MODEL NUMBERING: Z2-
-
SP1 - DISABLED
A
+ Z3+ B
SP2
Z3 -
-
Panel / Repeater + Z4+ SIL/
Z4- RES
-
0V EVAC/RSND
MXC102PU + FIRE+
FLT-
0V
- /CCH
0V
ALM/CCH
SP3
0V
Country FLT/LF SP4
/LF
TEST Z5+
SW1
C C Z5-
12 34 56 7 8
Number of zones (2, 4, or 8)
PL3
Z6+
Z6-

NVM Z7+
PIN 1
Z7-
H5 H3
PLUG
MICROCOM
PROG
Z8+
REP REP
+ Z8-
H2
H4
TB4
+
LOOP PWR
-
A
B
C C
H1
A
B
A - EXPANSION CARD PILLARS
B - TOP SCREWS ONTO EXPANSION CARD PILLARS
C - MICROCOM CARD PILLARS
DENOTES ATTACHED TO
UNDERSIDE OF BOARD
Fig. 2 Power Supply card PCB Layout Fig. 2 Expansion card PCB Layout
Fig. 1 Enclosure Dimensions
186 / 192
187 / 192
Microcom Communicator Relay Card
Weekly Test Cross Zone 1 and 2
A Microcom 08300 EUR-01 Communicator/ The relay card plugs-in to the power supply
board and provides a general fire relay and a The weekly test function provides an easy way to Zone 1 and 2 circuits can be configured to be one
MODEM can be plugged into the MXC to provide perform routine system tests where the controller cross wired zone, reported as zone 1. The first
remote signalling of fire and fault events. The general fault relay.
will sound all sounders for 10 seconds when a detector in alarm on either circuit will activate the
Microcom connects directly to the telephone The general fire and fault relays are changeover callpoint or detector is activated.The controller will buzzer, the zone 1 indicator and the zone 2 (1st stage)
system and provides line fault monitoring. types with both normally open and normally indicate the alarm, with the Fire, Zone, Sounder and output on the expansion card. When a detector on the
The telephone numbers and site details are written closed contacts. The fault relay is normally Signalling indicators on. A test event will be other circuit goes into alarm, so both in alarm, the
into an NVM using a Scantronics 7200 active and turned off when a fault condition is signalled. After 10 seconds, the controller will turn panel will enter the full fire alarm mode and in
programmer. The NVM is fitted into a socket on the present (or power is lost). off the sounders and indicators and return to the addition activate the zone 1 (2nd stage) output on the
power supply board. previous state leaving weekly test mode. expansion card.
FUNCTIONS A subsequent callpoint or detector activation will Silence Mode
Expansion Card cause a full alarm.
Fire and Fault Monitoring and Control Usually the front panel silence button can only be
See leaflet 120.415.756 for more details. Note: If the access code has been used to enable the used at user access level 2 or above to silence and to
The expansion card plugs-in to the power supply The MXC reports and manages alarms and faults panel controls, then the normal time-out is disabled. re-sound sounders. Alternatively, in configuration,
board and provides 4 extra detection zones, 8 in accordance with EN54 part 2. The controller This allows time for the user to reach the designated the silence button can be restricted to silence alone
darlington zone outputs, 1 darlington disabled buttons and indicators provide the user with the callpoint. at level 1 and above, or silence alone at level 2 and
output, a general fire relay, a general fault relay and information and controls to operate a fire system. above.
remote inputs to mimic the evacuate, resound, Non-latching alarm Zone, Sounder and Signalling Test Evacuate + ✓
silence and reset buttons.
When this input is active, the controller will The MXC provides facilities to test either zones, The normal mode for the front door evacuate button
The detection zones offer the same features as enter the alarm condition. The general fire sounders or signalling. This is normally considered can be changed so that instead of needing a key or
zones 1 to 4, but they do not support 2-wire indicators will be turned on and the buzzer will to be for engineers use and is available by putting the access code to enable the button, the button is always
sounders. (See ‘Detection Zones’ details). sound continuously. All sounders will be on and controller into test mode using the button inside the enabled but must be confirmed within 5 seconds by
The 8 zone outputs switch to 0V when a zone is in alarm signalling will be activated (if present). enclosure. pressing the ✓button.
alarm. They are all darlington outputs each capable All indications and outputs will clear when the When testing a zone, the controller will sound all
of sinking up to 50mA. It is recommended that the input clears. sounders, even if disabled, on the system for 4 Repeaters
Rev: 16.10.06 / ECN 22349

power is supplied from the controller auxiliary seconds when a zone is placed in alarm by either a
output so that the protection diodes are in circuit. The MXC controller can support up to 4 repeaters on
Non-latching fault detector or a callpoint. The controller will then an opto-isolated 2-wire bus. The repeaters will
The disabled output switches to 0V when a When this input is active, the controller will automatically reset the zone. mimic the displays of the master controller and
disablement or a delay function has been engaged. enter the fault condition. The general fault The sounder test allows the sounders on each zone to provide full use of the primary control buttons.
It is a darlington output capable of sinking up to indicator will be on with the buzzer pulsing. The be activated zone by zone; or the conventional
50mA. It is recommended that the power is The communications link between the main panel
fault signalling will be activated (if present). sounders to be activated on their own. and the repeaters is monitored, a failure will raise a
supplied from the controller auxiliary output so that
the protection diodes are in circuit. All indications and outputs will clear when the The signalling test will send a test message via the general fault. The link to the display PCB is also
input clears. Microcom or set the fire signalling output. monitored and a failure will raise a general fault. A
The general fire and fault relays are changeover failure of the CPU or software will raise a system
types with both normally open and normally closed Class change Delays fault.
contacts. The fault relay is normally active and
turned off when a fault condition is present (or Activating this input will operate all sounders on The MXC may be configured using the overlay to Note: The main panel polls a repeater every second.
power is lost). the system. The sounders activated LED only delay sounder or signalling outputs by up to 10 Thus with 4 repeaters, commands or faults may take
will be on. The sounders remain on whilst the minutes. (Maximum allowed by EN54). The default up to a maximum of 4 seconds to reach the main

The remote inputs to mimic the evacuate, resound, input is active and turn off when it clears. delay is 3 minutes. panel.
silence and reset buttons are monitored for short
circuits only and activate when the input is switched Note: The 2-wire sounders will turn on 2s after The outputs to be delayed and the delay period are
the input is activated and turn off 2s after it is set in configuration mode. The period set applies to MK/tj
to 0V via a resistor. The evacuate (47kΩ) and
resound (27kΩ) inputs share a circuit.The silence cleared. all delayed outputs. The delay is then turned on or off 12th May 2003
(47kΩ) and reset (27kΩ) inputs share a circuit. from the operating menu.
Line fault No Signalling
These remote inputs mimic the same operation as
the controller blue buttons except that the controller This input is specifically for monitoring faults For installations that do not use the fire signalling
does not have to be enabled by key or access code. from external signalling equipment. It will raise outputs, the signalling activated and delayed status
The silence input can only turn off the sounders it a signalling fault when active and pulse the indicators on the front door can be disabled and will
cannot resound. (This ensures that when the input is buzzer. The indications and buzzer will clear not come on in the alarm condition. The outputs will
operated it puts the sounders into a known state). when the fault clears. still operate as normal in this mode.
The Silence and Reset can be activated together, or
the Evacuate and Resound can be activated
together, using a single resistor (18kΩ) on each
circuit.
120.415.754 Issue 5
Job reference: Date:
Site: Engineer:
MXC10x/20x 2/4/8 Zone Panel with M600 detectors

Battery Calculation Table
Normal Load Alarm Load
Item Select max Load mA Total Load max Load mA Total Load
CONTROL EQUIPMENT Panel Size Normal/Fault Normal mA Alarm Alarm mA

2 ZONE PANEL (MXC102P)* 50 120
4 ZONE PANEL (MXC204P)* 65 145
8 ZONE PANEL (MXC208P)*
(includes expansion card already fitted) 100 200
Internal Options
Microcom Communicator 10 20
Expansion card (outputs only) 10 35
2-Wire Sounders
Symphoni 0.05 5
602SB/SBD 0.06 7
Detectors
M600 Series detectors (normal) 0.1
M600 Series detectors (in alarm) 40
Conventional Sounder Outputs

BEDLAM 0 30
BANSHEE 0 17
Fire and Fault Outputs

FIRE OUTPUT LOAD 30
FAULT OUTPUT LOAD
24V Auxiliary Output Loads
Normal Total (mA) Alarm Total (mA)

X X
Standby Time (h) Alarm Time (h)
Standby Capacity (mAh) Alarm Capacity (mAh)
Results Total Capacity = Standby + 1.2 x Alarm (mAh)

Charger type MXC 20x INTERNAL Convert to Ah ( ÷ 1000)
Batteries (max. 7Ah) Ageing factor ( x 1.25) (Ah)
Required Capacity Ah
* - Calculations assume unused zones fitted with EOL.
Page 4 of 4
Rev: 16.10.06 / ECN 22349

189 / 192
MX CONVENTIONAL FIRE CONTROLLER Installation and Commissioning 120.415.494 Issue 5

- INSTALLATION - Open the door of the controller by undoing the allen EXPANSION CARD FIELD WIRING
screw found under the hinged flap to the right of the
This sheet describes how to install the MX indicators. If required, fit the Expansion Card into the The field wiring must be installed using cable that
Conventional controller (MXC). Please read all controller BEFORE connecting field wiring cables. meets the manufacturers recommendations and the
instructions before starting to install. These Unplug the internal ribbon cable to the door- Refer to the Expansion Card Installation sheet.
mounted display PCB, at the power supply board local wiring codes.
instructions are specific to the MXC and cannot be Complete any high voltage wiring checks. Check
considered to cover every aspect of a fire alarm end only.
MAINS CONNECTION the resistance of each zone and sounder circuit is
installation. less than the maximum given on the PA & SD sheet.
CHANGING THE DOOR FOR The connection to the mains supply must be via an
Installers should be familiar with BS5839: Part 1. isolating switch reserved solely for the controller. Connect the bases and sounders and check all
Cabling and earthing should comply with the current BOTTOM CABLE ENTRY
The cover must be coloured red and labelled ‘FIRE wiring circuits for continuity, polarity and that they
issue of ‘IEE Wiring Regulations’. Consultation If the bottom entry knockouts are required for the ALARM: DO NOT SWITCH OFF’. Appropriate are clear of short circuits. Note: If diode bases are
with the local Fire Officer is recommended to ensure cables, then the rear enclosure needs to be mounted protection of no more than 20 amperes must be used, it may not be possible to check the continuity
compliance with any special local requirements. upside down with the front door turned over as provided on this mains supply. of a whole circuit with a standard electrical meter.
All field wiring and other devices to be used with the follows:
Activate the switch/relay connected to any general
MXC must be installed according to the Place the controller on a flat surface, open the door WARNING: inputs (eg, class change) in turn and check that the
manufacturers recommendations and must meet and unplug the internal ribbon cable as described resistance of each input circuit is the required value
any local national requirements. above. A LABEL MUST BE AFFIXED ADJACENT THE
as given on the PA & SD sheet. Check shared inputs
CONTROLLER GIVING THE LOCATION OF THE
Slide out both hinge pins holding the door to the MAINS ISOLATING DEVICE FOR THE CONTROLLER separately.
rear box. Lift the door from the rear box and turn
CAUTION: If a Microcom communicator is to be fitted in the
box around. controller, a telephone lead is needed at the
DO NOT USE HIGH VOLTAGE TEST EQUIPMENT,
Carefully place the door onto rear box, so that the Connect the 230V AC mains to terminal block TB1, controller for connection to the Microcom
SUCH AS A MEGGER, WHEN THE CONTROLLER as below. Ensure safety cover is replaced over
OR OTHER EQUIPMENT IS CONNECTED TO THE webs of the hinge mesh together. terminals.
FIELD WIRING AS THIS WILL CAUSE DAMAGE. power supply.
Refit the hinge pins and check the door opens and If the controller is to be used with external
closes smoothly. signalling equipment, then that equipment must be
installed with its own PSU and with the required
MOUNTING cables and terminations for connection to the fire
Rev: 16.10.06 / ECN 22349

CAUTION: and fault signalling terminals in the controller.
The MXC should be located in an accessible
OBSERVE STATIC HANDLING PRECAUTIONS
position at a working height, preferably near an Check the resistance of each signalling circuit,
WHEN HANDLING ELECTRONIC ASSEMBLIES.
entrance. It should not be in direct sunlight or near measured to the appropriate supply, is the required
a direct heat source. The area should be clean, dry value as given on the PA & SD sheet.
PREPARATION and well ventilated.
Check there are no buried cables or plumbing in the
Remove the MXC from its packing and ensure the wall where the controller is to be mounted and that
following items are enclosed: the wall is flat.
MXC Fire Controller with Logbook Using the template, drill 2 mounting holes and fit
Installation & Commissioning sheet suitable fixings or rawplugs.
Product Application & System Design sheet Clean any dust from the area. Drive screws partway
Wiring Diagram into the holes so that at least 25mm is left protruding
from wall.

Drilling Template
Lift the controller and slide the key slots over the
Installation Kit - consisting of: mounting screws to hang it in place. If the mains
Allen Key (for front door fixing screw) cable is entering from the back of the controller, BATTERIES
Plastic key remember to thread the cable through the hole as the
controller is fitted. The batteries should be correctly rated for the
End-of-line devices (one per zone) installation according to the PA & SD sheet.
Sleeving for end of line devices Check the screws are correctly located in the top of
slots then tighten. Check the controller is physically Fit the interconnecting lead between the batteries,
2 Sounder end-of-line resistors (27k) secure. noting the polarity.
Zone Location Insert Slide the batteries into place in the rear box.
Sheet of 5 logo labels MICROCOM COMMUNICATOR DO NOT CONNECT TO THE POWER SUPPLY
2 Jumper links If required, fit the Microcom mounting pillars into BOARD YET.
Mains Fuse 1A anti-surge HRC the controller BEFORE connecting the field wiring
Battery interconnecting lead cables. Do NOT fit Microcom onto the pillars yet or
Signalling output resistors (5 x 10k, connect it to the telephone lead. Refer to the
1 x 47k) Microcom Installation sheet.
MX CONVENTIONAL FIRE CONTROLLER Installation and Commissioning 120.415. 494 Issue 5
- COMMISSIONING - ZONE CIRCUITS Activate each input in turn and then together, PAPERWORK
c h e c k i n g t h e c o n t r o ll e r g iv e s t h e c o r r e c t
Remove the power from the controller. Connect the indications. Mark the commissioning date on the controller
WARNING: zone circuits to the controller. Ensure the end-of- batteries.
ISOLATE THE CONTROLLER MAINS SUPPLY AT THE line device is connected at the last device of each FIRE AND FAULT SIGNALLING Complete the front of the logbook and enter the
JUNCTION BOX AND DISCONNECT THE BATTERIES circuit and check the polarity. commissioning details in the event log.
BEFORE CONNECTING OR DISCONNECTING ANY OF Check the appropriate links are fitted to enable
THE CONTROLLER FIELD WIRING. Fit all the detectors in position. Check the detectors If required, fill-in the zone names on the location-
are the correct type and are securely mounted. monitoring of the connection.
insert and slide into the slot provided behind the
Power up the controller and check that all zone fault Connect the circuits and power up the controller. overlay. Check that the text is visible.
INITIAL CHECKS c o n d i ti o n s a r e c l e a r. C l e a r a n y f a u l t s b y Check no faults are reported.
Stick the logo label on to the area below the overlay.
Siemens Wind Power A/S / Data sheet for MXC panel (option)
disconnecting the circuit and checking for Disconnect each signal in turn at the external
Plug the display PCB cable back into the Power continuity, polarity or short circuits.
Supply board (or the Expander Card if an 8-zone signalling equipment and check that a signalling HAND OVER
controller). Test all the detectors and callpoints on the system in fault is indicated on the controller.
turn by putting each of them into alarm. Generate an alarm and a fault and check they are Ensure the responsible person knows how to
Fit end-of-line devices directly to the terminals of operate the system and is familiar with system
all unused circuits and end-of-line resistors to the Check that the correct audible alarms are heard and correctly signalled. Also carry out any checks
specified in the signalling equipment operation.
terminals of both conventional sounder circuits. the appropriate zone indicators are lit. Silence the
sounders and reset the controller after each test. documentation. Demonstrate to the responsible person(s) that the
Power up the controller and check the POWER system is working.
LED is on. Check all the indicators using the lamp Remove each detector in turn from the circuit (this CONNECTING FIRE AND
Rev: 16.10.06 / ECN 22349

must be done with the controller powered up) and Hand over the documents and the controller key.
test. The buzzer may pulse and the controller may
report many faults -ignore these for now. check that the appropriate zone fault is reported. FAULT OUTPUTS TO Show the responsible person the logbook, then
Check the fault clears when the detector is replaced. EXTERNAL SLAVE RELAYS place it behind the flap on the controller facia.
CONFIGURATION OPTIONS Where 2-wire sounders are used on the detection Check the appropriate links are fitted to disable
zones (zones 1 to 4 only), check that when the monitoring of these outputs. MK/tj
Fit the links to select the required options as shown sounders are activated that no zone faults are
on the PA & SD sheet. Changes to link settings will reported.
Connect circuits to the external slave relay input 14th May 2003
only be read by the controller after power up or coils and power up the controller.
following a hardware reset. Generate an alarm and a fault on the controller and
CONVENTIONAL SOUNDER check that the relays switch as required.
To set any options not available as link settings, put
the controller into configuration mode and using the CIRCUITS
configuration overlay, select the options required. Fit the end-of-line resistors to the last device on REPEATERS
Refer to the configuration sheet for details of how each circuit. Connect the sounder circuits to the Fit both of links PL1 to only ONE unit on the bus to
to edit these controller options. controller and power up. provide loop power - normally the master controller
Check that no sounder fault is reported. Clear any is used. (Links should be vertical).
BATTERIES faults by disconnecting the circuit and checking for Connect the master controller and all repeaters to
Remove the power from the controller. continuity, polarity or short circuits. the bus. Power up the master controller and one
Connect the battery leads to the batteries, observing Use ‘evacuate’ to activate the sounders. Check all repeater.
the polarity. The battery connecting lead should sounders are activated and are audible. Check that Use the configuration overlay to set the repeater
already be fitted. Note: The controller will remain the controller gives correct alarm indication and number on each repeater and configure the main
off until the mains supply is applied, even if the that no sounder faults are reported. panel with the repeaters connected.

batteries are fully charged. The controller can be Silence the alarms and reset the controller. Create some alarm and fault events on the master
powered up on batteries alone by pressing the reset Repeat the sounder test by triggering a callpoint and controller and confirm these are displayed correctly
button on the PSU board. then a detector, to generate an alarm. at the repeater. Check repeater controls operate. Do
Switch on the mains supply to power up the the same for the other repeaters on the bus, until all
controller. Wait approx. 2 minutes and check that NON-LATCHING ALARM / repeaters have been added. (A fault will be reported
the charger fault remains off. (The first battery test by the main panel until all repeaters are connected).
CLASS CHANGE INPUT
is carried out within the first minute after power-
up). Connect the circuit and power up the controller.
MICROCOM COMMUNICATOR
Activate each input in turn and then together,
AUXILIARY POWER OUTPUT c h e c k i n g t h e c o n t r o ll e r g iv e s t h e c o r r e c t Refer to the Microcom document:
Connect any external loads to the auxiliary output indications. 120.415.741
and power up the controller.
NON-LATCHING FAULT / EXPANSION CARD
Check that the device operates correctly in all
modes (at least check the mode that draws the most LINE FAULT CHANGE INPUT Refer to the Expansion card document:
power). This output will be turned off during Connect the circuit and power up the Controller. 120.415.756
190 / 192
controller reset.
Siemens Wind Power A/S /Data sheet for MXC panel (option) 191 / 192
Rev: 16.10.06 / ECN 22349

Rev: 16.10.06 / ECN 22349

Data sheet for H-series heat detectors (option)
H Series Fixed Temperature

K e y Fe a t u r e s
Heat Detectors
•
Self re-setting
Two wire supervised circuit
Approved by marine classification authorities
Compatible with other THORN low

voltage equipment
Special versions can be used in any Zone 1

or Zone 2 environment
Grade 3 to European Standard EN54

Part 5 1977.
The H600 and H900 range of fixed temperature heat detectors are designed to operate at 60°C and 90°C respectively. They
are particularly suited to areas where rapid changes in temperature and /or high areas where rapid changes in temperature
and/or high ambient temperature exist, together with unsuitable environmental conditions for smoke detectors.
This makes the detectors ideally suited for galleys, laundries, etc. The H600 and H900 series of detectors contains a heat
sensitive element which changes state at a pre-determined temperature, thereby closing an electrical contact. The detectors
do not latch in alarm, and will reset to normal (quiescent) state when the ambient temperature drops.
Siemens Wind Power A/S / Data sheet for heat detectors 203 / 204
Rev: 16.10.06 / ECN 22349

S200 PLUS Series

There are three different configurations of the detector available at both No BASEEFA certification is required for their use on intrinsically safe
temperature settings as follows: circuits in Zone 1 or Zone 2 environments. However, an appropriate
certified diode safety barrier system must be used between the H series
1. H600/H900 have no alarm LED indicating facility. detectors and the fire detection control equipment.
2. H601/H901 have the facility to drive remote LED alarm indicator.
3. H602/H902 have an integral LED alarm indicator fitted into the base of the There are also restrictions on cable types and lengths. The detail
detector. parameters will depend on the type of barrier used. System 601 [Cat.(1a)]
Special versions of the above six detectors are available for use in Zone 1 is a certified system incorporating the simple apparatus. Further details of
and Zone 2 hazardous areas. These units are fitted with a 390 ohm 2.5 watt the System 601 are given in the relevant technical publications.
current limiting resistor. This resistor enables the units to be classed as
simple apparatus which complies with BS 5345 Part 4 1977 clause 6.3.3.
33mm
Technical Information (Detectors)
Electrical False Ceiling
Heat Detector H600/H900

Operating Voltage: Up to 24 V dc
Quiescent Current:: Zero 41mm
Alarm Current: Limited by internal 390 ohm or
50 ohm resistor
82mm
Mechanical Ceiling mounting
Dimensions: 82mm dia x 41mm 110mm
Weight: 73 gm
Material: Cycolac ABS
Environmental
o o
Operating temperature range: -20 C to 100 C
up to 100% RH (Non-condensing) 100mm
o
Alarm temperature H6XX: 60 C Heat Detector H600/H900
o
H9XX: 90 C 2 Fixing Holes
5mm. on
128.5mm P.C.D.
Technical Data (Mountings) Deckhead mounting
Mechanical Ce i l i n g m o u n t i n g
Terminations: Max cable size 2.5mm2
Terminal base may be ceiling mounted as shown with or with-
Dimensions: See drawing out a gland back box mounted above the ceiling (as shown by
the dotted line).
Item Unit Weight Material
A Plastica Gland Box 60gm Noryl
B DHM7 230gm Glass Polyester DMC De c k h e a d m o u n t i n g
C DHMA 60gm Cycolac ABS This mounting is specifically designed for steel/solid deck-
head and gives the level of mechanical and environmental
protection required in these areas.
Two main types of detector mountings are available for the H Series of detectors. Four 20mm (knock outs) are provided for cable entry.
Ordering Information
Product Ref Description Product Code
M ountings
A Plastic Gland Box (if required) 400.001.004
B+C DHM 8 (including 2 x 20 mm glands) 517.001.130
60 C Detectors
H600 Fixed Temp Grade 1 516.014.017
H601 Fixed Temp Grade 1 (Remote LED Ind.) 516.014.021
H602 Fixed Temp Grade 1 (Integral LED Ind.) 516.014.019
H604 Fixed Temp Grade 1 (Integral LED Ind.) Intrinsically Safe 516.014.025
c/w DHM 8
90 C Detectors
H900 Fixed Temp Grade 1 516.014.018
H902 Fixed Temp Grade 1 (Integral LED Ind.) 516.014.020
H904 Fixed Temp Grade 1 (Integral LED Ind. ) Intrinsically Safe c/w DHM 8 516.014.025
Technical Information Sheet PSF108U Issue 1 www.tycofire.com ©Thorn Security Ltd. 2000
204 / 204 Siemens Wind Power A/S / Data sheet for heat detectors
Rev: 16.10.06 / ECN 22349

- Chapter 21 SHADOW DETECTOR

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 21 SHADOW DETECTOR

SWT - 2.3 - 82VS/93/101
• Appendix - Data sheet - shadow detector (option)

yyyy)

Document history

93/101

Appendix 10 - Data sheet - shadow detector (option)
See: chapter , “Data sheet - shadow detector,”


Data sheet - shadow detector
Shadow Detector and Light Sensor

Manual
Type no. shadow detector module : KK900155MO
Type no. light sensor module .. : KK900287MO
Version..................................... : 0.1 (0 series)
SW version .............................. : 2.3…
SET
kk-electronic a/s
Cypresvej 6
DK-7400 Herning
Tlf +45 9722 1033
Fax +45 9721 1431
E-mail: main@kk-electronic.dk
kk-electronic a/s Http: www.kk-electronic.dk
Siemens Wind Power A/S - Data sheet - Shadow detector / Rev: 07.04.2005 / ECN 16740 581 / 600
1 Contents
1 Contents ............................................................................................................................................................ 2
2 Introduction........................................................................................................................................................ 3
3 Principles Behind Shadow Calculation.............................................................................................................. 4
4 Shadow Detection Module ................................................................................................................................ 5
4.1 Parameter List ............................................................................................................................................ 5
4.2 Operation.................................................................................................................................................... 6
4.2.1 Keyboard............................................................................................................................................. 6
4.2.2 Structure of Menus.............................................................................................................................. 7
4.2.3 Menus ................................................................................................................................................. 8
4.2.4 The Effect of Stop/Start Delays........................................................................................................... 9
4.3 Connection Data for Shadow Detection Module ...................................................................................... 10
4.4 Turbine Error Messages and Settings ..................................................................................................... 10
4.4.1 Error Messages................................................................................................................................. 11
4.4.2 Settings ............................................................................................................................................. 11
4.4.3 Deactivating the Shadow Detector ................................................................................................... 11
4.5 Technical Specifications........................................................................................................................... 12
4.6 Light Sensor Module ................................................................................................................................ 13
4.7 Connection Data for Light Sensor ............................................................................................................ 13
5 Guide to Survey of Geographical Positions .................................................................................................... 14
5.1 Table for Entering Geographical Data: .................................................................................................... 14
5.2 Example of Shadow Detector Programming............................................................................................ 16
5.3 Programming of turbine data and time:.................................................................................................... 17
Dato ......................:07-04-05
Side.......................:2 of 20
582 / 600 Siemens Wind Power A/S - Data sheet - Shadow detector / Rev: 07.04.2005 / ECN 16740
2 Introduction
In sunny weather, the rotating blades of the wind turbine will cast moving shadows on the surrounding
landscape. This may represent a nuisance to neighbours to the turbine.
The shadow detector is used in order to eliminate such shadow nuisance to homes or other public
spaces (= zones) caused by wind turbines.
The shadow detector is programmed with data on the protected zones and on the turbine, and through
application of astronomy and geometry, it continuously calculates whether shadow nuisance occurs.
In case of shadow nuisance, the turbine is prompted to stop.
Dato ......................:07-04-05
Side.......................:3 of 20
3 Principles Behind Shadow Calculation
The background for the calculation of shadow nuisance is information on the turbine and the zones
which need to be protected. As many as 10 zones can be protected per shadow detector (zone 0 to 9)
The shadows from the turbine are calculated on the background of the position of the sun, which is
deduced from the time of day and the turbine position. Afterwards geometrical calculations are made
for each zone, which show whether shadows are found in the individual zones.
If shadows are detected in one or more zones, the turbine is prompted to stop.
However, the turbine is only stopped if the height of the sun is > 3°, and the distance to the zone less
than 1500m.
The following data must be available to the shadow detection module:

x Rotor diameter
x Tower height
x The geographical position of the turbine
x Width of Zones
x Height of Zones
x Geographical position of zones
The data formats etc. are seen in section 4.1, Parameter list.
Zone 0
Zone heigth
Rotor diameter
Zone width
Zone altitude
Zone latitude
Zone longitude
Zone 1
Zone heigth
Zone width
Zone altitude
Tower heigth
Zone latitude
Zone longitude
Zone ….
Zone heigth
Zone width
Turbine altitude Zone altitude

Turbine latitude Zone latitude
Turbine longitude Zone longitude
Dato ......................:07-04-05
Side.......................:4 of 20
4 Shadow Detection Module
Encoding of parameters for shadow calculation incl. time and date happens in the shadow detection module via
the shadow detection module keyboard and display. Data is stored in the shadow detector memory.
4.1 Parameter List
Turbine data:
Parameter Denomination Unit and format Range Menu no
Tower height Tower heigth [m] 0..255 MD1
Rotor diameter Rotor diameter [m] 0..255 MD2
Elevation–meters above sea level Turbine altitude [m] above sea level 0..5000 MD3
Geographical position – latitude Turbine latitude N. [m] UTM32 / WGS84 0..40000000 MD4
Geographical position – longitude Turbine longitude E. [m] UTM32 / WGS84 0..40000000 MD5
Geographical position – latitude Turbine lat. deg. [°N *100000] WGS84 +/-18000000 MD6
Geographical position – longitude Turbine long. deg. [°Ø *100000] WGS84 +/-8000000 MD7
Zone data:
Zone height Zone heigth [m] 0..99 ZD1
Zone width Zone width [m] 0..999 ZD2
Elevation–meters above sea level Zone altitude [m] above sea level 0..5000 ZD3
Geographical possition – lattitude Zone latitude [m] UTM32 / WGS84 0..40000000 ZD4
Geographical position – longitude Zone longitude [m] UTM32 / WGS84 0..40000000 ZD5
Stop delay StopDl Minutes +/-20 ZD6
Start delay StrtDl Minutes +/-20 ZD7
Timer data:
Time zone Time zone offset [t] GMT = 0, DK = 1 0..23 TD1
Year Years Years 2000..2100 TD2
Month Month Months 1..12 TD3
Date of month Date - 1..31 TD4
Day of week Day of week Sunday = 1 1..7 TD5
Hour Hour (Winter time) Hours 0..23 TD6
Minute Minute Minutes 0..59 TD7
Dato ......................:07-04-05
Side.......................:5 of 20
4.2 Operation
4.2.1 Keyboard
Keyboard Function
0..9 Numerical keys for entering values
Change between main menus
Change between main menus
SET Activates programming of shadow detection module
ENT Accepts the entered values
CLR Skips to the next menu without saving an unfinished entry
+/- Selects operational sign for parameter (not all parameters have operational signs)
Dato ......................:07-04-05
Side.......................:6 of 20
4.2.2 Structure of Menus
Main menus
HM1 HM2 HM3 HM4..HM14
Zone: 0123456789 DD-MM-YYYY HH:MM SW Version: Stop time Zone0..9:
Stat.:0000000000 Light: Status version nro. hh:mm to hh:mm
SET SET
SET
SET SET
Seletion 1
Zone: 0-9
CLR
Global : ENT
ENT 0..9
MD1 ZD1
Menus for entering turbine data
Menus for entering zone data

Tower heigth:[m] Zone N heigth:[m]
meters meters
Enter value Enter value
MD2 ENT / CLR ZD2 ENT / CLR
Rotordia.:[m] Zone N width:[m]
meters meters
Turbine Alt.:[m] Zone N Alt.:[m]
meters meters
Turbine Lat.:[m] Zone N Lat.:[m]
meters meters
Turbine Long:[m] Zone N Long.:[m]
meters meters
Turbine Lat.:[o] Zone N StopDl:min
degrees minutter
Turbine Long:[o] Zone N StrtDl:min
degrees minutter
ENT / CLR ENT / CLR
TD1
Time zone offset
hours
Enter value
TD2 ENT / CLR
Year:
Years
Enter value
TD3 ENT / CLR
Month:
Month
Enter value
TD4 ENT / CLR
Date:
Date
Enter value
TD5 ENT / CLR
Day of week:
nr (Sunday = 1)
Enter value
TD6 ENT / CLR
Hour:
local winter time
Enter value
TD7 ENT / CLR
Minute:
local time
Enter value
ENT / CLR
Dato ......................:07-04-05
Side.......................:7 of 20
4.2.3 Menus
Menu no. Description

HM1 Status of shadows in zone 0..9.
’0’ = no shadow in zone
’1’ = shadow in zone
HM2 Status of light sensor:
Sunny = Light measurement sufficiently high to stop the turbine.
Shady = Light measurement too low to stop the turbine.
No conn. = no light sensor connected, or defective light sensor.
HM3 SW version. Version number of shadow detection module software.
HM4..HM14 Calculated stop time for zone 0…9. The shown stop time includes chosen stop/start delays.
VALG1 Menu selection for encoding of data.
0 to 9 selects zone 0 - 9 for entering of data.
ENT selects entering of turbine data and time.
MD1 Entering tower height
MD2 Entering rotor diameter
MD3 Entering turbine elevation
MD4 Entering turbine position North via UTM
MD5 Entering turbine position East via UTM
MD6 Entering turbine latitude degrees North *100,000 (south is a negative value)
MD7 Entering turbine longitude degrees East *100,000 (west is a negative value)
TD1 Entering time zone. GMT (Greenwich Mean Time) = 0. DK = +1 hour.
TD2 Entering year
TD3 Entering month
TD4 Entering date
TD5 Entering day of week (used for prompting daylight saving time)
TD6 Entering hour local normal time (no summer time)
TD7 Entering minute local normal time (no summer time)
ZD1 Entering height of zone
ZD2 Entering width of zone
ZD3 Entering elevation of zone
ZD4 Entering degree of latitude of zone
ZD5 Entering degree of longitude of zone
ZD6 Entering of zone stop delay (time delay before stopping the turbine)
ZD7 Entering zone start delay (time delay before starting the turbine)
Dato ......................:07-04-05
Side.......................:8 of 20
4.2.4 The Effect of Stop/Start Delays
The zones can be programmed with stop/start delays.

The stop delay delays the time at which the turbine is stopped for shadow nuisance, and the start delay delays
the time at which the turbine is restarted.
The stop/start delays have prefix signs: Negative sign moves the original time to an earlier time, and positive sign
moves the time to a later time.
T_stop(t) T_start(t)
Stop delay Stop without delay 0
Start delay
1
Resulting stop
T_stop + stop delay 2
T_start + start delay 3
10
11
- + - +
Figure 1: The effect of stop and start delays on individual stop times
Dato ......................:07-04-05
Side.......................:9 of 20
5
6 7
Normal stop
0 1 2 2
Resulting stop
6 7
5
8
9 10 11
3 3 4
9 10 11
8
Figur 2: The effect of stop and start delays over time

4.3 Connection Data for Shadow Detection Module
Plug no. Pin no. Function Conductor colour

X1 1..16 Display -
X2 1..8 Keyboard -
X6 1 GND Brown
X6 2 4..20mA signal from light sensor Green
X6 3 4..20mA signal from light sensor Yellow
X6 4 4..20mA signal from light sensor Pink
X6 5 4..20mA signal from light sensor Grey
X6 6 +24VDC/200mA supply to light sensor White
X7 1 +24VDC supply to shadow detector module (computer box) -
X7 2 GND -
X7 3..4 NO relay output: shadow detector module error -
Open: ERROR / Closed: OK
X7 5..6 NO relay output: shadow detection -
Open: shadows detected / closed: no shadows detected
X8 1..2 Display backlight -
4.4 Turbine Error Messages and Settings

Turbines which have shadow detectors installed have 2 error messages and one setting parameter designated to
the shadow detector functions.
Dato ......................:07-04-05
Side.......................:10 of 20
4.4.1 Error Messages
Error numbers apply to V1041_DK ES524521 Ver: 01.06.14
Error Error text in turbine control Turbine reaction

number display
UF95 Stop delay when shade Stopped until stop signal from shadow detector is deactivated.
Stop and start times are stored in the turbine error log.
UF96 Shade detector fault Stop signals from the shadow detector are ignored and the
shadow detector is reported defective through this message.
Stop and start times are stored in the turbine error log.
4.4.2 Settings
Parameter number applies to V1041_DK ES524521 Ver: 01.06.14
Parameter Error text in turbine control Function

number display
UP138 Stop delay when shade Indicates for how long a stop signal from the shadow detector
must remain active before the turbine is stopped.
Area: -1..120 sec., where ’-1’ switches off the shadow detector.
Resetting the turbine computer is not necessary.
4.4.3 Deactivating the Shadow Detector
The shadow detector is reset by entering the parameter ”stopdelay” = -1.

See the section reg. turbine settings.
Dato ......................:07-04-05
Side.......................:11 of 20
4.5 Technical Specifications
Timer............................... : Quartz, temperature compensated (+/- 5 min. per year)

Automatic change-over to daylight saving time:
Geographical data format : WGS84, UTM (WGS84)

Min. height of sun............ : 3° (when the sun is lower, the turbine is not stopped)
Max. distance to zone ..... : 1500m (if the zone is further away, the turbine is not stopped)
Detected sunlight valid.... : 5 minutes
Minimum stop time.......... : 1 minute
Dato ......................:07-04-05
Side.......................:12 of 20
4.6 Light Sensor Module
Cloudy or hazy weather will not cause shadow nuisance even though the position of the sun may
indicate so. The shadow detector can be connected to a light sensor module which is used for
measuring actual daylight.
As the intensity of daylight varies over the year, the operational factor is the contrast between the
relative light intensities measured by 4 individual light sensors pointing in 4 different directions.
One or two light sensors will always be exposed to more light than the remaining sensors whenever
the system is exposed to directional light such as direct sunlight.
In cloudy or hazy weather all 4 sensors will be exposed to roughly the same amount of light.
A generally high level of light will also be considered intense enough to cause shadow nuisance.
The signals from the 4 sensors are fed to the shadow detector which subsequently calculates whether
the light is strong enough to cause shadow nuisance. If the light is strong enough and a zone is
subjected to shadows, the turbine is stopped. If the light is not strong enough to cause shadow
nuisance, the turbine is not stopped.
Borderline cases may occur for which the light sensor is unable to estimate the light correctly. In fog,
the general light level may be high enough to be interpreted as sunlight, although no defined shadows
exist on the ground. Moreover, low fog may hinder the sunlight in reaching the ground, while the light
sensor which is positioned in the sunlight above the fog detects a light level much higher than that on
the ground.
The conditions which prompts the turbine to stop are the possibility of shadows in a zone and the
existence of sunlight. The condition “sunlight” lasts for at least 5 minutes. This means that a single
drifting cloud passing the sun in less than 5 minutes does not prompt the turbine to interrupt a shadow
nuisance stop.
In most cases, the shadow detector will be able to detect a defective light sensor and will ignore its
function.
4.7 Connection Data for Light Sensor
Plug no. Pin no. Function Conductor colour

X6 1 GND Brown
X6 2 4..20mA output signal from sensor 4 Green
X6 3 4..20mA output signal from sensor 3 Yellow
X6 4 4..20mA output signal from sensor 2 Pink
X6 5 4..20mA output signal from sensor 1 Grey
X6 6 +24VDC supply White
Dato ......................:07-04-05
Side.......................:13 of 20
5 Guide to Survey of Geographical Positions
If no geographical data exists for turbine and zones in the applied format (UTM32/WGS84), a survey
must be made. The geodetic datum is selected to ensure compatibility with the internationally used
datum of the GPS system WGS84 (= EUREF89).
This means that any GPS unit can be used for making the survey for the shadow detector module.
WGS84 can be indicated in two different ways. By longitude and latitude or by UTM. UTM is a
projection of the surface of the earth into zones. Within the zones, meters North and meters East are
used. The UTM format is used for defining the relative position of the zones compared to the turbine.
For this reason it is important that all UTM measurements refer to the same UTM zone (e.g. 32V which
is North Jutland and South Norway). The longitude and altitude are used for calculating the position of
the sun. It is not possible to enter decimal numbers in the shadow detector. For that reason the
numbers must be multiplied by 100,000 before entering the integral number. Latitude South and
longitude West are entered negative while latitude North and longitude East are entered positive.
When entering 0 for both longitude and latitude, the position of the sun will be calculated in the same
way as in version 2.2 of the shadow detector. This calculation is, however, an approximation and will
only function reasonably accurately in Denmark.
Make sure that the measurements are sufficiently precise – uncertainties in the geographical data will
mean differed turbine stop times. An uncertainty of less than 5m will usually give satisfactory results.
The zone height is defined by measuring the height of the protected window. See the illustration in
section 3.
The width of the zone is centred on the geographical position, i.e. the position is always placed in the
middle of the zone.
5.1 Table for Entering Geographical Data:
Turbine data
Tower height Rotor diameter Altitude Latitude UTM [m] Longitude UTM [m]
Latitude [deg *100000 N] (South = -) Longitude [deg *100000 E] (West = -)
Data f. zone 0
Zone height Zone width Altitude Latitude UTM [m] Longitude UTM [m]
Data f. zone 1
Data f. zone 2
Data f. zone 3
Data f. zone 4
Data f. zone 5
Data f. zone 6
Dato ......................:07-04-05
Side.......................:14 of 20
Data f. zone 7
Data f. zone 8
Data f. zone 9
Dato ......................:07-04-05
Side.......................:15 of 20
5.2 Example of Shadow Detector Programming
The following data for the turbine and 2 zones has been defined in the survey:
Turbine data
Tower height Rotor diameter Altitude Latitude UTM [m] Longitude UTM [m]
60 54 48 6235822 490943
Latitude [deg *100000 N] Longitude [deg *100000 E]
Data f. zone 0
Height of zone Width of zone Altitude Latitude UTM [m] Longitude UTM [m]
5 20 43 6236125 490650
Data f. zone 1
Height of zone Width of zone Altitude Latitude UTM [m] Longitude UTM [m]
4 15 53 6235510 491245
For zone0 the turbine must be stopped 5 minutes in advance and started 5 minutes later.
For zone 1 the turbine must be stopped 5 minutes later and started 5 minutes in advance.
The shadow detector is programmed 01-07-2002, at 13:00 am.
Dato ......................:07-04-05
Side.......................:16 of 20
5.3 Programming of turbine data and time:
Dato ......................:07-04-05
Side.......................:17 of 20
HM1
Zone: 0123456789
Stat.:0000000000
Press ’SET’ to access setup
VALG1
Zone: 0-9
Global : ENT
Press: ’ENT’ for setup of global data
MD1
Tower heigth:[m]
meters
Enter turbine height in meters = 60 + ENT
MD2
Rotordia.:[m]
meters
Enter turbine rotor diameter in meters = 54 + ENT
MD3
Turbine Alt.:[m]
meters
Enter turbine elevation in meters above sea level = 48 + ENT
MD4
Turbine Lat.:[m]
meters
Enter turbine position in meters north = 6235822 + ENT
MD5
Turbine Long:[m]
meters
Enter turbine position in meters east = 490943 + ENT
MD6
o
Turbine Lat.:[ ]
degrees *100000
Enter turbine position degrees North times 100000 =
5626714 + ENT
MD7
Turbine Long:[o]
degrees *100000
Enter turbine position degrees East times 100000 =
TD1 885377 + ENT
Time zone offset

hours
Enter time zone displacement (Denmark 1 hour) = 1 + ENT
(Greenwich = 0hrs)
TD2
Year:
Years
Enter year = 2002 + ENT
TD3
Month:
Month
Enter month = 7 + ENT
TD4
Date:
Date
Enter day = 1 + ENT
TD5
Day of week:
nr (Sunday = 1)
Enter week day = sunday = 1
TD6
Hour:
local normal time
Enter hour of day = 12 + ENT
TD7
Minute:
local normal time
Dato ......................:07-04-05
Enter minute = 0 + ENT
Side.......................:18 of 20
Return to main menu
Programming of Zone 0 Data:
HM1
Zone: 0123456789
Stat.:0000000000
VALG1
Zone: 0-9
Global : ENT
Press: ’0’ for zone 0 setup
ZD1
Zone N heigth:[m]
meters
Enter height of zone 0 = 5 + ENT
ZD2
Zone N width:[m]
meters
Enter width of zone 0 = 20 + ENT
ZD3
Zone N Alt.:[m]
meters
Enter elevation of zone 0 = 43 + ENT
ZD4
Zone N Lat.:[m]
meters
Enter zone 0 position in meters North = 6236125 + ENT
(Equator = 0m)
ZD5
Zone N Long.:[m]
meters
Enter zone 0 position in meters East = 490650 + ENT
(Greenwich = 0m)
ZD6
Zone N StopDl:min
minutes
Enter zone 0 stop delay -5 (use +/- prefix sign). This will
make the turbine stop 5 min. before the standard setting.
ZD7
Zone N StartDl:min
minutes
Enter zone 0 start delay +5 (use +/- prefix sign). This will
make the turbine start 5 minutes later than the standard
setting.
Return to main menu
Dato ......................:07-04-05
Side.......................:19 of 20
Programming of Zone 1 Data:
HM1
Zone: 0123456789
Stat.:0000000000
VALG1
Zone: 0-9
Global : ENT
Press: ’1’ to set up zone 1
ZD1
Zone N heigth:[m]
meters
Enter height of zone 1 = 4 + ENT
ZD2
Zone N width:[m]
meters
Enter width of zone 1 = 15 + ENT
ZD3
Zone N Alt.:[m]
meters
Enter elevation of zone 1 = 53 + ENT
ZD4
Zone N Lat.:[m]
meters
Enter zone 0 position in meters North = 6235510 + ENT
(Equator = 0m)
ZD5
Zone N Long.:[m]
meters
Enter zone 0 position in meters East = 491245 + ENT
(Greenwich = 0m)
ZD6
Zone N StopDl:min
Retur til hovedmenu
minutes
Enter zone 0 stop delay +5 (use +/- prefix sign). This makes
the turbine stop 5 minutes before standard setting.
ZD7
Zone N StartDl:min
minutes
Enter zone 0 start delay -5 (use +/- prefix sign). This makes
the turbine start 5 minutes before the standard setting.
Return to main menu
Dato ......................:07-04-05
Side.......................:20 of 20
- Chapter 22 ICE DEC EQUIPMENT

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 22 ICE DEC EQUIPMENT

SWT - 2.3 - 82VS/93/101
• Appendix - Data sheet - ice dector (option)

yyyy)

Document history

93/101

Appendix - Data sheet - ice detector (option)
See: chapter , “Ice detector / trouble shooting,”
See: chapter , “Ice detector / service guide,”
See: chapter , “Data sheet - ice detector,”


Ice detector / trouble shooting
Wavin-Labko Oy Trouble Shooting 13.02.2006

Labkotie 1 guide for service
FI-36240 Kangasala
FINLAND
Tel. +358 20 1285 200
Fax +358 20 1285 530
E-mail: level@wavin-labko.fi
Internet: www.wavin-labko.fi
D80139Ae.doc
Page 1/1
LID 3210C TROUBLE SHOOTING GUIDE FOR SERVICE
In case of any operational problem check first that the power supply is correct (green power indication
light) plus that the fault relay is not de-energized.
Fault: The signal amplitude stays constantly at a lower level and there are no icing conditions:
a) Amplitude below 150: Check the wiring and contacts. Should this not help replace the sensor.
b) Amplitude 150-200 and the used frequency other than 0: The sensor part is defect. Replace it or
consult your nearest service.
c) Amplitude 200-230: Adjust the max. amplitude to 250 by turning the trimpot in the control unit clockwise.
Fault: The detector reacts to snow blended rain or heavy rainfall:
Set the parameter [ ] that controls the alarm level to a smaller value f.ex. to 80-120. If this does not help
try other frequencies (1,2,3) and/or various alarm levels.
Fault: The sensor does not react on ice:
Try other frequencies (1,2,3) and/or set the alarm level higher.
Fault: There appears a temperature value 85 in the serial communication:
Disturbances in the temperature element (Dallas). The wiring has been changed in the model 3210C after
which this has not been obtained.
Fault: Error 8 during the heating:
The thermostat will drop at 60°C, adjust the heating parameters heat on/off [ ] to a lower value.
Fault: The sensor indicates ice constantly (amplitude 0-50)
a) The sensor wiring is off.

b) The crystal wire is off.
SWT-3.6-107 / Trouble shooting for Ice detector 605 / 606

Rev: 16.10.2006 / ECN 22349

606 / 606 SWT-3.6-107 Off-shore / Trouble shooting for Ice detector
Rev: 16.10.2006 / ECN 22349

Ice detector / service guide
Wavin-Labko Oy LID-3210C
Labkotie 1 SERVICE GUIDE
FI-36240 KANGASALA
FINLAND
Tel. +358 02 1285200
Fax +358 02 1285530
E-mail level@wavin-labko.fi
13.2.2006
1/1 D80140Be
1. Mechanical check/cleaning
- Remove all dirt and other mechanical unwanted substances
- Check that there are no damages due to vibration or shock on the sensor
2. Cabling
- Check visually that there are no visible damages in the

cables, inlets or connectors. All cables damaged through the
insulation should be replaced.
- Check that the cable inlet or connector is not subject to any
torque and that the rainwater cannot penetrate downwards
the cable into the connection box (see drawing)
- seal the cable connectors with the vulcanic adhesive tape
to make extra care that the rainwater does not cause any
problems inside the sensor or cable
Should the cable be replaced check the last mentioned with
extra care.
3. Signal lights
Make sure that the control unit is powered and the Power
LED is lit.
4. Function check
a) Spray appropriate cooling spray on a wet sensor wire
appr. 15 sec. The LID 3210 should indicate icing.
b) During the spraying check that the Ice-relay trips.
c) Check that the unit starts to heat up the sensor after
indicating ice: The Heat-LED will be lit and the sensor starts
to heat up
d) Check also that the heating stops after appr. 5 min and the Heat light will go out.
Warning: During heating the sensor surface will be hot! Do not touch it!
SWT-3.6-107 Off-shore / Service guide for Ice detector 607 / 608

Rev: 16.10.2006 / ECN 22349

608 / 608 SWT-3.6-107 Off-shore / Service guide for Ice detector

Rev: 16.10.2006 / ECN 22349

Data sheet - ice detector
Wavin-Labko Oy
Labkotie 1
FI-36240 Kangasala
FINLAND
Tel. Int + 358 20 1285 200
Fax Int + 358 20 1285 530 23.02.2006
E-mail: level@wavin-labko.fi D80081Ee
LID-3210C
ICE DETECTOR FOR WIND TURBINES
INSTALLATION MANUAL
We reserve the right for changes without notice Copyright © Wavin-Labko Oy 2006
SWT-3.6-107 Off-shore / Data sheet for Ice Detector 609 / 634

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
Note on Safety
The products of Wavin-Labko Oy are designed to be safe when operated in the manner
described in this manual. The safety of this product can not be guaranteed if the product
is used in any other way than is specified in this manual.
Caution, risk of danger
Warning!
This equipment must be connected to protective earth (PE).

Disconnect mains supply before removing covers.
Note also that the unit detects only the icing of the sensor part
– not e.g. of the rotor blades!!!
2/25
610 / 634 SWT-3.6-107 Off-shore / Data sheet for Ice Detector

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
TABLE OF CONTENTS
Note on Safety ..........................................................................................................................................................................2

1.0 INTRODUCTION TO LID-3210C ICE DETECTOR.......................................................................................................4
2.0 INSTALLATION OF THE LID-3210C SENSOR PART .................................................................................................5
2.1 Placement .......................................................................................................................................................................5
2.2 Main parts.......................................................................................................................................................................6
2.3 Other components...........................................................................................................................................................7
2.4 The Sensor part assembly...............................................................................................................................................7
2.5 Mounting of the control unit ..........................................................................................................................................8
3. ELECTRICAL INSTALLATION........................................................................................................................................9
3.1 Internal connections .......................................................................................................................................................9
3.2 External connections ......................................................................................................................................................9
3.3 Setting the power on.....................................................................................................................................................10
3.4 Communicating with the Ice Detector..........................................................................................................................11
3.5 Operation modes, fail indication ..................................................................................................................................11
4. TESTING, SIMULATION AND SETUP..........................................................................................................................12
4.1 Simulation of the ice signal ..........................................................................................................................................12
4.2 Setup of the sensitivity .................................................................................................................................................13
4.3 Testing the Fault-relay operation..................................................................................................................................13
4.4 Putting into operation ...................................................................................................................................................14
5. Technical specifications ....................................................................................................................................................15
5.1 Mechanical Casing: ......................................................................................................................................................15
5.2 Environment: ................................................................................................................................................................15
5.3 Power Supply: ..............................................................................................................................................................15
5.4 Signal Ranges:..............................................................................................................................................................15
5.5 Outputs: ........................................................................................................................................................................15
5.6 Safety:...........................................................................................................................................................................15
Appendix A: Operation Modes ..............................................................................................................................................16
A.1 Power-up Mode ...........................................................................................................................................................17
A.2 Diagnostic Mode .........................................................................................................................................................17
A.3 Sensing Mode ..............................................................................................................................................................18
A.4 Detecting Mode ...........................................................................................................................................................18
Appendix B: Ranges and parameters .....................................................................................................................................20
B.1 Measurement ranges ....................................................................................................................................................20
B.2 Operational parameters ................................................................................................................................................20
Appendix C: Settings..............................................................................................................................................................21
C.1 Commands ...................................................................................................................................................................21
C.2 Abbreviations used ......................................................................................................................................................21
C.3 Reading a parameter example......................................................................................................................................21
C.4 Setting a parameter value example ..............................................................................................................................22
C.5 Restart command example ...........................................................................................................................................22
C.6 Unidentified command or data.....................................................................................................................................22
Appendix D: Maintenance and Troubleshooting ...................................................................................................................23
Appendix E: Connection Diagram .........................................................................................................................................25
3/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
1.0 INTRODUCTION TO LID-3210C ICE DETECTOR

Detection method:
The sensor of the LID-Ice Detector utilizes ultrasonic principle that can detect icing
conditions within time intervals between heating and cooling of the special sensor wire.
The sensor signal is digitally controlled and within the preset limits the ice warning
signal is given.
The sensor data is given out both as a standard DC-signal (4 to 20 mA DC) and serial
output (RS-232). A potential free relay output for the de-icing controls is also included.
Operation in brief:
The signal amplitude of the ultrasonic sensor varies between 0 - 255 increments. The ice
alarm level (=de-icing level of the probe) can be set manually as a parameter value
through the RS-232 serial connection. Sensor de-icing power and maximum temperature
of the sensor resistor can also be set as separate parameters. Additionally the sensitivity
of the ultrasonic sensor can be adjusted by changing the respective parameters. There are
about 20 parameters altogether to control and set the sensor to suit for different
conditions and purposes.
0C 15.3 255
08 -1.5 255
LID duty
cycle
0D 48.2 53
0D -1.5 53
When ice is detected the ice warning signal (ICE DETECTED) is obtained and indicated
by a relay tripping (ice Relay).
If RS-232 output is used, the ice accumulation rate can be derived as an amplitude
damping rate. The frequency of the obtained ice alarms indicates the accumulation rate of
ice. Sensor status, the status of the temperature sensor and the signal amplitude are given
as output signals from the LID-3210C. The signal is sent in every 4 seconds through the
serial output.
4/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
High sensitivity and a fast response of the start of the icing conditions are necessary. This
is especially needed when automatically ice prevention systems of wind turbine blades
are used. Even a very thin ice layer on the wind turbine blade surface spoils the
aerodynamics of the blade and cuts down the turbine production power with tens of
percents.
The intervals of the heating and cooling sequence can be adjusted by parameter settings.
As a total it takes from few minutes up to half an hour for the sensor to return to the
sensing mode.
This Document describes the Hardware and Software functions of the LID-3210C Series
Ice Detectors.
The Labko Ice Detectors have been especially developed for the arctic wind power
applications.
2.0 INSTALLATION OF THE LID-3210C SENSOR PART

2.1 Placement
The sensor should be mounted so that free air flow is granted. The heating power and
signal cables are connected to the transmitter unit with ready made cables. The
recommended installation position of the sensor is such that the connection box is located
at the top (see below picture). The control unit (LID-Controller) is recommended to be
placed in a weatherproof housing.
2.1.1. Mechanical check/cleaning

- Remove all dirt and other mechanical unwanted substances
- Check that there are no damages due to vibration or shock on the
sensor
2.1.2. Cabling
- Check visually that there are no visible damages in the cables,
inlets or connectors. All cables damaged through the insulation
should be replaced.
- Check that the cable inlet or connector is not subject to any torque
and that the rainwater cannot penetrate downwards the cable into the
connection box (see drawing)
- seal the cable connectors with the vulcanic adhesive tape to make
extra care that the rainwater does not cause any problems inside the
sensor or cable
Should the cable be replaced check the last mentioned with extra
care.
2.1.3. Signal lights

Make sure that the control unit is powered and the Power LED is lit.
5/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
2.1.4. Function check

A real ice simulation is also possible using ice spray and water spraying: Cool down the
sensor e.g. in the freezer below zero. Then ice spray on the sensor plus spray water on the
same spots on the sensor wire. If the sensor does not react please repeat this until the
amplitude goes down and the ice relay trips.
Warning: During heating the sensor surface will be hot! Do not touch it!
This instrument is designed for installation and use in wind turbines or weather
stations only!
2.2 Main parts

The LID-3210C Ice Detector is designed for flush mount on the tail wing leading edge or
other flat surface. It consists of a sensor part and a control/amplifier unit placed in a
separate enclosure. The sensor includes an ice-sensor and a heating element. It is to be
noted that the signal and heating cable standard lengths are 10 m and may not be
shortened when installing!
6/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
2.3 Other components
There are three important sources of information:
a) Test Protocol made in acc. to factory testing

Each Labko Ice Detector is equipped with an individual test protocol before
shipping.
Note that this protocol also includes the factory settings!
b) The Serial Number:
It is very essential that the sensor and control units carry the same serial nr because
all testing and factory settings are made for each individual pair that form a complete
Ice Detector. Also the test protocol refers to the same serial nr.
c) Technical Manual:
Please check always that you are using the right manual for your Ice Detector model
only!
2.4 The Sensor part assembly
Please see to that free air flow is granted to the sensor. Free air distance above sensor
must be min 500 mm. Any flammable or melting material are not allowed near on the
sensor. A 350W heating resistor is included in the sensor body. A temperature sensor is
placed in the center part of the heater. A safety thermostate is mounted on the body to
brake the heating circuit if the plate temperature rises over 50 degC.
Warning!
If the heating of the probe is tested in still air, the surface temperature of the heater
may rise far over 100 degC before power cutoff by T1 or the safety thermostate.
Never open the covers of the sensor. Hazardous voltage may exist.
7/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
There are various mounting parts in the delivery set for different installations according
to mounting place. Contact to the vendor for more instructions of the mounting.
NOTE!
All sensor cables must be installed as far as possible from the disturbing cables or
devices.
2.5 Mounting of the control unit
It is recommended to place the control unit inside a weatherproof instrument cabinet.

Control unit is mounted with four screws. Be sure that the unit is mounted carefully on a
stable platform. The mounting position is freely chosen by the user.
Warning!
8/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
3. ELECTRICAL INSTALLATION
3.1 Internal connections
ICE SENSOR: HEAT:

Use only the factory Use the factory
made cable (incl.) made cable (incl.)
Warning!
Hazardous voltage may exist in the HEAT connector.
The heating power and signal cables are connected to the transmitter unit into their
marked connectors using the factory made cables.
3.2 External connections
9/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
POWER IN PC connection CONTROL OUTPUT
1 = L1 brown LID PC D9 pin A1(+) & A2 (-) 4 to 20 mA DC

2 = N blue GND 1 ----------------- 5 A3 = Shield
TXT 2 ----------------- 2 B1 = Ice Relay NO
3 = No connection RXD 3 ----------------- 3 B2 = Ice Relay Common
4 = EARTH, PG yell/green B3 = Ice Relay NC
Use the special RS-232 C1 = Fault Relay NC
serial cable which is
C2 = Fault Relay Common
delivered with the product.
C3 = Fault Relay NO
Note! As an option it is possible to equip the serial output also with a RS 485
interface or a radio / GSM modem.
Please consult the factory.
When special PC-cable is not used, use always the cover of the connector for better
weather protection.
The power in and control cables are not included in a standard delivery. The delivery
includes all parts of the connectors. The cable assembly must meet with the local electric
safety requirements.
3.3 Setting the power on
The main functional blocks of the controller are

- power supply
- heating power control block
- serial communication RS 232 for data logging plus interactive
communication for setting and reading system parameters.
- ice-sensing electronic circuitry
- temperature measurement channel
- 4-20 mA current transmitter for the ice sensing value
- Relay outputs for Fault and Ice Indication
When the power is switched on to the LID-3210C the LEDs PWR and FAULT will lit.
Please note that the FAULT relay is energized when there is no alarm (producing thus a
fail-safe-operation).
The unit is now ready for testing, communication or setup.
10/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
3.4 Communicating with the Ice Detector
The signal status, eventual alarms etc. can be obtained by using a PC equipped with an
ordinary terminal program (Terminal, HyperTerminal, ProComm+ or other). Connect the
PC RS232 port with its cable to the output connectors marked ”PC” on the LID-3210C
control unit.
Set the terminal program as per follows:
communication speed 2400 Baud

character length 8 Bit
number of stop bits 1
parity no
full duplex
incoming CR translation CR/LF
When the power is switched on to the LID-3210C the unit gives as an answer the
following type of data string:
08 +18.5 254 (no fail, sensing mode, temp. +18.5 qC, ice signal 254 = no ice)
Please note that the signal values may vary accordingly.
Now the unit is connected and ready to report ice, testing or setup.
3.5 Operation modes, fail indication
The LID-3210C works in the following modes:
- Power-up
- Sensing
- Detecting
- Diagnostics
Each mode may have several phases of operation. The system checks itself also
continuously for failures and indicates both issues by sending the information on the
serial channel as a report as follows.
The first character is the failure code. Second character is the operation mode.
Fail Mode Temperature Amplitude
Example: 08 -05.5 254

(No fail, Sense Mode, temp. –5.5qC, Signal 254 bit (= no ice).
The various modes and diagnostics are described in more details in Appendix A.
11/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
4. TESTING, SIMULATION AND SETUP

4.1 Simulation of the ice signal
1. Connect a PC as described in chapter 3.4. Switch the power on.
2. Change the parameter P17 to 000. This represents the highest sensitivity. The
amplitude will then fall below 100. (Instructions for changing the settings are described
in Appendix C.)
3. If the signal amplitude goes down below the ice value (= parameter 00) the system
goes into the Detected-mode. (If signal amplitude did not drop below ice value, an alarm
can be achieved by changing the parameter 00 so that it’s above the amplitude value.)
NOTE: The sensor heating goes then on (the corr. LED will lit) causing that its
temperature will rise over 100 degr.C! The ICE-relay will also switch on and the pin
numbers B1 and B2 at the CONTROL OUTPUT will close. Please note also that the
heating mode can be interrupted by switching the power off.
4. Now you have checked the basic operations.
5. Please return parameter values of P00 and P17 to their original factory setting (see the
test protocol delivered together with the unit). Should the signal value (when there is no
ice present) considerably below 255 this can be corrected by turning the range setup
trimmer (located on the control unit pcb) clockwise.
6. A real ice simulation is also possible using ice spray and water spraying: Cool down
the sensor e.g. in the freezer below zero. Then ice spray on the sensor plus spray water on
the same spots on the sensor wire. If the sensor does not react please repeat this until the
amplitude goes down and the ice relay trips.
12/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
4.2 Setup of the sensitivity

There are two ways to set this up:
a) By changing the sensor frequency by the Parameter P17
000 = Ice test only (please note that the amplitude stays below 255)
001 (normal; default)
002 (normal)
003 = N.A.
b) By raising the Ice Detected-level plus Ice Not Detected-value:
P00 P01
Normal (default.) 120 150
More sensitive e.g. 150 180
Less sensitive e.g. 080 100
Ice signal Ice detected!

(0...255)
Ice value
255
P01
150
P00
120
(When both parameters P01 and P00 are increased

the detector sensitivity increases accordingly)
Ice warning ON!

Time
4.3 Testing the Fault-relay operation
1. Switch the power on.

2. The pin numbers C1 and C2 of the CONTROL OUTPUT connector are closed in
normal status (=no fault). This means that the relay stays energized.
3. Switch the power off again.
4. The fault situation can be simulated e.g. by replacing the SENSOR cable. Now switch
the power on.
5. The FAULT-relay shall now be de-energized (pin nbrs C2 and C3 connected) and the
FAULT-LED off.
6. Now you have accomplished the fault simulation and tested the corr. relay operation.
You can now install the LID-3210C into its final operation.
13/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
4.4 Putting into operation
1. It is always advisable to start the operation by using the factory settings (please see
the test protocol).
2. Should e.g. the sensitivity be too high/low and the frequency setting change proves to
give better results please remember to check whether there is also a need to readjust the
range. This can be done with the trimmer inside the control unit. This is the one and only
trimpot in the control unit. Please note that the trimpot is a high precision 30-turn
trimmer and the amplitude increases when turning clockwise. If, however, there appears a
need to adjust this please note that the default setting has been done in -5C and thus, in
order to reach an appropriate adjustment the sensor should be on zero degrC or below .
3. Additionally, the icing response and other characteristics of the system can be
affected by changing the ice level parameters (P17 and P00).
4. After satisfactory dynamics is obtained it is always best to check the operation in
other circumstances after a while (weeks or perhaps a month from start-up). It is to be
kept in mind that icing can occur in many kinds of weather conditions and there is
nothing else more difficult to predict than the nature!
Important when running the system:

Under special circumstances like fog in coastal areas or under sub-cooled rain etc. it
is possible that the ice condensates on rotating turbine blades but not on non-
moving objects - like the ice sensor. In such cases the LID cannot detect any ice.
Therefore it is always recommended to check that this kind of ice building is not
present and – if uncertain – always to stop the turbine manually to avoid any
damages.
14/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
5. Technical specifications
5.1 Mechanical Casing:
Ice Detector Sensor Unit 366 x 85 x 80 (15) mm, IP65
Controller Unit: 188 x 278 x 130 mm, IP65
5.2 Environment:
Sensor -25…+125qC (operational)
Control Unit -25…+50qC (operational)
5.3 Power Supply:

Detection Element Heating Unit 230 VAC, 350 W
Controller Unit 230 VAC, about 50 W max
Connection cable for Heating Unit 3 x 0.75 mm square rubber cable
Fuses IEC 127 5 x 20 mm/ 6.3 AT (See maintenance
document)
5.4 Signal Ranges:
Ice Signal amplitude range 0 - 255 = 0 - 5 V
Temperature Sensor range -55…+125 qC
Temperature Resolution 0.5 qC
5.5 Outputs:
Serial RS232 compatible
PC communication program like PROCOMM+ or equivalent can be used with following settings
Communication speed 2400 Baund
Character length 8 Bit
Number of stopbits 1
Parity no
Amplitude analog signal 4 to 20 mA DC
5.6 Safety:
Electric safety, class I EN 61010-1 (1993) + A2 (1995)
EMC Emission EN 50081-2
EN 55014-1, Conducted interference
EN 55022, Radio interference field strength
Immunity EN 50082-2
ENV 50140 (61000-4-3) Radiated radio-frequence
electromagnetic field.
IEC 1000-4-4 (IEC 801-4), Electrical fast transient
IEC 61000-4-5, Surge Immunity test
IEC 61000-4-11, Power Supply Failure
This instrument is designed for installation and use in wind turbines or weather stations only.
15/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
Appendix A: Operation Modes

The detector is operating in one of the following modes
- Power-up
- Sensing
- Detecting
- Diagnostics
Each mode may have several phases of operation. The system checks itself also
continuously for failures and indicates both issues by sending the information on the
serial channel as a report as follows.
The different fields are delimited with a space character. Fail and Mode characters have
no space in between.
Fail Mode Temperature Amplitude
Example: 08 -05.5 254

No fail, Sensing Mode, Tmp. –5.5qC, Signal 254 bit (= no ice).
The reason of failure can be interpreted from the Fail -character as follows:
Fail character Meaning
Heating T1 sensor Ice sensing
0 OK OK OK
1 OK OK Failed
2 OK Failed OK
3 OK Failed Failed
8 Failed OK OK
9 Failed OK Failed
A Failed Failed OK
B Failed Failed Failed
The operation mode of the LID 3210C can be interpreted from the Mode character as
follows:
Mode character Meaning
Power-up Sensing Detecting Heating Ice sensed
mode mode mode
0…7 YES - - - -
8 NO YES NO OFF NO
C NO NO YES OFF NO
D NO NO YES OFF YES
E NO NO YES ON NO
F NO NO YES ON YES
16/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
A.1 Power-up Mode
In power-up mode, functioning of the temperature sensor, the heating circuit and the ice
sensing circuits are tested. If the temperature sensor fails, the heating circuit is not tested
and the Fail Mode is entered. If the temperature sensor is OK the heating test is entered.
If the heating fails the Fail Mode is entered and the ice sensing test is not made.
A failure in the ice sensing circuit is first understood as normal ice detection from LID
point of view and the system starts heating the sensor. The sensor is heated to a
temperature where ice sensing should not be possible. If ice is still sensed the Fail Mode
is entered.
This procedure may take considerable time if the ambient temperature is very low and
the detector is covered by thick ice.
If no ice is sensed during the heating procedure then the circuit is considered OK and the
system enters the Sensing Mode.
A.2 Diagnostic Mode
Updating the Fault Relay is stopped when entering this mode and the relay is deactivated
as a sign of a failed condition.
If Diagnostic Mode is entered from the Power-up test the first status data to be sent on
the serial channel may be one of the following
- 20<CR> system failed because temperature sensor failed
- 80<CR> system failed because heating sensor failed
- 10<CR> system failed because ice sensing sensor failed
The fail status is repeatedly sent within a loop checking the system as in the power-up
test.
The Diagnostic Mode is entered from Sensing or Detecting Modes if any of the above
mentioned fails. The status data is repeatedly sent from within a loop checking the
temperature sensor.
In this failure mode the first characters of the status information is one of the following
terminated with the <CR> character.
Status Failure Failure detected in Mode

- 18 if Ice sensing fails Detecting, Cooling Phase
- 28 if T1 failed Any, even in Failed Mode
- 88 if Heating fails Detecting, Heating Phase
All combinations of Ice-sensing and Temperature Failures are possible as well as Heating
and Temperature Failures. The first status character is then one of the ones in the table
above.
If a Heating failure has been detected an Ice-sensing failure can't be detected and vice
versa. These failure Modes can be exited only by power recycling.
Temperature Failed Mode can be exited if the failure has disappeared or the power is
recycled. In the former case Sensing Mode is entered.
17/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
A.3 Sensing Mode
In Sensing Mode the Fault Relay is continuously updated and the Ice Relay is off.
Temperature and ice are measured and reports containing the following information are
sent on the serial channel with about 4 sec intervals which is the time to read the three
variables.
Status Tmp1 Ampl
08 -05.5 *172##<CR>
08 -05.5 *112##<CR>
0D -05.0 *040##<CR> ( ice sensed and detected bits are ON)
The different fields are delimited with a space character. If temperature sensor is detected
failed, this mode is left for Failed Mode.
A.4 Detecting Mode
The purpose of this mode is to indicate icing conditions by turning on the Ice Relay and
then to clean the detector from accreting ice by heating. This mode is divided into two
phases, heating and cooling.
Heating phase
The heating is turned ON for a number of 4 second intervals given by parameter P08, and
OFF for a number of intervals given by parameter P09 until T1 reaches the temperature
set by the value of parameter P03 when the heating is turned OFF. If parameter P15 is
given a value other than 000 in minutes the heating phase is extended by this time.
During the extension time the temperature of sensor T1 is kept between the values of
parameters P03 and P04. After this the heat is turned OFF. The time this phase takes is
completely dependent of the ambient thermal conditions. During this Phase the Failed
Mode is entered if either T1 or the heating fails.
Cooling Phase
At the beginning of this phase the ice sensing is checked and if ice is sensed there must
be a sensing failure and the Fail Mode is entered. The Fail Mode is also entered if the
temperature sensor fails.
If no ice is sensed, a cooling time set by the value of parameter P02 minutes is started. If
ice is sensed during this time the Heating phase is entered again and the Ice Relay stays
activated. If the time expires the Ice Relay is turned OFF and the Sensing Mode is
entered.
18/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
During the Detecting Mode reports are sent like in the Sensing Mode but the status
characters describe what is going on, as follows:
In the Heating Phase
- 0C Ice warning On
- 0D Ice warning On, Ice sensed
- 0E Ice warning On, Heat On
- 0F Ice warning On, Heat On, Ice sensed
in the Cooling Phase

- 0C Ice warning On
19/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
Appendix B: Ranges and parameters
B.1 Measurement ranges
The measured Ice signal amplitude range 0-255 = 0-5 V
Temperature sensor range -55..+125 degC

Resolution 0.5 degC
B.2 Operational parameters
Temperature parameters are set as ½ deg increments!!!!!

The parameter values set are given in the test report.
P-number Name Range Default

00 Ice detected 0-255 120 Amplval
01 Ice Not detected 0-255 150 Amplval
02 * Cooling Time 0-255 010 Min
03 * Heat Off 0-250 100 = 50 degC
04 * Heat On 0-250 090 = 45 degC
05 * Xmit burst 0-255 003 = 3 periods
06 * No of Temp sensors 0-002 001
07 Heating of sensor 0-255 001 0=No;>0=Yes
08 Heating On ratio N-on 0-255 255
09 Heating Off ratio N-off 0-255 000
The heating On ratio is calculated as follows

N-on/(N-on+N-off).
E.g. N-on=9;N-off=1 then power is
9/10*350W
10 * No of Ice measurements every transmission 0-255 255
11 * Max measured amplitude 0-255 250-255 Amplval
12 * Value for 4.0 mA 0-255 050
13 * Value for 20.0 mA 0-255 250
14 Direction of 4-20 o/p 0-001 000
Ampl0 = 4;Amplmax = 20 = 000
Amplmax = 4; Ampl0 = 20 = 001
17 * Xmit frequency select1 0-003 001
Parameters marked with an asterisk (*) should not be changed.
1
Note! If changed please check the amplitude value (255 when no ice is present at low temperatures)
and adjust with the trimpot in the control unit when needed!
20/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
Appendix C: Settings
Communication with the Ice Detector is used to read and change the operational
parameters as needed. The communication connection is RS232 compatible with
following parameters. A PC communication program like PROCOMM+ or equivalent
can be used with the following settings:
communication speed 2400 Baud

character length 8 Bit
number of stop bits 1
parity no
full duplex
incoming CR translation CR/LF
C.1 Commands
There are three different commands given as upper-case ASCII-characters (in capitals):
R = read parameter
S = set parameter
A = make a restart
The commands have the following syntax:
Rnn<CR>
Snnxxx<CR>
A<CR>
C.2 Abbreviations used
<CR> = ASCII carriage return character i.e. Enter-key

<SP> = ASCII space character
nn = two character parameter No (00...17)
xxx = three character parameter value (000...255)
In the following examples user activity is embraced in square-brackets [..] and detector
response in brackets {..} to clarify the protocol.
Each command is started by sending a Carriage Return character.
C.3 Reading a parameter example

[<CR>] ;User starts command
{?<CR>} ;Detector responds
[R01<CR>] ;User requests value of parameter01
{R01150<CR>} ;Detector returns command added with value
21/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
If no further activity is executed the detector returns to normal reporting activity after a
time-out period.
C.4 Setting a parameter value example
[<CR>] ;Command start

[S01175<CR>] ;Set parameter01 to 175
{S01175<SP>OK?<CR>} ;Detector echoes and asks for verification
{Y/N<SP>}[Y<CR>] ;either Yes or No. User accepts
{OK<CR>} ;Detector acknowledges verification
C.5 Restart command example
[<CR>] ;Command start

[A<CR>] ;Restart command
{Wait<CR>} ;Detector enters restart condition
C.6 Unidentified command or data
The detector will not identify commands other than said R,S or A, parameter numbers
other than 00 ...32 given as two characters or data in the range 000 ... 255 given as three
characters. In such a case the detector responds by sending EH?<CR> and a corrected
command has to be renewed (including the command start procedure).
22/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
Appendix D: Maintenance and Troubleshooting

MAINTENANCE
1. Check as regularly as possible (once a year as a minimum) that there are no visual damages on the
sensor part; especially on the ultrasonic sensor wire or the heating element. Check also that the
sensor is mounted properly without any bendings, loose elements etc.
2. Within certain intervals check also the functioning by connecting a PC with a terminal program
into the detector’s data output and check the following (please see the signal mode chart in the
chapter Operation in the manual):
2.1 That the sensor responds properly (e.g. that the fail and mode bits are according to the existing
situation)
2.2 That the temperature reading is correct
2.3 That the ice sensing reply is according to the existing situation
3. Check also all connectors, cabling etc. so that there are no visual loose contacts, contaminations
that might cause shortcuts or any tracks of corrosion.
Fuses:
Use fuses with the required rated current, voltage and specified type only. Used type of
the fuses are IEC127 approved 5 x 20 mm / 6.3AT.
Warning!
TROUBLESHOOTING
Detailled malfunctions:
1. Fault description: The signal amplitude stays constantly at a lower level and there are no icing
conditions:
a) Amplitude below 150: Check the wiring and contacts. Should this not help replace the sensor.
b) Amplitude 150-200 and the used frequency other than 0: The sensor part is defect. Replace it or
consult your nearest service.
c) Amplitude 200-230: Adjust the max. amplitude to 250 by turning the trimpot in the control unit
clockwise.
2. Fault description: The detector reacts to snow blended rain or heavy rainfall:
Check that the sensor is mounted to right direction (not directly against the wind). If this does not help
then set the parameters P00 and P01 that control the alarm level to a smaller value e.g. to 80-120. If
23/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
this does not help try other frequencies with P17 (1,2,3) and/or various alarm levels or consult the
supplier. It is recommended to obtain the parameter values.
3. Fault description: The sensor does not react on ice:
Check the amplitude level: If it is not below the setpoint for ice detected the sensor does not see ice:
Try other frequencies with P17 (1,2,3) and/or set the alarm level higher.
4. Fault description: There appears a temperature value 85 in the serial communication:
Disturbances in the temperature element (Dallas). Replace the sensor or contact your local service.
5. Fault description: The sensor indicates ice constantly (amplitude 0-50)
The sensor cable is broken or there is a bad contact. Please check.

Or:
The sensor or crystal wire or the crystal itself is broken. Change the sensor or contact your local
service.
6. Fault description: The LID 3210C does not give ice alarm even when there is ice on the rotor
blades:
Please check manually the real conditions of the sensor part!
When problems it is always appropriate to check the status and amplitude by using a PC plus to
check that all parameter values are correct.
24/25

Rev: 16.10.2006 / ECN 22349

LID-3210C D80081Ee
Installation Manual
Appendix E: Connection Diagram
25/25

Rev: 16.10.2006 / ECN 22349


Rev: 16.10.2006 / ECN 22349

- Chapter 23 ACOUSTIC WIND SENSOR

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 23 ACOUSTIC WIND SENSOR

SWT - 2.3 - 82VS/93/101
• Appendix - Data sheet, Acoustic wind sensor (option)

yyyy)

Document history

93/101

Appendix - Data sheet - acoustic wind sensor (option)
See “Acoustic wind sensor” on page 316


Acoustic wind sensor / Assembly Instructions / AS 537763 / 09.09.2003 315 / 346
Rev: 16.10.06 / ECN 22349

Acoustic wind sensor
316 / 346 Acoustic wind sensor / Assembly Instructions / AS 537763 / 09.09.2003

Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349


Rev: 16.10.06 / ECN 22349

- Chapter 24 VISIBILITY METER

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 24 VISIBILITY METER

SWT - 2.3 - 82VS/93/101
• Appendix - Data sheet, Visibility meter (option)

yyyy)
SWT - 2.3 - 82VS/93/101 / ZSM1005840_24 / 10-02-2009 / 671 / 674

Document history

93/101
672 / 674 SWT - 2.3 - 82VS/93/101 / ZSM1005840_24 / 10-02-2009 /

Appendix - Data sheet - visibility meter (option)
See “Montage af sigtbarhedsmåler / Fitting of visibility meter” on page 675
SWT - 2.3 - 82VS/93/101 / ZSM1005840_24 / 10-02-2009 / 673 / 674

674 / 674 SWT - 2.3 - 82VS/93/101 / ZSM1005840_24 / 10-02-2009 /

Montage af sigtbarhedsmåler / Fitting of visibility meter
ARBEJDS-INSTRUKTION
AI/WI 535909
WORK INSTRUCTION
Designer: JBE Beskrivelse: Sigtbarhedsmåler mont.
Description: Visibility meter mount.
Dato/Date: 16-06-03 Operation: Delmontage / Sub-assembly
ECN Nr.: 14315 Dele/Parts 533359, 537041

ECN Dato/Date: 08-03-04 Mølle type: 2,3 MW
Turbine type:
Der henvises i øvrigt til CH535967
Refer also to CH535967
Vígtigt : Samtlige bolte smøres i antiblock fedt. Spåner opsamles staks efter brug af boremaskine i
nacelle
Note: Lubricate all bolts with anti block grease. Remove all drilling chips immediately after
drilling in the nacelle
DK – Ved arbejde oven på nacelle skal der

altid arbejdes med seler. Der anhugges
ved gule anhugningspunkter.
GB – Always use a safety harness when

working on top of the nacelle. Hook on
to the yellow ancor points.
_____________________________________________________________________________________________________
AI/WI 535909-14315 Side/Page 1 / 8
Fitting of visibility meter 675 / 682

Rev: 24.05.05 / ECN 17003

DK – M5 gevind skæres op i bom for
sigtbarhedsmåler.
GB – Recut the M5 threading in the bar for

the visibility meter.
DK – Pt100 føler monteres i plade, og

forskruning tilspændes.
GB – Mount the pt100 sensor on the plate and

tighten the gland.
DK – Der opmærkes for M4 huller til

samleboks for pt100 føler. Bemærk at
hvis huller opmærkes udvendig er
huller spejlvendt.
GB – Mark the positions of the M4 holes for

the pt100 sensor box. Note that if the
hole positions are marked on the
outside, the holes are reverse.
_____________________________________________________________________________________________________
AI/WI 535909-14315 Side/Page 2 / 8
676 / 682 Fitting of visibility meter

Rev: 24.05.05 / ECN 17003

DK – Skråstiver monteres på bom.
Låsemøtrikker skal ved montage vende
bagud.
GB – Mount the cross-arm brace on the stand.

At assembly the lock nuts must face the
rear end.
DK – Bom for sigtbarhedsmåler løftes op på

nacelle, og huller opmærkes. Mål for
opmærkning er fra kant af overkappe til
midt af bom.
GB - Lift the stand for the visibility meter

onto the nacelle and mark the hole
positions. The measurement is from the
1210mm surface of the top cover to the centre of
the boom.
DK – Huller bores. Der laves Ø14 huller til

bom og Ø12 til skråstiver. Huller
afgrates og blank metal males med
rustværn.
GB – Drill the holes. Use Ø14 holes for the

stand and Ø12 for the cross-arm brace.
Deburr the holes and cover naked metal
with antirust agent.
_____________________________________________________________________________________________________
AI/WI 535909-14315 Side/Page 3 / 8

Rev: 24.05.05 / ECN 17003

DK – Bolte monteres i beslag. På inderside
monteres beslag med sikringsskive
imellem beslag og overkappe for
lynsikring.
GB – Fit bolts in the brackets. Use lock

washers on the inside between the
bracket and the top cover for lightning
protection.
DK – Samlinger ved overkappe fuges med

Sikaflex.
GB – Seal the joints on the top cover with

Sikaflex.
DK – Lynfang monteres på bom.

Låsemøtrikker peger mod bagende.
GB – Mount the lightning rod on the stand.

The bolts must face the rear end.
_____________________________________________________________________________________________________
AI/WI 535909-14315 Side/Page 4 / 8

Rev: 24.05.05 / ECN 17003

DK – Ledninger fra kontrolboks trækkes
igennem overkappe og til sigtbar-
hedsmåler ved bom.
GB – Pull the wires from the control box

through the top cover and to the
visibility meter on the stand.
DK – Stik og stelforbindelse monteres på

sigtbarhedsmåler.
GB – Mount the plug and the earth

connection on the visibility meter.
DK – Samledåse for pt100 føler monteres, og

kabel fra kontrolboks monteres i
samledåse iht. el diagram.
GB – Mount the junction box for the pt100

sensor and fit the cable from the control
box in the junction box in accordance
with the electrical diagram.
_____________________________________________________________________________________________________
AI/WI 535909-14315 Side/Page 5 / 8

Rev: 24.05.05 / ECN 17003

DK – Beslag monteres på bom, og der fuges
med sikaflex ved samling.
GB – Fit the bracket on the stand and seal

with sikaflex.
DK – Der fuges med sikaflex mellem

sigtbarhedsmåler og bom.
GB – Seal with Sikaflex between the

visibility meter and the stand.
DK – Bolte for topplade monteres.
GB – Fit the bolts for the top plate.
_____________________________________________________________________________________________________
AI/WI 535909-14315 Side/Page 6 / 8

Rev: 24.05.05 / ECN 17003

DK – Kontrolboks monteres
GB – Mount the control box
DK – Kabler trækkes i overkappe. Kabler

stripses pænt. Rustfri
befæstigelsesplade monteres på beslag
og kabler fastgøres. Kabler må ikke røre
beslag/overkappe.
GB – Position the cables on the top cover.

Tie the cables neatly. Attach an
anchor steel for cable strip on the
brackets and tie the cables onto
these. The cables may not touch the
bracket/top cover.
DK – Kabler fra kontrolboks afkortes og

monteres igen iht. el-diagram.
Overskydende ledninger stelforbindes.
GB – Shorten the cables from the control box

and re-fit them in accordance with the
electrical diagram. Connect any extra
wires to earth.
_____________________________________________________________________________________________________
AI/WI 535909-14315 Side/Page 7 / 8

Rev: 24.05.05 / ECN 17003

DK – PR-modul monteres i topboks, og
kabler monteres iht. el diagram.
GB – Fit the PR module in the top box and fit

the cables in accordance with the
electrical diagram.
DK – Afskærmning for flylys monteres.
GB – Cover for flight light is fitted.
_____________________________________________________________________________________________________
AI/WI 535909-14315 Side/Page 8 / 8

Rev: 24.05.05 / ECN 17003

- Chapter 25 AVIATION LIGHT

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 25 AVIATION LIGHT

SWT - 2.3 - 82VS/93/101
• Appendix - Data sheet, aviation light (option)

yyyy)

Document history

93/101

Appendix - Data sheet - aviation light (option)


Type: ORGA CIP100 (option)
Siemens Wind Power A/S / Flylys type: ORCA CIP 100 / 687 / 694
Rev: 16.10.06 / ECN 22349
688 / 694 Siemens Wind Power A/S / Flylys type: ORCA CIP 100 /
Rev: 16.10.06 / ECN 22349
CIP100 Manual
Typical lighting of wind turbine, as per FAA regulations AC 70/7460.1K
One medium intensity red flashing light per turbine, with multiple turbine synchronisation
OPTION 1 Flashhead mounted on top of nacelle

CIP100 Controller in nacelle
GPS020 on or in nacelle
System incoming power supply in nacelle
L350-864 Red LED

flashhead
Factory fitted GPS020

flashhead pigtail synchroniser
cable
Factory fitted
GPS020
connection cable
CIP100
controller 110-230Vac,
50-60Hz
500VA supply
oal wt1 L350-864 install guide manual r2
Rev: 16.10.06 / ECN 22349
CIP100 Manual
Inside view of CIP100 Controller
Fieldbus
terminator
System ALARM relay contacts
GPS020 cable terminals
Flashhead pigtail cable fieldbus terminals with

fieldbus terminator fitted
Flashhead pigtail cable power terminals

And
Incoming power terminals
Rev: 16.10.06 / ECN 22349
CIP100 Manual
2 Installation procedure
W Unpack the equipment and check the system parts for any transport damage.
W Start with mechanical installation of the flashhead, and Strobeline™ pigtail cable, CIP100 and
GPS020.
W Check that the flashhead is installed completely level – use the level indicators.
W The flashhead should ideally be protected by a grounded lightning rod (air terminal) if not already
protected by the turbine lightning protection system.
W The control panel is mounted inside the nacelle on a suitable secure vertical surface.
Consideration must be given to accessibility regarding the door opening requirements.
W The GPS020 is ideally mounted outside on top of the nacelle with the antenna facing upwards. It
may also be possible to mount the GPS020 inside the nacelle as long as the nacelle cover is not
metal, and the GPS020 reception is not shielded by the steel structure members of the nacelle.
W The GPS020 manual contains information to check proper satellite reception.
W Check after the mechanical installation that all mounting bolts and nuts are tightened.
W Fit the flashhead pigtail cable to the CIP100 enclosure using the provided cable glands. Follow the
separate installation sheet. It is very important to correctly fit the pigtail cable outer shielding to the
cable gland otherwise the protection of the system is not as it should be.
W Connect the flashhead pigtail cable to the terminal rail in the CIP100. The wires and terminals are
separately colour coded – fit the correct wire to the appropriate terminal.
Black = Power L
White = Power N
Green/yellow = Earth / ground (connect directly to earth rail)
Orange = Fieldbus A IN
Yellow = Fieldbus B IN
Grey (or black) sleeve = Fieldbus screen
W Connect the GPS020 cable to the terminal rail in the GPS020. The wires are marked to match the
label on the grey coloured terminals.
+ = Power +
- = Power –
S+ = sync +
S- = sync –
Earth = Earth/ground (connect directly to earth rail)
W Check that all system wiring connections are correctly made and that the wires are securely
connected in the terminals.
W Check that the fieldbus terminator device is plugged in on top of the yellow and orange terminals in
the CIP100
W Connect any external monitoring system to the appropriate status C/NO/NC relay contact(s)
W The cables should be checked for earth faults before applying any power to the system.
Rev: 16.10.06 / ECN 22349
CIP100 Manual
3 Turning the System ON
The CIP100 will have been programmed in the factory before despatch ready for the connection of the
flashhead in your system. It is usually not necessary to further programme the CIP100 unit.
Open the enclosure cover for the CIP100 so that you can observe the status LED indicators.
Turn on the 110-230Vac 50-60 Hz supply to the CIP100.
The CONFIG OK, SYSTEM OK and DAY mode LEDs will be ON
The display will show “-.-.” with the two dots flashing which shows that the system is initialising.
After approx 60 seconds the dots will stop flashing.
The display will show “- -“.
It may take several minutes for the GPS020 to initialise, when it does the “SYNC” LED will be on.
Rev: 16.10.06 / ECN 22349
CIP100 Manual
Check the correct operation of the system by using the manual “INTENSITY OVERRIDE” function.
During normal operation during the daytime the L350-864 light will be OFF – this setting can be manually
overridden as follows :
1 Press the INTENSITY OVERRIDE button on the right hand side of the screen.
2 The RED “INTENISTY OVERRIDE” LED on the left hand side of the screen will come on.
3 The system DAY or NIGHT intensity setting will be indicated by which GREEN LED is on.
4 Press the INTENSITY OVERRIDE button again
5 The intensity setting will change to the other mode as indicated by the GREEN LED.
Check that the lights change to the correct operating mode – allow 30 seconds for the white mode to
change to red mode.
6 Press the INTENSITY OVERRIDE button again
7 The RED “INTENSITY OVERRIDE” LED will go OFF and the system will operate in AUTO mode.
Make sure that you leave the system operating in AUTO mode.
4
5
3 6
Rev: 16.10.06 / ECN 22349
Rev: 16.10.06 / ECN 22349
Type: ORGA CIP200 (option)
Rev: 16.10.06 / ECN 22349
L303-865 Installation and Operation Guide
6.4 CIP SPECIFICATION
Communication Interface Processor (CIP 200) Obstruction Light System Controller
Type CIP200.1
Standard FAA, AC 70/7460-1K and AC 150/5345-43E.
Enclosure Salt water resistant die cast alloy enclosure with chromate
coating system.
Dimensions (l x d x h) approx. 16”w x 9”h x 4½”d (400 x 230 x 111 mm).
Mounting mounting brackets supplied for fixing to wall or unistrut.
Weatherproof protection NEMA4 and NEMA4X (IP66)

Weight approx. 18 lbs (8 kg).
o o
Operating Temperature -55 C (-67 oF) to +55 C (131 oF)
Humidity 95% relative humidity
Operating Supply Voltage 110-240 VAC, ±10%, 50-60 Hz.

Power consumption Maximum 10W
(30W with low temperature environment heater option).
System supervisor functions Control of flash character synchronization of up to 89

Orga obstruction lights (any combination of L-864, L-865
and dual L-864/865 medium intensity lights and L-810
side lights) in a system.
Control of light intensity of up to 89 obstruction lights in a
system, according to ambient light conditions.
System information functions LCD backlight display screen with membrane foil
keyboard.
“FAIL” screen with the ability to scroll through all recorded
“FAIL” events in the system.
Real time clock.
“CONFIGURE” screen to:
set system photocell mode (auto/day/night).
set real time clock.
adjust LCD screen backlit light intensity.
Local Alarm indications LCD display screen to show all “FAIL” events.
LED – red on “FAIL” event.
Reset/acknowledge FAIL conditions.
L303-865 Page 17 of 50
Rev: 16.10.06 / ECN 22349
Communication Interface Processor (CIP 200) Obstruction Light System Controller
Remote alarm indications contact relays for

“FAIL” conditions (NOTAM event):
Strobe four (4) consecutive missed flashes
Strobe incorrect light intensity (intensity mode failure)
Strobe incorrect color (for dual red/white lights)
Alarm conditions:
Power Failure
Marker Light failure
Photocell Status
Identification of which event and which strobe caused
the “FAIL” condition is made using the CIP display
screen.
Remote alarms are provided as 0-240 VAC/DC, 2A max,
non-inductive relay contacts (“dry contacts”).
Protection All system input & output connections are galvanically

isolated.
Lightning protection circuits as International Electro
Technical Committee Enhanced lightning protection
circuits are available as an optional item.
Complies with generic EMI (EN50082-2 part 2) and EMC
(EN50081-2 part 2) RF immunity and emission
standards.
Fuse.
Cable entries (3/4” NPT) 5 x Entries:

1 x Power in
1 or 2 x Orga Strobeline™ cable (for connection to light(s))
1 x Remote alarm connection
1 x GPS-connection for GPS020 (only with CIP200-G)
3 x Glands Standard provided
2 x Blindplug Standard provided
External cable connections Modular terminal blocks.
L303-865 Page 18 of 50
Rev: 16.10.06 / ECN 22349
6.5 CIP Information
Each flash head in the system has built in intelligent self-monitoring functions. The CIP unit
is able to access and monitor this information to control the overall operation of the system
and to provide external status information regarding the performance of the system.
Photocell Control and Intensity Mode Setting

Each flash head has built in photocells. The CIP monitors the photocell status information
of all the flash heads in the system and uses this information to determine the correct
system setting according to the ambient light levels. The CIP will determine the correct
system setting based on the majority condition of all of the photocells in the system.
The CIP will compare the readings of all the photocells in the system, in the event that a
photocell reading falls outside the accepted tolerance band the information from that
photocell is ignored. If all photocells are reported to have failed the CIP will generate a
“photocell FAIL alarm” and the system will be set to operate in daytime mode.
Monitoring Functions
The CIP will generate a FAIL alarm if any of the flash heads in the system report any of the
following conditions:
Flash head FAIL: missed 4 or more consecutive flashes.

Intensity FAIL: incorrect intensity step (flash head operating in wrong intensity setting)
Color FAIL: flash head operating in incorrect color mode (for dual L-864/865 flash
heads only).
Power FAIL: loss of power to the system

Marker Light FAIL: failure of any L-810 marker light (where installed)
The alarm relays are dry contact (2A, 240V AC/DC, Non-inductive) on the CIP terminal rail
for remote monitoring.
Details regarding the nature of system FAIL events are available on the CIP display screen.
All outstanding FAIL events are highlighted until they are manually accepted (by pressing
the “accept” button on CIP), after which time they are still shown as active alarms on the
CIP screen until the cause is resolved.
Manual Override Settings
The CIP is used to manually select the system photocell-operating mode (auto, high, low
settings).
The CIP has functions to allow for manual adjustment of the built in real time clock and the
LCD display backlight level.
L303-865 Page 19 of 50
Rev: 16.10.06 / ECN 22349
6.5.1 Connect the Power Supply
Make sure that the L303-865 flashheads are correctly connected to the CIP200, and that
the lenses are properly latched closed, before you first turn on the power supply. This will
prevent the occurrence of system FAIL and ALARM messages created during the start up
of a system that is not ready for operation.
1. Turn on the power supply. The system will automatically start up. The CIP200 screen
will turn on. The screen will display the message “INITIALISING SYSTEM”.
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4
1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
D A Y
I N I T I A L I Z I N G S Y S T E M
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
0 % 1 0 0 %
O R G A C I P 2 0 0 R OM v 2 . 2 1
2. After a short time the screen will display the MAIN MENU screen.
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4
1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
* F * A MA I N ME N U T W I L I G H T
1 F A I L S C R E E N
2 A L A RM S C R E E N
3 C O N F I G U R A T I O N ME N U
4 D I S P L A Y S T A T I O N S T A T U S
5 S H OW A C T I V E S T A T I O N S
O R G A C I P 2 0 0 v 1 . 0 1
3. It may take up to 5 minutes for the system to initialise and start to operate correctly.
Initially the lights will start to flash individually (not synchronised) at 2,000 Cd intensity.
The two lights in the system will then synchronise with each other and operate at the intensity step set by
the intensity input bits. Finally the individual systems will start to synchronise with each other provided
that the “SYNC” input signal from the GPS020 is present (only with CIP200-G).
4. The system automatically checks itself, if the system is operating correctly the LED on
the front of the CIP200 enclosure will be green.
Any faults the CIP200 will be shown on the display screen. There are two
types of faults
• FAIL events that indicate that the system has a major fault (the LED on the front
of the enclosure is red) and is not operating according to specification.
L303-865 Page 20 of 50
Rev: 16.10.06 / ECN 22349
• ALARM events (the LED on the front of the enclosure is yellow) that indicate an
advisory warning alarm.
6.5.2 Understanding the CIP200 System Status Condition Messages
The CIP200 screen can show a number of FAIL and ALARM messages. If a FAIL or
ALARM event is a result of a transient fault the CIP200 screen will still show the FAIL or
ALARM message even though the cause of the event is no longer active. This is because
we consider it important that the system operator be made aware of all system events,
including those that appear to have resolved themselves.
Transient faults are automatically reset on the IOM2409 I/O module digital outputs to the
turbine control system (only with CIP200-I).
5. The presence of any FAIL or ALARM events is indicated by a letter F (fail) or A

(alarm) in the top left hand corner of the CIP200 screen. A flashing “*” to the left of
the letter F or A indicates that a new, and unacknowledged, event has occurred.
6. A detailed description of a FAIL or ALARM event can be found by selecting the
appropriate category from the menu (using either the up and down arrow keys or the
numeric keypad, and then pressing ENTER). The next screen will show all current
FAIL or ALARM events according to the selected menu. The screen is divided into
two parts, move between the two screens using the left and right arrow keys. The
type of event is shown on the left hand screen and the details (status, date and time)
are shown on the right hand screen.
7. By pressing the F4 Accept key the highlighted event is “accepted” by the CIP200. In
order to easily identify if there are new FAIL or ALARM events the CIP200 a flashing
“*” next to the letter F or A in the top left hand corner of the screen can be seen if a
new, and unacknowledged, event has occurred.
If the cause of the event has been resolved the FAIL or ALARM message will
disappear when the “accept” button is pressed. If the cause of the event is still
unresolved the message will stay on the screen.
8. It is important that all FAIL or ALARM events are resolved before the system is
considered operational.
9. The Letter “S” indicates that the CIP200 is receiving the flash character
synchronisation signal from the GPS020 as applicable (only with CIP200-G).
10. The CIP200 has an internal audible warning sound device that will sound in the event
of a FAIL or ALARM condition. The audible warning sound device can be disabled by
removing a jumper on the circuit board on the inside of the lid of the CIP200. The
jumper is orange and is located on the bottom left hand corner of the circuit board
next to the ribbon cable connector.
The following messages may be seen on the CIP200 screen. They are intended to assist in
troubleshooting and fault finding.
L303-865 Page 21 of 50
Rev: 16.10.06 / ECN 22349
6.5.3 FAIL SCREEN MESSAGES
Flashing Letter F or A Letter S

“*”

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4
1 2 3 4 5 6 7 8 9 21
0 1 2 3 4 5 6 7 8 9 0 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
* F * A * S F A I L S C R E E N N I G H T
- - T O P O F F A I L L I S T - -
* s y s t e m w r o n g i n t e n s i t y s t e p
* L 8 6 4 s t a t i o n n u mb e r 0 1 F l a s h
* L 8 6 4 s t a t i o n n u mb e r 0 2 M i s s i n g
- - B O T T OM O F F A I L L I S T - -
ME N U - - - - A C C E P T
s * Tagno s Station description s Channel description s
⇐
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4
1 2 3 4 5 6 7 8 9 21
0 1 2 3 4 5 6 7 8 9 0 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
* F * A * S F A I L S C R E E N N I G H T
- - T O P O F F A I L L I S T - -
f a i l 0 7 - 3 1 - 0 0 1 2 : 3 0 : 3 8
f a i l 0 8 - 0 3 - 0 0 1 5 : 2 2 : 2 0
A b s e n t 1 0 - 1 1 - 0 0 0 9 : 0 0 : 1 0
- - B O T T OM O F F A I L L I S T - -
ME N U - - - - A C C E P T
s Status s Date & Time s Value s Unit s
11. FAIL Wrong Intensity Step

This indicates that the WT (wind turbine) system is not operating according to the
ambient light conditions when operating in stand alone mode (i.e. not controlled by the
turbine control system and with no GPS020 input SYNC signal with CIP200-G). The
system cannot determine the correct day or night operating mode due to damage to
one of the photocells in both of the flashheads.
This message will be accompanied by a “Photocell Alarm” condition in the ALARM
screens (see later). The WT system will default to night (ON) mode.
Check on the right hand screen to see if the status is “fail” or “normal”. If the status is
“normal” this indicates there was a temporary problem with the photocell readings but
it is now resolved.
If the status is “fail” this confirms the continued FAIL situation.
L303-865 Page 22 of 50
Rev: 16.10.06 / ECN 22349
The photocells are inherently very reliable so a problem with the photocell part of the
flashhead is very unlikely. In the event that a photocell is damaged then replace the
flashhead internal with a unit with the correct station address code.
12. FAIL Flash Fail

This indicates that the flashhead has missed four consecutive flashes. Check on the
right hand screen to see if the status is “fail” or “normal”. If the status is “normal” this
indicates there was a transient fault that is now resolved. If the status is “fail” this
confirms the continued FAIL situation.
If the light is still flashing this is probably due to the lamp getting near to the end of its
operating life as the flash ignition becomes less reliable at this time (replace the
lamp).
If the light is not flashing this could be because the lamp has actually failed, or could
indicate damage to the flashhead’s power supply module (first replace the lamp, if
this does not solve the fault replace the flashhead (internal) with a unit with the correct
station address code).
13. FAIL Missing Station

This indicates that the identified flashhead(s) (Station 1 or Station 2) is not
communicating with the CIP200. Check on the right hand screen to see if the status is
“absent” or “present”. If the status is “present” this indicates there was a temporary
loss of communication that is now resolved.
If the status is “absent” the continued loss of communication could be due to one of
the following conditions:
Two lights with the same Station Number
If on system start up the CIP200 indicates that both Station 1 and Station 2 are
“missing stations” then the most probable cause (assuming that the system
connections are correctly made) is that two lights with the same station number are
connected to the CIP200. Both Station 1 and Station 2 are reported as missing as the
CIP200 cannot properly determine the correct communication.
Turn off the power supply and remove the Strobeline™ field bus wire connections to
one of the lights (remove the orange and yellow wires from the CIP200 terminal rail).
Turn on the power supply. If the CIP200 now reports only one station as a “missing
station” note which station number is reported as missing.
Turn off the power supply and reconnect the Strobeline™ field bus wire connections
for the first light and remove the field bus wire connections for the second light. Turn
on the power supply. If the CIP200 reports the same station number as the “missing
station” this confirms that both lights have the same station number.
One of the two lights must be replaced with a unit with the correct “missing” station
number.
L303-865 Page 23 of 50
Rev: 16.10.06 / ECN 22349
No power at the flashhead.

Check that the “Danger High Voltage” LED inside the lens of the flashhead is flashing
(you will be able to see the LED near to the base of the lens on the right hand side
when looking at the light with the hinge at the back). If not this could indicate that
there is no external power supply, check connections of the Strobeline™ pigtail cable
at the CIP200.
If there is external power on the Strobeline™ cable check that the safety micro
switches operate correctly by working through the following checks.
Turn off the power supply and open the lens.
Identify the two safety micro switches on the right hand side of the base cone
assembly. On the lens adjacent to these micro switches check that the plastic block
fixed to the inside of the lens is correctly positioned so that the two safety micro
switches are depressed when the lens is in the closed position.
Check that the micro switches operate correctly. When the switches are gently
depressed they should return to the up position when released.
If the switches appear to be stuck they can be released by opening the flashhead
base unit. To do this undo the 4 “quick release” quarter turn screws holding the
internal cone assembly to the base.
Gently lift the internal cone unit away from the base, it can only be lifted a short
distance before the wiring connections restrict further movement.
Check that the micro switches are not caught under the switch levers on the circuit
board underneath the micro switches.
Carefully replace the cone internal assembly onto the flashhead base (make sure that
the micro switches are in the correct position above the circuit board) and recheck that
the micro switches now operate correctly when depressed and released.
Tighten the 4 “quick release” quarter turn screws that hold the internal cone assembly
to the base.
Close the lens and turn on the power supply.
If this does not resolve the problem it indicates that the flashhead’s internal power
supply is damaged, replace the flashhead internal with a unit with the correct station
address code.
L303-865 Page 24 of 50
Rev: 16.10.06 / ECN 22349
No communication with the flashhead.

If the “Danger High Voltage” LED inside the lens of the flashhead is flashing check the
field bus connections of the Strobeline™ pigtail cable at the CIP (orange, yellow and
screen wires). If everything is correct this indicates that the flashhead communication
module is damaged – replace the flashhead internal with a unit with the correct station
address code.
6.5.4 Checking the Field-Bus Connections by measuring impedance
It is possible to check the correct installation of the field-bus by measuring the impedance
between the field-bus wires.
Note that the system is fitted with two (2) fieldbus terminator devices (150ȍ resistor), one is
fitted in each flashhead.
Take the measurements with the two lights connected to the CIP200 and the power
TURNED OFF.
The values given are indicative and should be considered as guidelines only. The Mȍ field-
bus screen against potential earth measurements especially are subject to humidity levels.
Orange to Yellow
75ȍ OK
150ȍ 1 field bus terminator missing
50ȍ 1 field bus terminator too many
Orange (or yellow) against field-bus screen

4kȍ OK - 3 stations connected (2 lights and CIP200)
6kȍ Only 2 stations connected
12kȍ Only 1 station connected
Field-bus screen against potential earth

7Mȍ OK - 3 stations connected (2 lights and CIP200)
10Mȍ Only 2 stations connected
20Mȍ Only 1 station connected
L303-865 Page 25 of 50
Rev: 16.10.06 / ECN 22349
7.0 SPECIFICATION STROBELINE™ CABLE
The Strobeline™ cable combines into a single outer cover both the power conductors and
the control field bus wires. A single run of Strobeline™ cable is used to inter-connect all of
the obstruction lights to the CIP controller device.
Power Conductors 3 wires, AWG 12

Field bus conductors 1 x twisted pair shielded twinax 100 Ohms, AWG20
The above conductors are wrapped in aluminum polyester tape, which is in turn covered by a
tinned copper braid. The outer jacket is PVC (UL 2919).
Characteristics:
Operating Voltage : 300 volts max

Operating temperature : -55°C (-67 oF) to +85°C (+185 oF)
Impedance : 100 Ohms (± 5 Ohms)
Capacity between wires : < 60 pF/m
Capacity between screen and wire : < 80 pF/m
Attenuation at 100 Mhz : < 20 dB/100m
Velocity : 66%
Coverage of the twinax : > 85%
The generic type number for the field bus part of the Strobeline™ cable is:
BELDEN –m 9207 100-ohm twinax p/n 7362211 --- e34972 75C 1pr20
L303-865 Page 33 of 50
Rev: 16.10.06 / ECN 22349
Strobeline™ cable is finally connected to the CIP controller. CIP unit connections is shown below.
706 / 706
Special Note
Field Bus Terminator
In certain installations, this
terminator may not be
located in the CIP – refer to
individual kit specifications.
Legend
GPS020 Connection Relay contacts
terminals (only with
CIP200-G) NC= Normally Closed
NO= Normally open
Terminal Block
External
Monitoring
Relay
Outputs
Rev: 16.10.06 / ECN 22349

Strobe NO NC Marker NO NC General NO NC Intensity Day/Twi Horn NC NO Power NO NC
Siemens Wind Power A/S / Flylys type: ORCA CIP 200 /

Fail Alarm Alarm Night Fail
GPS 7V Power
GPS Sync. Pulse
FH1 Pigtail Blue
FH1 Pigtail Brown

FH1 Pigtail Screen
FH1 Pigtail Yellow

FH1 Pigtail Orange
Ground Ensure that the Ground Rail has a
FH1 Pigtail Yellow/Green Rail proper external earth provided
L303-865 Page 42 of 50
Type: ORGA GPS020 (option)
Siemens Wind Power A/S / Flylys type: ORGA GPS020 / 707 / 714
Rev: 16.10.06 / ECN 22349
708 / 714 Siemens Wind Power A/S / Flylys type: ORGA GPS020 /
Rev: 16.10.06 / ECN 22349
1 INTRODUCTION
This instruction manual provides information about installation, operation, maintenance and
recommended spare parts for the Orga GPS020 multiple system flash character synchroniser units as
used with Orga’s range of high intensity and medium intensity flashing Aviation Obstruction Light
systems.
1.1 GENERAL DESCRIPTION
The GPS020 synchronizer unit is designed to operate with Orga high intensity and medium intensity
obstruction light systems.
The GPS020 unit is used to synchronise the flash control time clocks in the CIP100 or CIP200 range of
controller. By synchronising these clocks the flash timing controls of all the CIPxxx controller s are set
to the same time base – resulting in a single flash time base in all controllers fitted with the GPS020
unit.
The use of the GPS020 in the obstruction light system is intended to maximize hazard warning to air
traffic and to minimize environmental impact concerns to ground level.
The GPS020 should typically be mounted in a position that ensures the antenna has a clear view of the
sky to maximise the satellite signal reception. It is possible that the GPS020 may work if placed in a
shelter or inside the nacelle of a wind turbine if the shelter or nacelle is made of a GRP based material.
The GPS020 has a set of status LEDs that can be used to determine the operation status and therefore
to verify the suitability of the chosen location.
The CIP100 or CIP200 controllers have a visible indication that they are receiving the SYNC time pulse
from the GPS020 unit.
GPS202 manual oal2 Page 5
Rev: 16.10.06 / ECN 22349
GPS020 FLASH CHARACTER SYNCHRONISER UNIT
2 DATASHEET
Key features
• Multiple system flash character synchroniser for use with Orga High
Intensity and Medium Intensity Obstruction Light Systems
• Very Low power consumption
• Power supply from Orga CIPxxx controller
• Easy to install
• Single cable connection to CIPxxx controller
• Internal LED status indicators
Specifications
• ICAO Annex 14 Volume 1. Third Edition July 1999 chapter 6
• Federal Aviation Authority AC 70/7460-1K and AC 150/5345-43E
Function
• Uses Global Positioning Satellite system to provide synchronising time signal to Orga CIPxxx based control systems so
that multiple systems that each has high intensity and/or medium intensity lights connected to a CIPxxx will all flash in
unison with each other.
Electrical characteristics
• Power consumption < 10W at 7Vdc from CIPxxx controller
Mechanical characteristics
• Painted aluminium alloy enclosure and external antenna
• IP66 Degree of Ingress Protection
• Operating temperature range –40...+55 °C
• GPS020 dimensions 335 x 200 x 119 mm incl. antenna: 3kg
Rev: 16.10.06 / ECN 22349
3 SYSTEM DESCRIPTION OF THE GPS020
A factory fitted multi core cable (5C x 1.5mm² / AWG14) is used to connect the GPS020 to the CIP100
controller.
The GPS020 draws its power from the CIP100 which has an internal 7V supply module for this purpose.
Do not connect mains power to the GPS020.
The GPS020 provides a real-time based synchronization pulse derived from the Global Positioning
Satellite (GPS) satellite system to the CIP100. The synchronization pulse is used to reset the flash
character time base of any system fitted with a GPS020. Any system with a CIP100 connected to a
GPS020 will therefore operate on the same flash character time base, and the lights in these systems
will flash in synchronization with each other.
The GPS020 has four LED’s inside the unit that can assist in determining the operating status of the
unit. Under normal operating circumstances it is not necessary to monitor these LED’s, they are
provided to give an understanding of the operating status during any troubleshooting activities.
GPS020 LAYOUT
Status LEDs
Connector for
cable to CIP100
controller
LED STATUS INDICATORS
PWR Green = Power ON
PPS Red = 1pps input time signal from

satellite system after satellite fix achieved
FIX Red = GPS satellite fix achieved
SYNC Red = OUTPUT SYNC

ON for 1 second every minute = 1ppm time
pulse to CIPxxx after satellite fix achieved.
Rev: 16.10.06 / ECN 22349
3.1 CONNECTIONS
The GPS020 is provided with a factory fitted cable for connection to the CIP100 (or CIP200) controller.
The connections to the CIP100 is made on the following termination points.
GPS020 cable connections

inside CIP100 CONTROLLER
Terminal 15 = Sync +
Terminal 16 = Sync –
Terminal 17 = Pwr 7V +
Terminal 18 = Pwr 7V –
The GPS020 is normally provided with a factory fitted connection cable. For reference the connections
inside the GPS020 are made to the plug and socket connector on the printed circuit board as follows;
GPS020 cable connections inside

GPS020
Terminal 1 = Pwr 7V +
Terminal 2 = no connection
Terminal 3 = Sync +
Terminal 4 = Sync –
Terminal 5 = Pwr 7V –
Terminal 6 = Connect to Earth rail
Rev: 16.10.06 / ECN 22349
4 MAINTENANCE
The GPS020 synchroniser unit is designed as a maintenance free unit.

Once the connections are properly and securely made and tested no further actions are required.
5 INSTALLATION INSTRUCTION
The GPS020 unit relies on acquiring a “fix” from a minimum of four GPS satellites. It is important that
the GPS020 units are mounted in such way that the antenna is pointed upwards, and that it has a clear
view of the sky. Be careful to consider how nearby structures might shield the GPS020 unit from the
satellites and so prevent them receiving the necessary signals.
If possible it is recommended to check the proposed position of the GPS020 unit before installation by
using a hand held GPS navigation device to make sure that at least four satellites are located.
Once an installation position is determined the correct operation of the GPS020 can be seen by
connecting the system and turning the system on.
The CIP100 controller has a “SYNC IN” LED which is ON if the CIP100 controller is receiving the sync
pulse from the GPS020.
The CIP200 controller will display the letter “S” on the top bar of the screen if the CIP200 controller is
receiving the sync pulse from the GPS020.
The SYNC indications on the CIPxxx controller will go off if no sync pulse is received for 3 minutes.
The GPS020 has a set of status LEDs inside which can be viewed by opening the enclosure cover (take
care not to touch the circuit boards).
The GPS020 can be attached to a suitable surface using the mounting lugs provided.
Orga can supply an optional mounting bracket to attach the GPS020 to a pole or tower leg.
Rev: 16.10.06 / ECN 22349
6 TROUBLESHOOTING
If a system of Orga high intensity and/or medium intensity obstruction lights fitted with the GPS020 unit
is not synchronizing with other similar systems then check the following points. Note that the GPS020
unit does not influence the synchronisation of the lights within a system (that is controlled by the CIP100
or CIP200), the GPS020 ensures synchronisation between different systems.
1. If possible open the cover from the GPS020 Synchroniser unit and check the status of the LEDs
in order to see if the power is still available to the GPS020.
2. If not check and restore power supply connections (7Vdc should be measured).
3. Check and note the status of the other LEDs on the GPS020 circuit board (PPS, FIX, SYNC).
4. Check the CIP100 or CIP200 is showing it is receiving the SYNC IN signal, if not and the
GPS020 appears to be working correctly based on it’s internal LED indicators check the correct
cable connections have been made between the GPS020 and the CIP100 or CIP200.
5. If the LEDs are operating, the CIP100 or CIP200 is showing it is receiving the SYNC IN signal
but the system is still not synchronizing with other systems, and assuming that the
synchronization signal is available, reset the GPS020 by disconnecting the power from the
GPS020 at the CIP100 terminal rail, wait for 5 minutes and reconnect the power to the GPS020.
6. If the system still does not synchronise with other systems please contact Orga for further
support.
Rev: 16.10.06 / ECN 22349
Type: ORGA L303-865 Medium intensity flash head
Siemens Wind Power A/S / Flylys type: ORCA L303-865 Flash Head / 715 / 728
Rev: 16.10.06 / ECN 22349
White Medium Intensity Light

H Type L303-865
J-1 Top Level Flash Head Junction Box
3 x Low Intensity Light Type L-810

¾
(Side Lights / Marker Lights)
J-2 Upper Level MLM Junction Box
2 x White Medium Intensity

½ Lights Type L303-865
J-1 Mid Level Flash Head Junction Box
¼ 3 x Low Intensity Light Type L-810

(Side Lights / Marker Lights)
J-2 Lower Level MLM Junction Box
CIP200
Controller
0
Figure 1 Simplified Diagram of a Multiple L303-865 Flash Head System
L303-865 Page 9 of 50
716 / 728 Siemens Wind Power A/S / Flylys type: ORCA L303-865 Flash Head /
42 / 54 Siemens Wind Power Rev:
A/S /16.10.06
Flylys type: ORCA
/ ECN L303-865 Flash Head /
22349
Rev: 16.10.06 / ECN 22349
5.0 FLASHHEAD SPECIFICATION

L303-865 Medium Intensity Flashing White Strobe Obstruction Light
5/8 “ (4x)
Application Marking of aviation hazards, typically structures such as

communication towers, antennas, electricity transmission and
distribution towers, chimneys, bridges and buildings.
Type L303-865.
Standard FAA, AC 150/5345-43E.
Effective intensity 20,000 Cd white nominal, during daytime.
2,000 Cd white nominal during nighttime.
Flash Character 40 flash per minute for L-865 white daytime mode and night time
mode, depending on photocell status, according to FAA
regulations.
Power Consumption 95W in daytime mode (average continuous at 40 fpm).
40W in nighttime mode (average continuous at 40 fpm).
Operating voltage 110-240VAC +/-10%, 50-60Hz.
Lens (Fresnel design) 300 mm diameter injection molded acrylic, UV resistant.
Divergence 360 degrees horizontal, 3 degrees @ 50% peak vertical.
Base material Polyurethane, UV-stabilized, high humidity resistant.
Mounting 4 holes of 5/8" at B.C.D. of 13¼".
Lamp Xenon flash tube.
Control Microprocessor based controller for power management, flash
character, and daylight on/off and failure alarm control.
Photocell Two internal photocells installed for automatic daytime and
nighttime operation and control.
Safety features Micro-switch provided to disconnect power on opening of the
flash head, “power connected” warning indication LED.
Alarm Volt free (dry) alarm contact for lamp failure in beacon, further
alarms and status information via CIP control unit.
Dimensions (lxdxh) Approx. 19" x 17" x 23", see drawing (485 x 435 x 585 mm).
Weight approx. 26 lbs (12 kg).
Cable integral 10-foot cable provided for connection to local junction
box.
Operating Temperature -55oC (-67 oF) to +55oC (131 oF)
Humidity 95% relative humidity
L303-865 Page 13 of 50
Rev: 16.10.06 / ECN 22349
10.0 POWERING UP PROCEDURE
The CIP unit will automatically confirm that the system is correctly installed and configured
when the incoming power supply is connected. It should not be necessary to change any
pre-set factory settings.
If anything is not working properly, see “trouble shooting” please refer to the Trouble
Shooting section of this manual, section 12.
11.0 MAINTENANCE
When convenient to do so, it is advised that the flash head units be inspected for any
mechanical or physical damage.
11.1 To Open the Flash head:
− Wherever possible the power supply to the flash head should be isolated prior to the
execution of any maintenance work.
− Release the four quick acting latches at the side of the top ring of the flash head, and
hinge them down.
− Open the flash head lens, by tilting it backward on its hinged section. Take care to
ensure that the lens hinges are securely in place to prevent the lens separating from the
base unit.
− Spring-loaded shaft hinges have been installed on the lens (see Figure 6), which must
be opened to completely remove the lens from the flash head. The lens must then be
lifted free of the flash head.
− Opening of the flash head activates the interlock micro switches – isolating the power
supply to the lamp control unit and discharging the capacitors. Wait until the flashing
indication LED is off to avoid electrical shock.
L303-865 Page 44 of 50
Rev: 16.10.06 / ECN 22349
Position of
concealed
lift-off hinges
Figure 6: Location of Flash Head

Lens Removal Hinges
11.2 To Close the Flash Head
− Because of possible condensation, it is advised to provide the fixture with a package of

drying agent powder (for example silica gel).
− Check before closing the flash head that the safety wire is not caught in the seal.
− Check if the "O" ring is in good condition, clean and properly positioned.
− Grease the "O" ring slightly with silicon grease.
− Close the flash head lens.
− Tighten the four latches.
L303-865 Page 45 of 50
Rev: 16.10.06 / ECN 22349
11.3 Flash Tube Replacement
− Isolate the power supply.

− Open the flash head (see section 11.1).
− Remove the flash tube, by turning its locking nuts counter clock wise.
− When released pull the flash tube from its socket
Warning:
Flash tube glass should not be touched with bare hands as the grease on your skin will
cause the glass to deteriorate, use it’s ceramic base as a grip. If the glass is touched,
wipe clean with cloth and alcohol.
− Install the replacement flash tube by inserting it into the base

− Fix the flash tube by turning its locking nuts clock wise.
− Close the flashhead (see section 11.2).
− Reconnect the incoming power supply.
11.4 Lens Replacement:
− Take tether cables off lens.

− Open the flash head (see section11.1)
− Open the lift-off hinges.
− Lift the lens from the base.
− Install the replacement lens.
− Lock the lift-off hinges.
− Close the flash head (see section11.2).
− Reattach tether cables to lens.
L303-865 Page 46 of 50
Rev: 16.10.06 / ECN 22349
Medium Intensity Strobe Obstruction Light
L303-864
L303-865
L303-864/865
L303-885
L303-866
Flashhead Internal Assembly Replacement Guide
Before installing the replacement internal unit please read

this manual carefully and retain it for future reference.
ORGA SUISSE SARL, HAMPTON, UNITED KINGDOM

Tel +44 (0) 20 8783 1211
Fax +44 (0) 20 8783 1911
E-mail : info@orga.org
Page 1/7
Rev: 16.10.06 / ECN 22349
Flashhead internal assembly replacement guide for L303 strobe light
Warning : “Do not look directly into the flashhead lens when the flashhead is operating – the flash
of light has an extremely high intensity”.
Tools
Medium size Philips type cross head screw driver.
Safety
Read through these instructions fully before starting.
Turn off the power supply to the system before starting.
Open the flashhead

Open the flashhead by releasing the four (4) latches and hinging the lens open.
Wait for five minutes before proceeding to allow the capacitors inside the unit to discharge to a safe level.
Safety Check
Identify the two photocells on each side of the cone. Looking from the front of the flashhead with the lens
hinged away from you the photocell on the left hand side of the cone has a label above it “ DANGER !!!
HIGH VOLTAGE INSIDE WHILE FLASHING.”
LED
This photocell has an LED positioned below the photocell device (see picture above).
If this LED is flashing red there is still high voltage present inside the unit.
Check that the power has been turned off.
Page 2/7
Rev: 16.10.06 / ECN 22349
Microswitches
Locate the position of the two microswitches next to the photocell on the right hand side of the cone when
looking from in front of the light with the lens hinged at the back away from you. These are safety switches
which discharge the internal capacitors when released.
The microswitches are spring loaded, check that the microswitches move freely and are in the up position.
Wait a further five minutes.
If the LED remains flashing do not proceed – this must mean that the power is still connected.
Recheck that the power supply to the system is turned off.
Remove the flashtube

Undoing the two locking screws that secure the flashtube to the holder.
Hold the flashtube by the ceramic base and gentle pull upwards.
Do not hold the flashtube by the glass parts.
Page 3/7
Rev: 16.10.06 / ECN 22349
Undo the cone locking screws

Use a Philips screwdriver to undo the four quarter turn release screws that hold the cone to the base.
Check the station number software configuration of the L303 strobe light
Lift the cone unit carefully upwards until you can see the green cable plugs.
Check the positions of the four rotary switches. The fourth switch (nearest to the corner of the circuit
board) is the one that indicates the station number setting of the light.
For Station 1 light the position of the switches will be 9-2-0-1 reading from right to left on the picture below
For Station 2 light the position of the switches will be 9-2-0-2 reading from right to left on the picture below
Ensure that any replacement light has the same factory set switch positions. If the switches are not in the
correct positions please contact Orga for advice.
Station number rotary switch
Page 4/7
Rev: 16.10.06 / ECN 22349
Disconnect the cable connections

Lift the cone unit carefully upwards until you can see the green cable plugs.
Grip the cable wrap and carefully pull the socket out of the plug of both of the two connected cables.
Grip the cable wrap and carefully pull the socket out of the plug of both of the two connected cables.
Page 5/7
Rev: 16.10.06 / ECN 22349
Remove the internal cone assembly from the base.

Lift the internal cone assembly away from the flashhead base.
Take care not to damage any of the components on the base of the internal units when they are not
installed in the flashhead base.
Place the old internal cone assembly into the packing supplied with the replacement unit.
Installation of the new replacement internal cone assembly
Installation of the new replacement internal cone assembly unit is achieved by following the above
sequence in reverse order.
Remove the new replacement internal cone assembly unit from the packing, keep the packing to return the
original internal cone assembly unit in.
Remove the flashtube from the new replacement internal cone assembly unit.
Undoing the two locking screws that secure the flashtube to the holder.
Hold the flashtube by the ceramic base and gentle pull upwards.
Do not hold the flashtube by the glass parts.
Position the new internal cone assembly on the base so that the safety microswtiches are correctly
positioned on the right hand side of the unit.
Reconnect the two cable connection plugs. The plugs can only be fitted into the correct socket and must
be the right way round, do not use undue force.
Position the cone assembly onto the base. If the cone appears not to properly sit on the base unit make
sure that the cables are not trapped.
Check that the safety microswtiches move freely when depressed.
Tighten the four locking screws.
Fit the flashtube

• Do not touch the glass parts with your fingers as this can lead to reduced lamp life.
• Hold the flashtube by the ceramic base, note the orientation of the pins and socket and fit the
flashtube into the holder.
• Tighten the locking screws finger tight only. Do not over tighten.
Close the lens and close the four latches.
Page 6/7
Rev: 16.10.06 / ECN 22349
Reconnect the power supply to the system.
Check the correct operation of the system.
Return the original internal cone assembly units to Orga as instructed.
Please include a note inside the box to identify for us :

• the site where the original unit was removed from
• the date of the exchange
• a brief description of the problem with the original unit
• a contact name and telephone number in case we need to find out more information.
Page 7/7
Rev: 16.10.06 / ECN 22349
Rev: 16.10.06 / ECN 22349
729 / 734
Beacon 1 BT 180-S
GPS
Rittal Cabinet Photocell
Antenna Beacon 2 BT 180-S
1
Beacon 1 Alarm 14 J7
Normaly closed relay contact. 1
15 3 1 50
Open on alarm. J4 2
2 51
1
Beacon 2 Alarm U2
16 J9
Normaly closed relay contact.
17 3
Open on alarm.
Day/Night Status 18 1
Closed contact in night mode. 1 10
19 2 J2
Sync
Open in day mode. 2 3 GND U3
3 4
J5 V+
4 5
LC 512 V- GPS
5 2 Receiver COAXIAL CABLE
6 D1-4
RY3 LED Light Suppressor
12 2 Diodes
Controller integrated in
11 14 3 Terminal Blocks
SW1
22 4
21
24 6 1
1 30
J6 2
A1 RY1 RY2 2 31
3
External Day/Night 12 12 1 1 32
- 24 A2
J1 J8
Siemens Wind Power A/S / Flylys type: BTI W-ROT

11 11 Yellow/Green
Control 14 14 2 2 33
Put on 24V DC for day mode. + 25
22 22 34 Shield
21 24 21 24
A1 A1
Low Intensity Select - 20 A2 A2
Put on 24V DC for 30% 1
Intensity. + 21 40
2
41
42 3
Low Intensity Select - 22 43 Yellow/Green
Put on 24V DC for 10% Shield
Rev: 16.10.06 - ECN 22349

Intensity. + 23 44
Overvoltage Protection
Status 230V 12
Normaly closed. Open when 13
overvoltage protection is damaged.
F1 11 12
+
Power Input 2 1 5 U4 6 U1
L 1 L
85-265V AC / 45-65Hz N 2 10A AC/DC
Average consumption N N 1 2
70VA.
PE 3 N 24V
Type: BTI W-ROT (option)
-
1.11 1.14
J1
Primary circuit breaker
monitor. 10
Normaly closed contact. Open 11
when circuit breaker is open.
BTI BRØNDBERG & TANDRUP
INTERNATIONAL A/S
Bygmestervej 6

DK-2400 Copenhagen NV
Denmark CB 180-S
Phone +45 35815800
Fax +45 35820099 Circuit Diagram
REVISED DRAWN BY SIZE FSCM NO DWG N O REV
13-09-2006 CN 284.06.010 1
DATE FILENAME
14-03-2001 CD.VSD SCALE 1:1 SHEET 1 OF 1
Beacon 1 BT 180-S
BT 180-S:
GPS
Rittal Cabinet Photocell
Antenna 170 candela Feuer W-Rot in night Beacon 2 BT 180-S
mode.
Switched off in day mode.
1
Beacon 1 Alarm 14 J7
Normaly closed relay contact. 1
15 3 1 50
Open on alarm. J4 2
2 51
1
Beacon 2 Alarm U2 FTW170 GPS
16 LC 512: J9
Normaly closed relay contact. Receiver:
17 3
Open on alarm.

LC 512 is a dual channel The GPS receiver
Day/Night Status 18
controller for the BT 180
1 generate a 5V/50mS
Closed contact in night mode. lantern. It generate the W-rot1 10
19 2 J2 pulseSync
once per
Open in day mode. character, and monitors the 2 3 GND
minute. An Error
3
power consumption in the
U3
Overvoltage 4 on the board
J5
lanterns.
LED V+
4 Protection: 5
LC 512 indicates
V- when GPS less
5 than
2 three satelites
Receiver COAXIAL CABLE
It 6has integrated alarm relays, Suppressor Diodes for are being received.
status relays, day/night
LED Lightcontrol D1-4 Suppressor
RY3Relay:
Control lightning protection of The LED can remain
12 circuit,
2 and Controller
buffered sync Diodes
the system. lit approx. 20
11 output. integrated in
Control Relay for 14 3 minutes after a cold Terminal Blocks
SW1
Rev: 16.10.06 - ECN 22349

external control of22 4 start-up. Overvoltage Protection:
21
the switching 24 6 1
between day & 1 Suppressor Diodes integrated
30
night mode . J6 in Terminal Blocks for lightning 2
A1 RY1Relay:
Control RY2Relay:
Control 2 31
protection of the system. 32 3
External Day/Night 12 12 1 1
Control
- 24 A2
Normaly inactive. 11
Control Relay for 14
11
Control Relay for14 2
J1 J8
2 33 Yellow/Green
Put on 24V DC for day mode. + 25
reducing the light 22
to reducing the light22 34
Shield
21
30% intensity in 24 to 10% 21 intensity 24
in
case off good case off good
visibility. A1 visibility. A1
Low Intensity Select - 20 A2 A2
Normaly inactive. Normaly inactive.
Put on 24V DC for 30% 1
Intensity. + 21 40
2
41
42 3
Low Intensity Select - 22 43 Yellow/Green
Put on 24V DC for 10% Shield
Intensity. + 23 44
Overvoltage Protection
Status 230V 12
Normaly closed. Open when 13
F1 11 12
Overvoltage
protection Power Supply: +
Power Input Automatic
2 Fuse: 1 circuit
5 for
U4 6 U1
L 1
230V AC L Switch Mode Power
24V
85-265V AC / 45-65Hz AC/DC
N 2 10A 10A
N automatic fuse for
N input. Supply for LC 512 and
Average consumption 1 2
70VA. PE 3 protection, and auxilary control
N relays.
24V
switch for monitoring The status of -
1.11
the status of fuse. 1.14 the circuit can
be monitored
on terminal
12 & 13.
J1
Primary circuit breaker
monitor. 10
Normaly closed contact. Open 11
when circuit breaker is open.
730 / 734
BTI
BRØNDBERG & TANDRUP
INTERNATIONAL A/S
Bygmestervej 6
Denmark CB 180-S
Phone +45 35815800
Fax +45 35820099 System Description
REVISED DRAWN BY SIZE FSCM NO DWG N O REV
13-09-2006 CN 284.06.040 1
DATE FILENAME
14-03-2001 SD.VSD SCALE 1:1 SHEET 1 OF 1
Beacon 1 Beacon 2
BT 180-S BT 180-S
Photocell Antenna
4 x 1,5mm² 4 x 1,5mm²
Yellow/Green
Yellow/Green
Shield
Shield
1
3
U3
30 31 32 33 34 50 51 GPS 40 41 42 43 44
Rittal Cabinet
1 2 3 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
L N PE
Overvoltage protection status 230V.
Power Input
Open when circuit breaker is open.
85-265V AC
Primary circuit breaker monitor.
Put on 24V DC for 30% intensity.
Put on 24V DC for 10% intensity.
45-65Hz
Closed contact in night mode.
Put on 24V DC for day mode.

External Day/Night Control.
Normaly closed. Open when
Average
Normaly closed contact.
consumption 70VA
Low Intensity Select.
Low Intensity Select.

Open in day mode.
Day/Night Status.
Beacon 1 alarm.
Beacon 2 alarm.
Open at alarm.
Open at alarm.
Alarm & Monitor Control inputs
BTI
INTERNATIONAL A/S Siemens Wind Power A/S
Bygmestervej 6
Denmark CB 180-S
Phone +45 35815800
Fax +45 35820099 Electrical Wiring Diagram
REVISED DRAWN BY SIZE FSCM NO DWG NO REV
13-09-2006 CN 284.06.001 1
DATE FILENAME
10-09-2003 EWD.VSD SCALE 1:1 SHEET 1 OF 1
Siemens Wind Power A/S / Flylys type: BTI W-ROT 731 / 734
Rev: 16.10.06 - ECN 22349
U1
24V
U2
1 Character Generator

2
3
10
11
12
13 U3
14
15 GPS
Rev: 16.10.06 - ECN 22349

16
17
18
19
20
21
22
23
24
25
30
31
32
33
34
40
41
42
43 F1 U4 J1 RY1 RY2 RY3
44
50
51
BTI BRØNDBERG & TANDRUP
INTERNATIONAL A/S
Bygmestervej 6
Denmark CB 180-S
732 / 734
Phone +45 35815800
Fax +45 35820099 Component Location
13-09-2006 CN 284.06.020 1
DATE FILENAME
14-03-2001 CL.VSD SCALE 1:1 SHEET 1 OF 1
PARTS LIST
No. Ref. Description Type/value Order No. Manufactor

1 F1 Autofuse 1P + N 10A 242268 Moeller
1 F1 Auxillary Switch ZP-NHK 248437 Moeller
1 J1 Schuko Power Connector EMG 45-SD-D/SC/LA/SI/YE 2940825 Phoenix
3 RY 1-3 Relay C7-A20/24V DC C7-A20/24V DC Releco
4 D1-4 Suppressordiode 1.5KE36CA 486-4347 RS Components
1 U1 Switch Mode Power Supply 230V 24V 12,5A SP-320-24 Meanwell
1 U2 LED Light Controller LC 512 LC 512-3 BTI
1 U3 GPS Receiver FTW-170 FTW-170 Flash Technologies
1 U4 Plugtrab PT 2-PE/S-230AC 2858357 Phoenix
5 Terminal Block GND ST 4-PE 3031380 Phoenix
18 Terminal Block ST 4 3031364 Phoenix
8 Terminal Block TT-STTB-PE-24 2858182 Phoenix
5 Stop Bracket E/NS 35N 0800886 Phoenix
3 RY 1-3 Relay Socket S7-M S7-M Releco
1 Cabinet Rittal AE 1038 1038.500 Rittal
1 Wall Mounting SZ 2433.000 2433.000 Rittal
1 Gas Spring Lift-O-Mat 150N 082503 Stabilus
1 Cable Gland RST M12 RST M12 Bernstein
1 Photocell PEC 510 PEC 510 Flash Technologies

1 GPS Antenna 40767-00 40767-00 Trimble
1 Box Polyester 02.08 11 08 Rose
1 Cable Gland RST PG16 RST PG16 Bernstein
2 Lantern 170Cd W-Rot BT 180-S BTI

30 Cable for Lantern 4 G 1,5mm² Ölflex Robust 215C Lapp Kabel

Brøndberg Tandrup International A/S CB 180-S
Bygmestervej 6 284.06.030
DK 2400 Copenhagen NV Parts List.xls Rev. 1
Phone +45 35815800 Fax +45 35820099 22-09-2006 / CN Page 1of 1
Siemens Wind Power A/S / Flylys type: BTI W-ROT 733 / 734
Rev: 16.10.06 - ECN 22349
734 / 734 Siemens Wind Power A/S / Flylys type: BTI W-ROT
Rev: 16.10.06 - ECN 22349
Type: BTI low intensity (option)
OL20 Obstruction Light
Electrical connection
Yellow/green
Shield
1 2 3 4 5 6
1-2: 24V AC/DC, polarity not importent.
3-4: (If present) Alarm Relay, Normaly closed,

open at alarm.
5-6: (If present) Extern Control Input. Put 5V DC on

wire #5 to switch off the light. 0V on wire #6.
Yellow/Green and Shield: Connect to earth.
Alignment
It is important that the light is aligned to the

horizontal plane due to the vertical light angle.
Use the spirit level for accurate alignment.
BTI
INTERNATIONAL A/S
OL20 Obstruction Light
Bygmestervej 6
Denmark
Phone +45 35815800 Installation Notes
Fax +45 35820099

25-04-2006 CN 244.06.101 1
DATE FILENAME
28-03-2006 INSTALLATION.VSD SCALE 1:1 SHEET 1 OF 1
Siemens Wind Power A/S / Flylys type: BTI Lavintensitet / 735 / 736
Rev: 16.10.06 - ECN 22349
736 / 736 Siemens Wind Power A/S / Flylys type: BTI Lavintensitet /
Rev: 16.10.06 - ECN 22349
- Chapter 26 SALA FALL PROTECTION SYSTEM

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 26 SALA FALL PROTECTION SYSTEM

SWT - 2.3 - 82VS/93/101
• Appendix - Data sheet, aviation light (option)

yyyy)

Document history

93/101

Appendix - Data sheet - SALA fall protection system (only

US)
See , “SALA fall protection system - User manual,”


SALA fall protection system - User manual
USER INSTRUCTIONS 2 LAD-SAF®

Flexible Cable Ladder Safety Systems
1
A Capital Safety Company x1-4 I S O

3
ANSI Z359
9001
&HUWL¿FDWH1o)0 ANSI A14.3
EN 353-1:2002
CSA Z259.2.1
3
10
FORM NO: 5902228 © Copyright 2009, DB Industries, Inc.
REV: M
SALA fall protection system - User manual 741 / 776

Rev: 14.07.09 / ECN 30997

FORWARD
This instruction describes installation and use of Lad-Saf® Flexible Cable Ladder Safety Systems. It
should be used as part of an employee training program as required by OSHA, ANSI, CSA, and CE.
WARNING: These instructions must be provided to the user and installer of this equipment. The
user and installer of this equipment must read and understand these instructions before use or
installation. Follow the manufacturer’s instructions for safety equipment used with this system.
Follow these instructions for proper use, inspection, and maintenance of this equipment. This
equipment is intended to be used as part of a complete LAD-SAF® ladder safety system. Alterations,
substitutions, or misuse of this equipment, or failure to follow instructions, may result in serious
injury or death.
IMPORTANT: If you have questions on the installation, use, maintenance, or suitability of this
equipment for your application, contact DBI-SALA.
IMPORTANT:%HIRUHXVLQJWKLVHTXLSPHQWUHFRUGWKHSURGXFWLGHQWL¿FDWLRQLQIRUPDWLRQIURPWKH
installation and service label in the maintenance log in section 9.0 of this manual.
PART LISTS AND PART REFERENCES

The Part Lists in the next section of this instruction illustrate and list the parts that can comprise a
typical Lad-Saf® Ladder Safety System. Because various part types may have multiple part options and
SDUWQXPEHUVSDUWUHIHUHQFHVLQWKHHQVXLQJLQVWUXFWLRQVZLOOXVHWKH,WHP1XPEHUGH¿QHGLQWKHOHIW
hand column of each Part List (e.g., TB-1, BB-5, etc.) where appropriate. Refer back to the Part Lists
for associated part numbers.
GLOSSARY REFERENCE BOXES

3 Numbered Glossary Reference Boxes on the front cover of this instruction reference
the following items:
1: Flexible Cable Ladder Safety Systems 2 : User Instructions 3 : Standards 4 : Top Bracket
5: Cable 6 : Full Body Harness with Front Attachment 7 : Detachable Cable Sleeve 8 : Cable
Guide 9 : System Label with i-Safe™ RFID Tag 10 Bottom Bracket
742 / 776 SALA fall protection system - User manual

Rev: 14.07.09 / ECN 30997

Figure 1: Part List TB - Top Brackets
ITEM ANSI, CSA, AS/NZS CE DESCRIPTION

TB-1 6116054 6116054 Top Bracket Galvanized
TB-2 6116056 KC36116056 Top Bracket Galvanized
TB-3 6116280 KC3PL280 Top Bracket Galvanized
TB-4 6116210 KC3PL210 Top Bracket Stainless Steel
TB-5 6116224 6116224 Top Bracket Galvanized

Rev: 14.07.09 / ECN 30997

Figure 1 (continued): Part List TB - Top Brackets

TB-8 6116120 6116120 Top Bracket, Galvanized, Telescoping
6116005 KC36110020 Top Bracket, Stainless Steel for 1-1/4” rung (2 clamps)
6116050 6116050 Top Bracket, Galvanized for 2” x 1-1/2” rung
TB-9 6116052 6116052 Top Bracket, Galvanized for 1-1/2” rung
6116325 6116325 Top Bracket, Stainless Steel for 1-1/8” rung
6116328 6116328 Top Bracket, Galvanized for 1-1/8” x 2” rung
TB-10 6116410 6116410 Top Bracket, Galvanized
TB-11 6116010 KC3PL10 Curved Ladder Top Bracket, Galvanized
TB-12 6116016 6116016 Curved Ladder Top Bracket, Stainless Steel

Rev: 14.07.09 / ECN 30997

Figure 1 (continued): Part List TB - Top Brackets

6116048 6116048 Top Bracket, Galvanized for 1-1/2” x 1-1/2” angle x 30o
6116051 6116051 Top Bracket, Galvanized for 1-1/4” angle
6116055 6116055 Top Bracket, Galvanized for 1” x 3/4” angle
TB13
6116057 6116057 Top Bracket, Galvanized for 1-1/2” x 1-1/2” angle
6116059 6116059 Top Bracket, Galvanized for 1” angle
6116282 KC36116282 Top Bracket, Galvanized for 1-1/2” x 1-1/2” angle (square spacer)
6116286 6116286 Top Bracket, Galvanized for 1-1/2” x 1-1/2” rung
6116290 6116290 Top Bracket, Galvanized for 1-3/4” round rung
6116291 6116291 Top Bracket, Galvanized for 1-3/4” x 2-1/4” rung
6116292 6116292 Top Bracket, Galvanized for 2-1/2” x 3/8” rung
TB14 6116293 6116293 Top Bracket, Galvanized for 2” x 1” rung
6116294 6116294 Top Bracket, Galvanized for 2” x 2” rung
6116324 6116324 Top Bracket, Stainless Steel for 2” round rung

Rev: 14.07.09 / ECN 30997

Figure 2: Part List BB - Bottom Brackets

6100090 KC3PL90 Bottom Bracket, Galvanized
6100091 KC36100091 Bottom Bracket, Galvanized, Extra-Long

BB-1
6100092 6100092 Bottom Bracket, Galvanized, 37”
6100093 6100093 Bottom Bracket, Galvanized, 48”
6100060 6100060 Bottom Bracket, Galvanized for 2” x 1-1/4” rung
6100070 6100070 Bottom Bracket, Stainless Steel

BB-2
6100073 6100073 Bottom Bracket, Stainless Steel for 1-1/8” x 2” rung
6100128 6100128 Bottom Bracket, Galvanized for 1-1/2” rung
6100072 6100072 Bottom Bracket, Stainless Steel for 2” round rung
6100100 KC361001W Bottom Bracket, Galvanized for 1-1/2” x 1-1/2” rung
6100110 6100110 Bottom Bracket, Galvanized for 1-1/4” x 2-1/4” rung
6100111 6100111 Bottom Bracket, Galvanized for 4” x 2” rung
BB-3 6100112 6100112 Bottom Bracket, Galvanized for 2” x 1” rung
6100113 6100113 Bottom Bracket, Galvanized for 1-3/4” round rung
6100114 6100114 Bottom Bracket, Galvanized for 2-1/2” x 3/8” rung
BB-4 6100095 KC3PL95 Bottom Bracket, Stainless Steel
BB-5 6100224 6100224 Bottom Bracket, Stainless Steel
BB-6 6100015 KC3PL822 Bottom Bracket, Galvanized

Rev: 14.07.09 / ECN 30997

Figure 2 (continued): Part List BB - Bottom Brackets

6100035 KC36100035 Bottom Bracket, Galvanized
BB-7
6100038 KC36100038 Bottom Bracket - Stainless Steel
BB-8 6100045 6100045 Bottom Bracket, Galvanized
6100055 6100055 Bottom Bracket, Galvanized for 1-1/2” x 1-1/2” angle 30o
6100065 KC36100065 Bottom Bracket, Galvanized for 1-1/2” x 1-1/2” x 3/16” angle
(square spacer)
BB-9
6100131 6100131 Bottom Bracket, Galvanized for 1/14” angle
6100132 6100132 Bottom Bracket, Galvanized for 1-3/4” angle
6100134 6100134 Bottom Bracket, Galvanized for 1” rung

Rev: 14.07.09 / ECN 30997

Figure 3: Part List CG - Cable Guides

CG-1 6100249 6100249 Cable Guide, Stainless Steel, 45O bend
CG-2 6100140 6100140 Cable Guide
6100400 KC3PL330 Cable Guide, Galvanized
CG-3 6100401 6100401 Cable Guide, Stainless Steel
6100402 6100402 Cable Guide, Galvanized, 1-3/4” center
6100430 KCPL379 Cable Guide, Galvanized
6100431 6100431 Cable Guide, Galvanized

CG-4
6100432 6100432 Cable Guide, Stainless Steel
6100435 6100435 Cable Guide, Stainless Steel, 4” extra length
6100420 6100420 Cable Guide, Galvanized, (Stainless Steel hardware), 1-1/4” x 2” rung
6100421 6100421 Cable Guide, Stainless Steel, 1-1/4” x 2” rung
6100422 6100422 Cable Guide, Stainless Steel, 1-3/4” x 1-3/4” rung
CG-5 6100425 6100425 Cable Guide, Stainless Steel, 2” x 1” rung
6100426 6100426 Cable Guide, Stainless Steel, 2” x 2” rung
6100427 6100427 Cable Guide, Stainless Steel, 1-5/8” x 1” rung
6100428 KC36100428 Cable Guide, Galvanized, 1-1/2” rung
6100457 KC3PL333 Cable Guide, Stainless Steel
6100448 KC36100448 Cable Guide, Stainless Steel, 1-1/15” angle rung
6100449 6100449 Cable Guide, Stainless Steel, 2-3/8” x 7/8” rung

CG-6
6100453 6100453 Cable Guide, Stainless Steel, 1-1/4” angle rung
6100454 6100454 Cable Guide, Stainless Steel, 1” x 3/4” angle
CG-7 6100525 6100525 Cable Guide, Stainless Steel, 1-1/2” angle rung
CG-8 6100455 6100455 Cable Guide, Stainless Steel, 1-1/4” x 1-1/4” angle
6100505 KC3PL190 Cable Guide, Stainless Steel

CG-9
6100506 6100506 Cable Guide, Stainless Steel, 1-1/4” x 1-1/4” x 3/16” angle

Rev: 14.07.09 / ECN 30997

Figure 3 (continued): Part List CG - Cable Guides

6100460 6100460 Cable Guide, Stainless Steel, w/Twist 39O
CG-10 6100461 6100461 Cable Guide, Stainless Steel, w/Twist 27O
6100462 6100462 Cable Guide, Stainless Steel, w/Twist 45O
CG-11 6100475 6100475 Cable Guide, Stainless Steel, 1-1/2” x 1-1/2” angle 30O
CG-12 6100533 6100533 Cable Guide, Stainless Steel, w/Latch and Clamp Plate
CG-13 6100532 6100532 Cable Guide, Galvanized, w/Latch
6100530 KC36100530 Cable Guide
CG-14
6100531 6100531 Cable Guide, no U-Bolt
6100515 KC3PL105 Cable Guide, Galvanized
CG-15 6100516 KC36100516 Cable Guide, Galvanized, w/Caps
6100517 6100517 Cable Guide, Stainless Steel
CG-16 6100470 6100470 Cable Guide
6100520 6100520 Cable Guide, Stainless Steel, 4.313” long
6100521 6100521 Cable Guide, Galvanized, w/Caps
CG-17
6100522 6100522 Cable Guide, Galvanized
6100523 KC3PL310 Cable Guide, Stainless Steel, 4.125” long

Rev: 14.07.09 / ECN 30997

Figure 4: Part List SO - Stand-Offs

SO-1 Top/Bottom Bracket Horizontal Stand-Off
SO-2 6100710 KC36100710 Top/Bottom Bracket Weld-On Stand-Off
SO-3 Cable Guide Round Leg Stand-Off Support
6100600 6100600 Top/Bottom Bracket Angle Stand-Off, 60O angle, 2” - 2-1/2” angle size, Stainless Steel
6100601 6100601 Top/Bottom Bracket Angle Stand-Off, 60O angle, 3” - 3-1/2” angle size, Galvanized
O
SO-4 6100636 6100636 Top/Bottom Bracket Angle Stand-Off, 90 angle, 3” - 3-1/2” angle size, Galvanized
6100644 6100644 Top/Bottom Bracket Angle Stand-Off, 90O angle, 3-1/2” - 4”angle size, Stainless Steel
SO-5 Top/Bottom Bracket Round Leg Stand-Off
O
6100610 6100610 Cable Guide Angle Leg Stand-Off Support, 60 angle, 2” - 2-1/2” angle size, Galvanized
6100611 6100611 Cable Guide Angle Leg Stand-Off Support, 60O angle, 3” - 3-1/2” angle size, Galvanized
6100612 6100612 Cable Guide Angle Leg Stand-Off Support, 60O angle, 3” - 3-1/2” angle size, Stainless Steel
SO-6 6100623 6100623 Cable Guide Angle Leg Stand-Off Support, 90O angle, 4” - 4-1/2” angle size, Galvanized
O
6100629 6100629 Cable Guide Angle Leg Stand-Off Support, 90 angle, 8” - 8-1/2” angle size, Galvanized
O
6100630 6100630 Cable Guide Angle Leg Stand-Off Support, 90 angle, 8” - 8-1/2” angle size, Stainless Steel
6100631 6100631 Cable Guide Angle Leg Stand-Off Support, 90O angle, 3-1/2” - 4” angle size, Stainless Steel
6100135 6100135 Cable Guide Stand-Off Support, Galvanized
SO-7
6100136 KC36100136 Cable Guide Stand-Off Support, Stainless Steel

Rev: 14.07.09 / ECN 30997

Figure 5: Part List LS - LAD-SAF® Detachable Sleeves
ITEM ANSI, CSA CE MANUAL DESCRIPTION

LS-1 6116541 5902112 Flex Sleeve, 8.0 mm or 9.5 mm (5/16” or 3/8”), Sleeve Only
(ANSI A14.3, CSA Z259.2.1)
LS-2 6116540 5902112 Flex Sleeve, 8.0 mm or 9.5 mm (5/16” or 3/8”), w/Carabiner
(ANSI A14.3, CSA Z259.2.1)
LS-3 6116506 5902112 Flex Sleeve, 8.0 mm, w/Captive Aluminum Carabiner
(EN353-1:1993)
LS-4 6116507 5902414 Flex Sleeve, 8.0 mm or 9.5 mm (5/16” or 3/8”), w/Shock Pack
(EN353-1:2002) & Carabiner

Rev: 14.07.09 / ECN 30997
1.0 APPLICATIONS
1.1 PURPOSE: LAD-SAF®ÀH[LEOHFDEOHODGGHUVDIHW\V\VWHPVDUHGHVLJQHGWRSURYLGHSURWHFWLRQDJDLQVWIDOOLQJ

IRUSHUVRQVFRQQHFWHGWRWKHV\VWHPZKLOHFOLPELQJ¿[HGODGGHUVRUVLPLODUFOLPELQJVWUXFWXUHV
A. APPLICATIONS: LAD-SAF®V\VWHPVLQFOXGHLQVWDOODWLRQVRQ¿[HGODGGHUVRUODGGHUOLNHFOLPELQJ
surfaces that are part of a structure. Examples include; water tank ladders, mono poles (wood, steel, or
concrete) buildings, manways, antenna structures, and towers.
1.2 LIMITATIONS: LAD-SAF® systems are not intended to be installed on portable ladders. These systems are
designed for use on ladders that are generally vertical. Ladders must be at least 75 degrees from horizontal
for proper system operation, except for curved top bracket installations. The following application limitations
must be considered before installing or using the LAD-SAF® system.
A. LADDER STRUCTURE: The ladder structure to which the system is installed must be capable of
withstanding the loads applied by the system in the event of a fall (see Section 2.3).
B. SYSTEM CAPACITY: The number of users allowed on the system at one time varies depending on the
type of system and installation. Generally, system capacities range from one to four users. See sections
2.0 and 3.0 for more information on capacity limitations. System capacities are based on a maximum
user’s weight, including tools and clothing, of 310 lbs (140.6 kg).
C. FALL CLEARANCE: Fall clearance below the feet of the user and the ground or other surfaces must not
be less than 7 ft. (2 m).
D. ENVIRONMENTAL HAZARDS: Use of this equipment in areas with environmental hazards may
require that additional precautions be taken to reduce the possibility of injury to the user or damage
to the equipment. Hazards may include, but are not limited to: high heat caused by welding or metal
cutting; caustic chemicals; seawater; high voltage power lines; explosive or toxic gases; moving
machinery; sharp edges.
E. COMPONENT COMPATIBILITY: LAD-SAF® systems must be installed and used as a complete
system. Only DBI-SALA’s detachable cable sleeve (see Figure 5) may be used with this system. DBI-
SALA recommends using a full body harness with a front attachment for ladder climbing. A body belt
is not recommended for use with the LAD-SAF® system. If a fall occurs when using a body belt it may
cause unintentional release and possible suffocation because of improper body support. Substitutions of
equipment or system components must not be made without the written consent of DBI-SALA.
F. TRAINING: This equipment is intended to be installed and used by persons who have been trained in
its correct application and use.
1.3 Refer to applicable local, and national requirements governing this equipment for more information on
ladder safety systems and associated components, including OSHA 1910.27.
2.0 SYSTEM REQUIREMENTS
2.1 COMPATIBILITY OF COMPONENTS AND SUBSYSTEMS: This equipment is designed for use with DBI-
SALA approved components and subsystems. The use of non-approved components and subsystems may
jeopardize compatibility of equipment, and could affect the safety and reliability of the complete system.
2.2 COMPATIBILITY OF CONNECTORS: Connectors used with this system (hooks, carabiners, D-rings)
must be capable of supporting a minimum of 5,000 lbs (22.2 kN). Use caution to assure compatibility of
hooks and the connection point. See section 4.4 on making connections. Non-compatible connectors may
unintentionally disengage (roll-out). Connectors must be compatible in size, shape, and strength. Self
closing/self locking connectors are highly recommended by DBI-SALA.

Rev: 14.07.09 / ECN 30997
2.3 LOAD REQUIREMENTS FOR STRUCTURE AND BRACKET CONNECTIONS: The climbing structure to which
the LAD-SAF® system is installed must be capable of supporting the loads imposed by the system. For calculation
purposes the required bracket load may be assumed to be distributed evenly between the number of rung
attachments. For example; the TB-3 top bracket is supplied with three rung connections. The load required for
each rung for a single user system is 1,125 lbs (5.0 kN) per rung (3,375 lbs [15.0 kN]/3).
A. TOP BRACKET: The top bracket connection loads include system pretension and forces associated with
arresting a fall. Load requirements for the top bracket vary depending on the number of users allowed
on the system at one time, top bracket model, and type of connection to the structure.
1. The following top brackets allow up to four users on the system at one time:
Item Numbers; TB-2, TB-3, TB-4, TB-6, TB-7, TB-10 and Part Numbers; 6116048, 6116050, 6116051,
6116052, TB-1, 6116055, 6116057, 6116059, TB-5, 6116282, 6116286, 6116290, 6116291,
6116292, 6116293, 6116294, 6116295, 6116296, 6116328.
Note: Other installation requirements may limit the number of users allowed on a system. See section 3.0.
Top Bracket Connection Loads: One user on the system: 3,375 lbs (15.0 kN)
Two users on the system: 4,350 lbs (19.3 kN)
Three users on the system: 5,325 lbs (23.7 kN)
Four users on the system: 6,300 lbs (28.0 kN)
Exception: TB-1 top bracket is designed for use with 6116336 or 6116337 grab bar extension. When
the grab bar is used as a connection for a personal fall arrest system the bracket connection must
VXSSRUWDPLQLPXPRIOEVN1RUOEVN1IRUDFHUWL¿HGDQFKRUDJH6HH$16,
Z359.1 and OSHA regulations.
2. These top brackets allow one user only:
Item Numbers; TB-8, TB-11 and Part Numbers; TB-9 (KC36110020), 6116325, and 6116324
Top Bracket Connection Loads: One user on the system: 3,375 lbs (15.0 kN)
B. BOTTOM BRACKET: The bottom bracket connection must be capable of supporting a system
pretension load of 750 lbs (3.3 kN) in the direction of loading.
3.0 SYSTEM INSTALLATION
3.1 LAD-SAF® systems are designed for easy installation onto a variety of ladder structures. To begin the
installation you need to know the model numbers of the top and bottom brackets, cable guides, and type of
cable (galvanized or stainless steel). Figures 1, 2, and 3 identify most models. Some brackets are designed
to be installed using stand-off supports which go between the bracket and structure. You need to know
model numbers of stand-off supports if included with your system. See Figure 4 for model numbers of most
stand-off supports. Follow the instructions for the models included in your system.
Generally, the LAD-SAF® system is installed from the top of the ladder down. The basic procedure is:
Step 1. Install the top bracket

Step 2. Connect the cable to the top bracket
Step 3. Install the cable guides
Step 4. Install the bottom bracket
Step 5. Tension the cable
Step 6. Inspect the installation
Planning the installation can minimize the amount of time on the ladder and improve safety.
WARNING: Use caution when installing LAD-SAF® systems. Wear personal protective equipment,
including safety glasses and steel-toed shoes. Use personal fall arrest or restraint systems when
exposed to a fall hazard. Use caution when installing LAD-SAF® systems near electrical power lines.
LAD-SAF® cables are conductive. Do not connect to a partially installed LAD-SAF® system.
3.2 WELDING RECOMMENDATIONS: Some installations require welding brackets to the structure. DBI-SALA
UHFRPPHQGVWKDWZHOGLQJEHFRPSOHWHGE\DFHUWL¿HGSURIHVVLRQDOZHOGHULQDFFRUGDQFHZLWKDSSOLFDEOH
QDWLRQDOZHOGLQJFRGHVRUVWDQGDUGV%DVHDQG¿OOHUPDWHULDOVPXVWEHFRPSDWLEOHZLWKJDOYDQL]HGRU
VWDLQOHVVVWHHOGHSHQGLQJRQWKHPDWHULDOVRI\RXUV\VWHP3URWHFW¿QLVKHGZHOGVIURPFRUURVLRQZLWK
coating or paint.

Rev: 14.07.09 / ECN 30997
3.3 TOP BRACKET INSTALLATION: Before
installing the top bracket it is recommended that Figure 6 - Installing Top Brakcets
the ladder or climbing structure be evaluated
E\DTXDOL¿HGHQJLQHHUWRGHWHUPLQHLIWKHORDG
UHTXLUHPHQWVIRUWKHV\VWHPDUHVDWLV¿HG Height
above
Top
A. INSTALLATION OF TB-2, TB-3, TB-10 Height above Connection
TOP BRACKETS: Top Connection
Direct Connection to Ladder:

See Figure 6 for typical installations of the
TB-3, TB-10, and TB-2 top brackets onto a
round rung ladder. The top bracket should be
positioned to allow users safe access when
connecting or disconnecting from the system.
The top bracket is typically mounted in the
center of the climbing surface for ease of
climbing, but may be located towards the side
of the ladder if required.
TB-3, TB-10:
7KHWRSEUDFNHWPD\EHLQVWDOOHGZLWKXS
to four feet extending above the top rung
connection for systems limited to one
user. This will allow the use of only two
ladder rung clamps. Ensure the ladder will
withstand the required loads between the
two rungs.
TB-2 & TB-3 TB-10
7KHWRSEUDFNHWPD\EHLQVWDOOHGZLWKXS Installation Installation
to three feet extending above the top rung

connection for systems allowing up to two
users simultaneously.
7KHWRSEUDFNHWPD\EHLQVWDOOHGZLWKXSWRWZRIHHW
Figure 7 - Stand-off Support
extending above the top rung connection for systems
Connection
allowing up to four users simultaneously.
TB-2:
7KHWRSEUDFNHWPD\EHLQVWDOOHGZLWKXSWR¿YHIHHW
extending above the top bracket connection for systems
allowing up to four users simultaneously.
WARNING: One rung clamp (two for the TB-10 bracket) is designed
to bolt through the bracket and onto the rung. This clamp must not
be omitted, or the bracket may slip under load.
Install rung clamps using the hardware provided. Do not
substitute other fasteners. Torque fasteners to 20-25 ft-lbs
(27.1-33.9 N-m).
Stand-off Support Connection:
Figure 6 shows the installation of the TB-3 top bracket using
a horizontal stand-off bracket. These installations are limited
to one user on the system at a time. Use hex bolts in place of
U-bolts to attach the TB-3 top bracket to the horizontal stand-
off. Torque fasteners to 20-25 ft-lbs (27.1-33.9 N-m).
Ladder Rung Support:
Figure 8 shows the installation of the 6100151 ladder rung
support piece. The rung support is used to support hollow
rungs with a minimum inside diameter between 1 in. (2.54 cm) TB-3 Installation
and 1-1/8 in. (2.86 cm). In some applications the ladder rungs with Horizontal Stand-Off

Rev: 14.07.09 / ECN 30997
Figure 8 - Ladder Rung Support Piece
17” (43 cm) Max

outside dimension

Rev: 14.07.09 / ECN 30997
must be supported in order to meet required strengths and
to prevent rung collapse. The rung support piece can be Figure 9 - Installing Top Bracket
used on those rungs supporting top brackets, cable guide and Grab Bar
and bottom brackets.
The ladder or climbing structure must be evaluated by a
TXDOL¿HGHQJLQHHUWRGHWHUPLQHLIWKHORDGUHTXLUHPHQWVIRU
WKHV\VWHPZLWKUXQJVXSSRUWVDUHVDWLV¿HG
Install ladder rung support at each LAD-SAF® component
connection point.
B. INSTALLATION OF TB-1 TOP BRACKET AND
6116336 GRAB BAR:
See Figure 9 for a typical installation of the TB-1 top
bracket onto a round rung ladder. The top bracket should
be positioned to allow users safe access when connecting
or disconnecting from the system. The top bracket is
typically mounted in the center of the climbing surface for
ease of climbing, but may be located towards the side of TB-1 Top Bracket
the ladder if required.
WARNING: The top rung clamp bolts through a plate that

is welded onto the bracket. This rung clamp must not be
omitted, or the bracket may slip under load.
Install rung clamps using the hardware provided. Do not

substitute other fasteners. Torque fasteners to 20-25 ft.-lbs
(27.1-33.9 N-m).
The 6116336 grab bar is installed by sliding the grab
bar into the square tube of the bracket and installing the
detent pin into the grab bar.
C. INSTALLATION OF TB-11 AND TB-12 CURVED
LADDER TOP BRACKETS: TB-1 Top Bracket and
6116336 Grab Bar
See Figure 10 for a typical installation of the TB-11 and
TB-12 top brackets onto a curved round rung ladder. The
top bracket should be positioned to allow users safe access when connecting or disconnecting from the
system. Adjust the top bracket position so that the carrier cable conforms to the curvature of the ladder.
Cable guides must be positioned along the ladder curve to prevent the cable from contacting the ladder.
See section 3.4 for information on cable guides. The top bracket is typically mounted in the center of
the climbing surface for ease of climbing, but may be located towards the side of the ladder if required.
Install rung clamps using the hardware provided. Do not substitute other fasteners. Torque fasteners to
20-25 ft-lbs (27.1-33.9 N-m).
D. INSTALLATION OF TB-4, TB-6, AND TB-7 BOLT-ON TOP BRACKETS:
See Figure 11 for a typical installation of the TB-4, TB-6, and TB-7 top brackets. The top bracket should
be positioned to allow users safe access when connecting or disconnecting from the system. The top
bracket is typically mounted in the center of the climbing surface, directly above the ladder, for ease of
climbing, but may be located towards the side of the ladder, 12 inches (30.5 cm) maximum from center,
if required. The top brackets are to be connected to the structure with a DBI-SALA or customer supplied
VWDQGRIIVXSSRUW6WDQGRIIVXSSRUWVPXVWVXSSRUWWKHORDGVVSHFL¿HGLQVHFWLRQDQGPXVWEH
compatible with the LAD-SAF® system.

Rev: 14.07.09 / ECN 30997
Figure 10 - Installing Curved Ladder Top Brackets
TB-11 Top Bracket TB-12 Top Bracket

Installation Installation
Figure 11 - Installing Bolt-on Top Bracket & Weld-on Stand-off

1-1/8”
(2.86 cm)
SO-2 Stand-Off
TB-4, TB-6, TB-7 Top Brackets with Installation
SO-2 Stand-Off Installation
Angle Leg and Round Leg Stand-off Installation:

See Figure 12 for the installation of the angle and round leg stand-off supports. Install stand-off
supports using the hardware provided. Do not substitute other fasteners. Torque 3/8-inch fasteners
to 20-25 ft-lbs (27.1-33.9 N-m). Install the top bracket to the stand-off support using the 1/2-inch
fasteners provided. Torque 1/2-inch fasteners to 40-45 ft-lbs (54-61 N-m). Note: For the TB-6 stand-off,
fasteners are not supplied. DBI-SALA recommends using lock washers, double nuts, or other methods
to ensure fasteners will not loosen.
SO-2 Weld-on Stand-off Installation:

Install the SO-2 stand-off support as shown in Figure 11. See section 3.2 for welding recommendations.
The stand-off must be perpendicular to the pole surface and in-line with the carrier cable.

Rev: 14.07.09 / ECN 30997
WARNING: Installations that use the angle Figure 12 - Installing Angle Leg & Round Leg Stand-offs
leg or round leg stand-off support brackets are
limited to one user on the system at a time.
E. INSTALLATION OF TB-5 WOOD

POLE TOP BRACKET:
See Figure 13 for a typical
installation of the TB-5 top bracket
onto a wooden pole. The top bracket
should be positioned to allow users
safe access when connecting or
disconnecting from the system. The
top bracket is typically mounted in
the center of the climbing surface for
ease of climbing, but may be located
towards the side of the ladder if
required. Use 1/2-inch fasteners (not
provided) to attach the top bracket
to the pole. Fasteners should extend
through the pole when possible.
DBI-SALA recommends using lock
washers, double nuts, or other
methods to ensure fasteners will not loosen.
Figure 13 - Installing TB-5 Top Bracket
F. INSTALLATION OF TB-9, TB-13, AND TB-14 TOP
BRACKETS:
See Figure 14 for a typical installation of the top bracket
onto a ladder. Some brackets utilize rung spacers while
others do not (see Figure 1). The top bracket should be
positioned to allow users safe access when connecting
or disconnecting from the system. The top bracket is
typically mounted in the center
Figure 14 - Typical of the climbing surface for ease
Installation of Top of climbing, but may be located
Bracket towards the side of the ladder if
required.
The top bracket may be installed
with up to 4 ft. (1.2 m) extending
above the top rung connection TB-5 Top Bracket
Installation
for systems limited to one user.
This will allow the use of only two
ladder rung clamps. Ensure the
ladder will withstand the required
loads between the two rungs.

The top bracket may be installed with up to 3 ft. (0.9 m) extending above the top
rung connection for systems allowing up to two users simultaneously.

The top bracket may be installed with up to 2 ft. (0.6 m) extending above the top
rung connection for systems allowing up to four users simultaneously.
WARNING: One rung clamp (lower connection) is designed to bolt through the bracket
and onto the rung. This clamp must not be omitted, or the bracket may slip under load.
Install rung clamps using the hardware provided. Do not substitute other fasteners.
Torque fasteners to 20-25 ft-lbs (27.1-33.9 N-m).

Rev: 14.07.09 / ECN 30997
G. INSTALLATION OF TB-8 TELESCOPING TOP BRACKET:
See Figure 15 for a typical installation of the TB-8 top bracket onto Figure 15 - Installing
a round rung ladder. The top bracket should be positioned to allow TB-8 Top Bracket
users safe access when connecting or disconnecting from the system.
The top bracket is typically mounted in the center of the climbing
surface for ease of climbing, but may be located towards the side of
the ladder if required. The TB-8 top bracket is designed to mount at
or near the top of the ladder and telescope up when in use. Typical
installations include access ladders into manholes and under trap
doors.
Installations that use the TB-8 top bracket are limited to one user on
the system at a time.
Install rung clamps using the hardware provided. Do not substitute
other fasteners. Torque fasteners to 20-25 ft-lbs (27.1-33.9 N-m).
TO OPERATE: Pull up on the bracket handle and rotate it clockwise
to lock it in place. Secure the front attachment point on a full body
harness to the carrier cable with a Lad-Saf® detachable cable sleeve
TB-8 Top Bracket
and climb up and down the ladder. (See the Lad-Saf® Detachable Installation
Cable Sleeve User Instruction Manual for details). When you are done
rotate the bracket handle counterclockwise and allow the bracket to
slide back down into the stationary bracket.
H. INSTALLATION OF D-RING ANCHORAGE: The D-ring Anchorage
is designed for used with the DBI-SALA Force2™ energy absorbing
lanyard and full body harness. The D-ring Anchorage must be
attached to a Lad-Saf® top bracket that is attached to a structure
that meets the top bracket load requirements. See Figure 16.
APPLICATION: The D-ring anchorage Figure 16 - Installing D-ring Anchorage
must be used in accordance with local
requirements for fall arrest or rescue
systems.
INSTALLATION: See Figure 16. Install the
D-ring anchorage assembly no more than 6
in. (15.2 cm) above the ladder rung where
the top clamp plate of the Lad-Saf® top
bracket is attached. The D-ring must be on
6” (15.24 cm)
the climbing (cable) side of the top bracket. above top
Clamp the D-ring anchorage assembly to Clamp Plate rung
the top bracket with the fasteners provided
with the assembly. Torque fasteners to
20-25 ft.-lbs (27.1-33.9 N-m).
USE: Connect the lanyard end of the

energy absorbing lanyard to the D-ring
anchorage. Connect the energy absorber
end to the back D-ring on your full body
harness. Do not disconnect from the
Lad-Saf system before connecting to the
D-ring anchorage.
4. SWING FALLS: Swing falls occur when

the anchorage point is not directly above
the point where a fall occurs. The force
of striking an object in a swing fall may
cause serious injury. See the instructions
provided with the energy absorbing
lanyard for more information.

Rev: 14.07.09 / ECN 30997
3.4 INSTALLATION OF CARRIER CABLE TO TOP BRACKET:
WARNING: Keep the carrier cable and carrier clamp clean during installation. Contamination of
the carrier clamp or cable could cause the clamp to malfunction.
A. INSTALLATION OF GALVANIZED CARRIER CABLE:

1. Lay the carrier cable out on the ground in a clean area by rolling the coil. Do not pull cable from center
of coil. For some installations it may be easier to lower the carrier cable from the top connection level
down to the bottom bracket. If so, carefully lower the cable by unspooling without twisting the cable at
the top connection. Do not drop the cable to the lower level.
WARNING: Carrier cable is very stiff and may spring out of coil unexpectedly. Use caution
when unrolling cable. Use appropriate safety gear, including gloves and safety glasses,
when unrolling cable.
Inspect the cable for shipping damage before proceeding. Do not install damaged cable.
2. See Figure 17 for installation of the galvanized carrier cable into the top bracket. Ensure the end of cable is
free of kinks and unraveled strands. Pass the cable up through the top bracket pipe and the urethane shock
absorber. Install the washer and carrier clamp onto cable with the cone of carrier clamp pointing down. At
least 1.0 in. (2.5 cm), but no more than 2 in. (5.1 cm). of cable must protrude through the carrier clamp.
Figure 17 - Installing WARNING: Excess cable protruding Figure 18 - Installing

Galvanized Carrier Cable through the carrier clamp may prevent Stainless Steel
installation of the cap. If this occurs, cut Carrier Cable
Cap off extra cable. Do not remove carrier
clamp from cable to avoid damage to the
Washer carrier clamp.
Carrier
Clamp Seat the carrier clamp into shock absorber
(2.54 cm) E\SXOOLQJ¿UPO\RQFDUULHUFODPSEHORZWKH
1.0 in. Min WRSEUDFNHWSLSH,QVWDOOFDSE\VHDWLQJLW¿UPO\
2.0 in. Max
(5.08 cm) Shock
onto the pipe.
Absorber
B. INSTALLATION OF STAINLESS STEEL
CARRIER CABLE:
1. Lay the carrier cable out on the ground in a
Top Bracket clean area by rolling the coil. Do not pull the
Pipe cable from the center of the coil.
WARNING: Carrier cable is very stiff, and

may spring out of the coil unexpectedly.
Carrier Use caution when unrolling cable. Use
Cable
appropriate safety gear, including gloves
and safety glasses, when unrolling cable.
Inspect the cable for shipping damage before proceeding. Do not install damaged cable.
3. See Figure 18 for installation of a stainless steel carrier cable into the top bracket. Most stainless steel
FDUULHUFDEOHVDUHVXSSOLHGZLWKDVZDJJHGHQG¿WWLQJIRUFRQQHFWLRQWRWKHWRSEUDFNHW7RLQVWDOOWKH
carrier cable, feed the free end of the cable down through the top bracket pipe and the urethane shock
DEVRUEHUXQWLOWKHVZDJH¿WWLQJLV¿UPO\VHDWHGLQWRWKHVKRFNDEVRUEHU,QVWDOOWKHFDSE\VHDWLQJLW
¿UPO\RQWRWKHSLSH

Rev: 14.07.09 / ECN 30997
3.5 INSTALLATION OF CABLE GUIDES, ALL MODELS:
Figure 19 - Installing Cable
&DEOHJXLGHVSURWHFWWKHFDUULHUFDEOHIURPFKD¿QJDJDLQVWWKH Guides
ladder or structure and to prevent the climber from excessively
GHÀHFWLQJWKHFDEOHIURPVLGHWRVLGH&DEOHJXLGHVVKRXOGEH
positioned at approximately 25 ft (7.62 m) intervals along the
carrier cable between the top and bottom brackets, and at any
point along the system where the cable may abrade against the CG-15 Cable Guide
structure. Cable guides should be staggered along the system

to reduce harmonic effects of the wind, such as at 23 (7.01), 25
(7.61), and 27 (8.23) feet (m) intervals. For high wind areas “L”
shaped cable guides may be used. The “L” shaped cable guides
should be alternated with opening on the left, then right, etc. up
CG-3 Cable Guide
the ladder. Latching cable guides are also available.
See Figure 19 for a typical installations of cable guides onto
a ladder. Some cable guides utilize rung spacers and clamp
plates while others do not (see Figure 3). Install the cable guide
CG-5 Cable Guide
using the hardware provided. Do not substitute other fasteners.
Torque fasteners to 20-25 ft-lbs (27.1-33.9 N-m).
SO-7 Weld-on Stand-off Support Installation:
Install the SO-7 stand-off as shown in
Figure 20 - Installing Weld-on Cable Guides
Figure 20. See section 3.2 for welding
recommendations. The stand-off must be
perpendicular to the pole surface and in-line
with the carrier cable.
Angle Leg and Round Leg Stand-off
Support Installation: CG-4
Cable Guide
See Figure 21 for typical installations of angle

leg and round leg stand-off supports. Install the
stand-off support using the hardware provided. SO-7
Stand-Off
Do not substitute other fasteners. Torque
fasteners to 20-25 ft-lbs (27.1-33.9 N-m).
Install the cable guide to the stand-off support
using the hardware provided. Do not substitute
other fasteners. Torque fasteners to 20-25 ft-lbs (27.1-33.9 N-m).
Figure 21 - Installing Angle Leg & Round Leg Stand-off Supports

Rev: 14.07.09 / ECN 30997
3.6 INSTALLATION OF BOTTOM BRACKET AND
CARRIER CABLE TENSION ADJUSTMENT: Figure 22 - Installing Bottom
Before installing the bottom bracket it is recommended Brackets
that the ladder and/or climbing structure be evaluated by
DTXDOL¿HGHQJLQHHUWRGHWHUPLQHLIWKHORDGUHTXLUHPHQWV
IRUWKHV\VWHPVSHFL¿HGLQVHFWLRQDUHPHW
NOTE: Depending on the length of the system, and

the environment in which the system is installed,
it may be necessary to periodically re-tension the
system. Extreme temperature ranges and very long
systems will likely require periodic re-tensioning.
The tension indicator can be purchased separately.
Contact DBI-SALA for details.
A. INSTALLATION OF BB-1, BB-2, BB-3, AND BB-9

BOTTOM BRACKETS:
See Figure 22 for a typical installation of the bottom
bracket onto a ladder. Some brackets utilize “U”-bolts
while others utilize bolts and clamp plates to attach
to the ladder (see Figure 2). The bottom bracket
should be positioned to allow users safe access when
connecting or disconnecting from the system. The bottom bracket must be mounted in-line (vertically)
with the top bracket.
WARNING: One rung clamp is designed to bolt through

the bracket and onto the rung. This clamp must not be
omitted, or the bracket may slip under load. Figure 23 - Installing Bottom
Brackets to Horizontal Standoff
Install the rung clamps using hardware provided. Do
not substitute other fasteners. Torque fasteners to 20-
25 ft-lbs (27.1-33.9 N-m).
Stand-off Support Connection:
Figure 23 shows the installation of the above bottom
brackets using a horizontal stand-off bracket. Use hex
bolts provided in place of U-bolts to attach the bottom
bracket to the horizontal stand-off. Torque fasteners to
20-25 ft-lbs (27.1-33.9 N-m).
Carrier Cable Tension Adjustment:
Figure 22 shows the assembly of the tension rod to the
bottom bracket and carrier cable. Loosely clamp the
saddle clips around the carrier cable. Slide the tension
rod down the carrier cable and through the hole in the
EUDFNHWXQWLOVXI¿FLHQWWKUHDGVDUHH[SRVHGWRDOORZ
the installation of the tension indicator, washers, and
nuts. Remove the slack in the carrier cable by the
pulling cable though the saddle clips. Tighten saddle
clips to 35 ft.-lbs (47.5 N-m). Tighten the tensioning
nut until the ring on the tension indicator is sheared off.
A small amount of grease on the tension rod threads
will reduce the effort required to tension the carrier
FDEOH,IWKHUHDUHLQVXI¿FLHQWWKUHDGVH[SRVHGWR
fully tension the carrier cable, pull more carrier cable
through the saddle clips on the tension rod and repeat
the procedure. When correct carrier cable tension is
reached tighten the jam nut against the tensioning nut.
Cut off excess cable just below the lower saddle clip.

Rev: 14.07.09 / ECN 30997
Figure 24 - Installing Bottom Brackets
Compress Compress
to 5-1/2” to 5-1/2”
(14 cm) (14 cm)
BB-4 Bottom Bracket BB-6 Bottom Bracket

Installation Installation
B. INSTALLATION OF BB-4, BB-5, AND BB-6 BOTTOM BRACKETS:

Bottom Bracket Installation:
See Figure 24 for a typical installations of the BB-4 and BB-6 bottom brackets onto a round rung ladder.
See Figure 25 for a typical installation of the BB-5 bottom bracket with a weld-on stand-off support. The
bottom bracket should be positioned to allow users safe access when connecting or disconnecting from
the system. The bottom bracket must be mounted in-line (vertically) with the top bracket.
WARNING: One rung clamp is designed to bolt through the bracket and onto the rung. This
clamp must not be omitted, or the bracket may slip under load.
Install the rung clamps using the hardware provided. Do not substitute other fasteners. Torque
fasteners to 20-25 ft.-lbs (27.1-33.9 N-m).
Weld-on Stand-off Installation:
Install the SO-2 stand-off support as shown in Figure 25. See section 3.2 for welding recommendations.
The stand-off must be perpendicular
to the pole surface and in-line with the Figure 25 - Installing Bolt-on Bottom Bracket &
carrier cable. Weld-on Stand-off
Carrier Cable Tension Adjustment: 1-1/8” (2.86 cm)
Figures 24 and 25 show the assembly
of the tension rod to the bottom
bracket and carrier cable. Loosely
clamp the saddle clips around the
carrier cable. Slide the tension rod
down the carrier cable and through
WKHKROHLQWKHEUDFNHWXQWLOVXI¿FLHQW
threads are exposed to allow the
installation of the washers and nuts.
Remove slack in the carrier cable by
pulling the cable through the saddle
clips. Tighten the saddle clips to
Compress
35 ft.-lbs (47.5 N-m). Tighten the to 5-1/2”
tensioning nut until the carrier cable (14 cm)
is taut. A small amount of grease on
the tension rod threads will reduce
the effort required to tension the
carrier cable. Compress the spring to BB-5 Bottom Bracket and
SO-2 Stand-Off Installation
approximately 5-1/2 in. (14 cm). Do
24- User manual

SALA fall protection system 763 / 776
Rev: 14.07.09 / ECN 30997
not completely compress the spring. If
WKHUHDUHLQVXI¿FLHQWWKUHDGVH[SRVHG Figure 26 - Installing Bottom Brackets and
to fully tension the carrier cable, pull Weld-on Stand-off
more carrier cable through the saddle 1-1/8” (2.86 cm)
clips on the tension rod and repeat the

procedure. When the correct carrier
cable tension is reached, tighten the jam
nut against the tensioning nut. Cut off
excess cable just below the lower saddle
clip.
C. INSTALLATION OF BB-7 BOLT-ON
BOTTOM BRACKETS:
See Figure 26 for a typical installation of
the BB-7 bottom brackets. The bottom
bracket should be positioned to allow
users safe access when connecting or
disconnecting from the system. The
bottom bracket must be mounted in-line
(vertically) with the top bracket. The
6100035 and 6100040 bottom brackets
BB-7 Bottom Brackets
are designed to be connected to the and SO-2 Stand-Off Installation
structure using a DBI-SALA or customer
supplied stand-off support. Customer
VXSSOLHGVWDQGRIIVXSSRUWVPXVWEHFDSDEOHRIZLWKVWDQGLQJWKHORDGVVSHFL¿HGLQVHFWLRQDQGPXVW
be compatible with the LAD-SAF® system.
Weld-on Stand-off Installation:
Install the SO-2 stand-off support as
shown in Figure 26. See section 3.2 for Figure 27 - Installing Angle Leg & Round Leg Stand-offs
welding recommendations. The stand-
off must be perpendicular to the pole
surface and in-line with the carrier cable.
Angle Leg and Round Leg
Stand-off Installation:
See Figure 27 for the installation of
round and angle leg stand-off supports.
Install stand-off supports using the
hardware provided. Do not substitute
other fasteners. Torque 3/8 inch
fasteners to 20-25 ft.-lbs (27.1-33.9
N-m). Install bottom bracket to stand-
off support using 1/2-inch fasteners
provided. Torque 1/2-inch fasteners to
40-45 ft.-lbs (54-61 N-m).
Figure 26 shows the assembly of the
tension rod to the bottom bracket
and carrier cable. Loosely clamp
the saddle clips around the carrier
FDEOH6OLGHWKHWHQVLRQURGGRZQWKHFDUULHUFDEOHDQGWKURXJKWKHKROHLQWKHEUDFNHWXQWLOVXI¿FLHQWWKUHDGV
are exposed to allow the installation of the tension indicator, washers, and nuts. Remove slack in the carrier
cable by pulling the cable though the saddle clips. Tighten saddle clips to 35 ft.-lbs (47.5 N-m). Tighten the
tensioning nut until the ring on the tension indicator is sheared off. A small amount of grease on the tension
URGWKUHDGVZLOOUHGXFHWKHHIIRUWUHTXLUHGWRWHQVLRQWKHFDUULHUFDEOH,IWKHUHDUHLQVXI¿FLHQWWKUHDGVH[SRVHG
to fully tension the carrier cable, pull more carrier cable through the saddle clips on the tension rod and repeat
the procedure. When the correct carrier cable tension is reached, tighten the jam nut against the tensioning
nut. Cut off excess cable just below the lower saddle clip.
Rev: 14.07.09 / ECN 30997
D. INSTALLATION OF BB-8 WOOD POLE Figure 28 - Installing Wood Pole Bottom
BOTTOM BRACKET: Bracket
See Figure 28 for a typical installation of the
BB-8 bottom bracket. The bottom bracket should
be positioned to allow users safe access when
connecting or disconnecting from the system.
The bottom bracket must be mounted in-line
(vertically) with the top bracket. Use 1/2-inch
fasteners (not provided) to attach the bottom
bracket to the pole. DBI-SALA recommends using
lock washers, double nuts, or other methods to
ensure fasteners will not loosen.
Figure 28 shows the assembly of the tension rod BB-8 Wood Pole Bottom Bracket
to the bottom bracket and carrier cable. Loosely Installation
clamp the saddle clips around the carrier cable.
Slide the tension rod down the carrier cable
DQGWKURXJKWKHKROHLQWKHEUDFNHWXQWLOVXI¿FLHQWWKUHDGVDUHH[SRVHGWRDOORZWKHLQVWDOODWLRQRIWKH
tension indicator, washers, and nuts. Remove slack in the carrier cable by pulling the cable though the
saddle clips. Tighten saddle clips to 35 ft.-lbs (47.5 N-m). Tighten the tensioning nut until the ring on
the tension indicator is sheared off. A small amount of grease on the tension rod threads will reduce
WKHHIIRUWUHTXLUHGWRWHQVLRQWKHFDUULHUFDEOH,IWKHUHDUHLQVXI¿FLHQWWKUHDGVH[SRVHGWRIXOO\WHQVLRQ
the carrier cable, pull more carrier cable through the saddle clips on the tension rod and repeat the
procedure. When the correct carrier cable tension is reached, tighten the jam nut against the tensioning
nut. Cut off excess cable just below the lower saddle clip.
E. 5900172 COUNTERWEIGHT:
To install the 5900172 counterweight onto the carrier cable, loosen the saddle clips and pass the carrier
cable through the counterweight. Position the counterweight to allow users safe access when connecting
or disconnecting from the system. Tighten the saddle clips against the carrier cable.
3.7 FINAL INSPECTION AFTER INITIAL INSTALLATION AND SYSTEM IDENTIFICATION:
A. Install the installation and service label onto the ladder or structure in a prominent location. Use the
steel wire provided with the label to attach it to the ladder or structure. Before installing the label, mark
the installation date and number of users allowed in the appropriate locations on the label. Use a metal
OHWWHUVWDPSWRPDUNWKHODEHO5HFRUGWKHV\VWHPLGHQWL¿FDWLRQLQIRUPDWLRQLQWKHInstallation Check
Lists at the end of this manual.
B. $IWHULQVWDOODWLRQFRQGXFWD¿QDOLQVSHFWLRQRIWKHV\VWHPDVIROORZV
(QVXUHDOOIDVWHQHUVDUHLQSODFHDQGSURSHUO\WLJKWHQHG
(QVXUHWKHFDUULHUFDEOHLVSURSHUO\WHQVLRQHG'RQRWXVHWKH/DG6DI® system if the bottom of the
cable is not secured/tensioned with the bottom bracket assembly.
)RUFDEOHVWHUPLQDWHGZLWKDFDUULHUFODPSWKHFDEOHVKRXOGH[WHQGDERYHWKHFDUULHUFODPSLQ
2.0 in. (2.5 cm - 5.0 cm).
(QVXUHWKHFDUULHUFDEOHGRHVQRWDEUDGHDJDLQVWWKHVWUXFWXUHDWDQ\SRLQW
(QVXUHWKHV\VWHPLQIRUPDWLRQLVUHFRUGHGRQWKHODEHODQGLQVSHFWLRQORJ
4.0 LAD-SAF® SYSTEM USE
4.1 BEFORE EACH USE inspect the system according to section 5.0. Do not climb a structure that is
not in good condition. Verify from the label markings that the system has been formally inspected
within the last year. Do not use a defective or improperly maintained LAD-SAF® system. Inspect
the detachable cable sleeve according to manufacturer’s instructions. Inspect the full body
harness according to manufacturer’s instructions.

Rev: 14.07.09 / ECN 30997
4.2 PLAN your use of the LAD-SAF® system before starting work. Consider all factors that will affect
your safety before starting your work. The following list gives some important points to consider
when planning your work:
Ensure the system is rated for the number of users required on the system before use.
Consider hazards associated with connecting and disconnecting from the system. Ensure
adequate anchor points, landing platforms, or other means are available at connection and
disconnection points to allow safe transitions to and from the system.
Be aware of hazards in the work area that could cause injury to the user or damage to the
system, such as; high heat, electrical hazards, chemical hazards, or moving machinery.
A minimum fall clearance of 7 ft. (2 m) is required between the user’s feet and surface below.
7KHXVHUPD\QRWEHSURWHFWHGDJDLQVWKLWWLQJWKHJURXQGRUODQGLQJGXULQJWKH¿UVWIW
m) of ascent or last 7 ft. (2 m) of descent. Extra care should be taken when ascending or
descending the portion of the ladder below the bottom bracket of the Lad-Saf™ system.
Use caution when climbing. Avoid carrying tools or equipment that do not allow your hands
to be free for climbing. Ensure items carried are secure to avoid dropping them on climbers
below. Climb within your ability. Long climbs may require several rest stops during ascent
or descent to avoid exhaustion. Avoid climbing in high winds or severe weather whenever
possible.
If a fall occurs the user (employer) must have a rescue plan and the ability to implement it.
4.3 TRAINING: It is the responsibility of the user and purchaser of this equipment to assure
they are familiar with the instructions, operating characteristics, application limits, and the
consequences of improper use of this equipment. Users and purchasers of this equipment must
be trained in the correct care and use of this equipment. Contact DBI/SALA for additional training
guidelines.
5.0 INSPECTION
5.1 FREQUENCY:
Before Each Use: Visually inspect the full body harness, ladder safety sleeve, Lad-Saf®
system installation, and ladder structure. Use the guidelines provided in section 5.2 to check
the system to the extent possible for attaching. Check the system label (section 8) to verify
that annual inspection is current. If the condition of the system is in doubt, do not use.
Formal Inspection: A formal inspection of the ladder safety sleeve, the LAD-SAF®
installation, and the ladder structure must be performed at least annually by a competent
SHUVRQRWKHUWKDQWKHXVHU6HH6HFWLRQVDQGIRULQVSHFWLRQVSHFL¿FV
After a Fall: If a fall occurs with the ladder safety sleeve or on the LAD-SAF® system a
formal inspection of the entire system must be performed by a competent person other than
the user. A separate fall protection system (not the Lad-Saf® system) should be used while
inspecting the system. See sections 5.2, 5.3 and 5.4. Record the inspection results in the
Inspection and Maintenance Logs at the end of this manual.
5.2 INSPECTION GUIDELINES - LAD-SAF™ LADDER SAFETY SYSTEM:

; Top Brackets: Reference Figure 16 & Figure 17.
Inspect for proper installation (see Sections 3.3 & 3.4).
Check for visible damage or corrosion. Look for cracks, bends or wear that could affect the
strength and operation of the system. Inspect welds. Look for cracked or broken welds that
could affect strength of bracket. Replace parts if defects are found.
Check for loose or missing fasteners that secure top bracket to structure (bolts, clamp plates,
U bolts). If fasteners are loose, re-tighten to the torque levels listed. Torque on 3/8 inch
fasteners should be 20-25 ft-lbs (27-34 N-m). Torque on ½ inch fasteners should be 40-45 ft
–lbs (54-61 N-m). Retighten as necessary.
Rev: 14.07.09 / ECN 30997
Inspect carrier clamps (some models will contain a swaged on carrier lug in place of the
carrier clamp- see Figure 17). Cable should extend above carrier clamp 1.0 inch (2.5 cm) to
2.0 inch (5.0 cm). Adjust cable if amount of cable extension is outside of described range.
Steel washer should be present between carrier clamp and shock absorber.
Look down the inside of the pipe and inspect the shock absorber for damage such as cracks or
splits. The bottom of the shock absorber should project out the bottom hole in the top bracket
pipe. Replace the shock absorber if defects are found.
,QVSHFWWKHFDSWKDW¿WVRQWKHWRSRIWKHSLSH&KHFNIRUFUDFNVRUGDPDJHWRWKHFDS7KH
FDSVKRXOG¿WVHFXUHO\RQWRWKHSLSH5HSODFHLIGHIHFWVDUHIRXQG
; Bottom Bracket: Reference Figure 21.
Check for proper installation (see Section 3.6).
Check for damage or corrosion. Look for cracks, bends or wear that could affect the strength
and operation of the system. Replace parts if defects are found.
Check for loose or missing fasteners that secure bottom bracket to the structure. If fasteners
are loose, re-tighten to listed torque levels. Torque on 3/8 inch fasteners should be 20-25
ft-lbs. (27-34 N-m). Torque on ½ inch fasteners should be 40 -45 ft. –lbs. (54-61 N-m).
Retighten as necessary.
Inspect the tension rod assembly. Make certain saddle clips securely retain the cable. Check
torque on saddle clamps – 35 ft. lbs. (47 N-m). Replace or retighten if defects are found.
; Cable Guides: Reference Figure 18.
Check cable guides for damage. Look for wear or damage to black urethane. Cable guides
should restrain the cable and prevent cable contact with the ladder/structure. Cable guides
should be placed approximately every 25 ft (8 m) or closer if required. Replace parts if defects
are found.
Check cable guide fasteners. The fasteners should the secure cable guide in position. Tighten
as necessary.
; Cable and Cable Tension: Reference Figure 21 and Figure 23.
Inspect the cable for corrosion, kinks, or damage that will affect strength and impede the
cable sleeve from traveling on the cable. Look for worn or broken strands of wire. Inspect for
signs of abrasion against the ladder or structure. Replace the cable if defects are found.
Inspect the cable tension. For systems that utilize a compression spring (Figure 23), the
spring in the bottom bracket should be compressed to 5-1/2 inch (13.8 cm) length. For
systems that utilize a tension rod and tension indicator washer (Figure 21), the washer should
be indicated (center ridge sheared off) and the washer imbedded fully into hole of bottom
bracket. You should not be able to pull tension rod down by hand. Cable should be tight
enough to prevent contact with the ladder/structure. Re-tension the cable if necessary. For
bottom brackets that contain an indicating washer, a new washer (part no. 9504239) should
be installed if the cable is re-tensioned. Tighten the system until indicating washer ring is
sheared off. Do not over-tension the system.
; Installation and Service Label: Reference Section 8.
Inspect the installation and service label. The label should be securely attached and fully
legible. The installation date and number of users allowed on the system should be clearly
marked on the label. Record the inspection date on the label after inspection is completed.
; Ladder/Climbing Structure:
Inspect the ladder/climbing structure to which the Lad-Saf® system is attached. Make sure
the structure is in good condition, secure, and safe to climb. If the condition of the structure is
questionable, consult instructions and/or personnel familiar with the structure prior to use.
5.3 INSPECTION GUIDELINES - LAD SAF® DETACHABLE CABLE SLEEVE:
Inspect the LAD-SAF®GHWDFKDEOHVOHHYHSHUWKHLQVSHFWLRQVWHSVGH¿QHGLQWKHDVVRFLDWHG8VHU

Instructions. See Figure 5 for a listing of LAD-SAF® sleeve models and their respective User Instructions.

Rev: 14.07.09 / ECN 30997
5.4 If inspection reveals an unsafe or defective condition remove the ladder safety system
or the safety sleeve from service and destroy it or contact an authorized service center Figure 29 -
for repair. i-Safe™
RFID Tag
5.5 I-SAFE™ RFID TAG:
The Lad-Saf®V\VWHPLQFOXGHVDQL6DIH5DGLR)UHTXHQF\,GHQWL¿FDWLRQ
(RFID) tag (Figure 28). The RFID tag can be used in conjunction with the
i-Safe handheld reading device and web based portal to simplify inspection and
inventory control and provide records for your fall protection equipment. If you
DUHD¿UVWWLPHXVHUFRQWDFWD&DSLWDO6DIHW\&XVWRPHU6HUYLFHUHSUHVHQWDWLYH
(see back cover); or if you have already registered, go to www.capitalsafety.
com/isafe.html. Follow the instructions provided with your i-Safe handheld
reader or on the web portal to transfer your data to your web log.
6.0 MAINTENANCE, SERVICING, STORAGE

6.1 The LAD-SAF® installation requires no scheduled maintenance. See section 5.0 for inspection related
maintenance issues. If the carrier cable becomes heavily soiled with oil, grease, paint, or other substances,
clean it with appropriate cleaning solutions. Do not use acid or caustic chemicals that could damage the
cable.
6.2 The LAD-SAF® sleeve may be cleaned using commercial parts-cleaning solvents and rinsed with warm,
soapy water. Light machine oil may be applied to the moving parts if required. Do not use excessive oil,
or allow oil to contact the cable clamping surfaces. Store the detachable cable sleeve in a cool, dry, clean
environment, out of direct sunlight. Avoid areas where chemical vapors exits. Thoroughly inspect the sleeve
after extended storage.
7.0 SPECIFICATIONS
7.1 All top and bottom brackets, cable guides, carrier cable, and fasteners are made of galvanized or stainless
VWHHO&RQWDFW'%,6$/$IRUPDWHULDOVSHFL¿FDWLRQGHWDLOVLIUHTXLUHG7KH/$'6$)® system, when installed
according to the user instructions, meets OSHA, ANSI (ANSI A14.3), CSA (Z259.2.1), CE (EN 353-1:2002),
and AS/NZS (AS/NZS 1891.3:1997) requirements.
8.0 LABELING
8.1 These following label must be securely attached and fully legible:
1. WARNING: Manufacturer’s instructions

supplied with this product at time of
shipment must be followed for proper
installation, use, inspection and
maintenance. Unauthorized alteration
or substitution of system elements
or components is prohibited. Do not
use system with incompatible safety
sleeves. Before each use inspect system
visually for defects. Formally inspect
system in accordance with instructions
at least annually. Failure to heed
warnings may result in serious injury
or death.
2. System Capacity
3. Inspections
4. Date of Inspection
5. Inspected By
6. Date of Next/Annual Inspection
2 6
3 4 5

Rev: 14.07.09 / ECN 30997
INSTALLATION CHECKLIST
Serial Number(s):
Model Number(s):
Date Purchased: Date of First Use:
Ensure all fasteners are in place and properly tightened.

Install Date:
Ensure the Carrier Cable is properly tensioned.
Approved By: Ensure the Carrier Cable does not abrade against the structure at any point.
Corrective Action/Maintenance: Ensure system information is recorded on the system label and Inspection and Maintenance Log:
Components of the LAD-SAF system include an i-Safe™ Radio Frequency (RFID) tag. The RFID tag can be used
in conjunction with the i-Safe handheld reading device and web based portal (www.capitalsafety/isafe).to
simplify inspection and inventory control and maintain electronic records for your fall protection equipment.

Install Date:

Install Date:

Install Date:

Install Date:

Rev: 14.07.09 / ECN 30997
Serial Number(s):
Model Number(s):

Install Date:

Install Date:

Install Date:

Install Date:

Install Date:

Rev: 14.07.09 / ECN 30997
Serial Number(s):
Model Number(s):

Install Date:

Install Date:

Install Date:

Install Date:

Install Date:

Rev: 14.07.09 / ECN 30997
INSPECTION AND MAINTENANCE LOG
Serial Number(s):
Model Number(s):
Inspect Top and Bottom Brackets: Inspect for damage, corrosion, or rust. Look for cracks, bends, or
Date: wear that could affect strength and operation. Inspect for missing fasteners; retighten or replace as necessary.
Inspect Cable Guides: Ensure cable guide is not warn or bent and still locks onto the cable. Inspect for
Approved By:
loose or missing fasteners; retighten or replace as necessary.
Corrective Action/Maintenance: Inspect Carrier Cable: Look for worn or broken strands. Inspect for signs of abrasion against ladder or
structure. Cable must not contact ladder or structure. Replace damaged cable as necessary. Check the carrier
cable tension, ensuring there is no slack. Re-tension the cable as necessary.
Inspect Ladder Structure: Inspect ladder structure for damage, rust, or deterioration that could affect
strength of the ladder.
Inspect Labels: All labels (see Section 8) should be securely attached and fully legible. Record inspection
dates on the system label.
Approved By:
Approved By:
Approved By:
Approved By:

Rev: 14.07.09 / ECN 30997
Serial Number(s):
Model Number(s):
Approved By:
Approved By:
Approved By:
Approved By:
Approved By:

Rev: 14.07.09 / ECN 30997
Serial Number(s):
Model Number(s):
Approved By:
Approved By:
Approved By:
Approved By:
Approved By:

Rev: 14.07.09 / ECN 30997
A Capital Safety Company
CSG USA CSG Canada Ltd. CSG Northern Europe Ltd.

3833 Sala Way 60 Export Boulevard &KULVWOHWRQ&RXUW6WXDUW5G
Red Wing, MN 55066-5005 Mississauga, Ontario L5S 1Y9 0DQRU3DUN5XQFRUQ
Toll Free: 800.328.6146 Canada &KHVKLUH:$678.
Phone: 651.388.8282 Toll Free: 800.387.7484 Phone: +44 (0) 1928 571324
Fax: 651.388.5065 Phone: 905.795.9333 Fax: +44 (0) 1928 571325
solutions@capitalsafety.com Fax: 905.795.8777 csgne@csgne.co.uk
sales.ca@capitalsafety.com
CSG EMEA (France) CSG Asia Pte Ltd. CSG (Aust) Pty Ltd.
Le Broc Center No. 6, Tuas Avenue 18 )DULROD6WUHHW6OLYHUZDWHU
Z.I. 1ère Avenue-5600 M Singapore 638892 Sydney, NSW 2128
%3&DUURV&HGH[ Phone: +65 6558 7758 Australia
Phone: +33 (0)4 97 10 00 10 Fax: +65 6558 7058 Phone: +61 (2) 9748 0335
Fax: +33 (0)4 93 08 79 70 inquiry@capitalsafety.com Fax: +61 (2) 9748 0336
information@capitalsafety.com sales@capitalsafety.com.au
www.capitalsafety.com

Rev: 14.07.09 / ECN 30997
Rev: 14.07.09 / ECN 30997

- Chapter 27 SKY MAN TH250 SERVICELIFT (option)

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 27 SKY MAN TH250 SERVICELIFT (option)

SWT - 2.3 - 82VS/93/101
• Appendix - SKY MAN TH250 servicelift

yyyy)

Document history

93/101

Appendix - Data sheet - SKY MAN TH250 servicelift (option)
Safety Service / repair work is only allowed by authorised personnel.
See , “Sky man TH250 service hoist,”


Sky man TH250 service hoist
Installation manual - Service hoist TH 250
SWT-3.6-107 Off-shore / Opstillingsmanual 781

Rev: 28.08.08 / ECN 28833

Introduction
The Service- and inspection car Service hoist ® TH250 is manufactured by:
Manufacturer: SKY MAN INTERNATIONAL N.V.
Zone 3, Hoek 76, Dep. 43-44
B-2850 Boom
BELGIUM
Descriptive plate The following data is marked on the Service hoist:
Approval: CE
Type: TH250
Serial no./year: _______/_______
Max. load: 250 kg.
Net weight: 150 kg.
Speed: 0.3 m/s
Approval no.: 2001-1-0162
Note:
The Service hoist for wind turbine installation is CE-approved in accordance with
“Machine Directive” (98/37/EF) appendix IIB.
This means that if the service hoist is built into a “turbine”, the service hoist must
not be used until this “turbine” has been declared in accordance with relevant reg-
ulations set out by the manufacturer.
TECHNICAL DATA
Load Max. 250 kg
Max. Travel height 100 M
Travel speed 0,3 m/sec.
Net. weight 150 kg
Motor
Power 1,8 kW
Voltage/Hz 690 volt - 50 Hz
Fuse 16 amp.
782 SWT-3.6-107 Off-shore / Opstillingsmanual

Rev: 28.08.08 / ECN 28833

Safety precautions
SKY MAN N.V., a Sky Man distributor or “trained person”, or another certified
“competent person”, must annually perform a “Service inspection” of the service
hoist installation.
This installation manual is directed to staff in charge of maintenance and inspec-

tion of wind turbines, as well as persons trained in the use and maintenance of
the service hoist, e.g. wind turbine fitters.
Special information on the left side is used throughout the entire manual concern-
ing areas which the reader should pay special attention to, as lacking of attention
could pose a safety risk, endanger personnel or cause damage to material.
All users of the service hoist must at minimum be instructed in, as well as under-
stand, the following guidance sections:
IMPORTANT! TH250 is approved for lifting 2 persons or 250 kg.
“Only competent personnel are allowed to use the Service hoist.
“Do not exceed the maximum load.
“The personnel using the service hoist must be equipped with approved
equipment for personal safety, meaning harness, safety cable and safety
helmet.
“Use of the emergency ladder is not allowed unless the Service hoist is
stopped due to emergency stop.
“Only competent personnel are allowed to handle and install the Service
hoist.
“Before the Service hoist is taken into use for the first time, it must be
checked according to the section: See, “EXTERNAL EQUIPMENT (STAN-
DARD CHECK)”
“Check the motor shaft gear and gear box of the service hoist for abnormal
wear after 50 hours of continuous and intensive use and/or at every annual
service check; replace if necessary.
If the service hoist has not been used within 6 months, See , “Standard
check,” “Standard check” must be performed.
Use of the service hoist “The area surrounding the anchor point for the driving wire and the safety wire
must be kept clear.
“The Service hoist must not be operated unless all safety guards and railing is in
order and placed correctly.
“When the Service hoist is unattended, it must be in the lowest position, and the
emergency stop must be activated.
Noise emission The noise emission from the service hoist is less than 70 dB (A), measured from
a distance of 1 m.

Rev: 28.08.08 / ECN 28833

Safety equipment
• “The drive motor is equipped with a brake which is able to stop and hold secure
a fully loaded Service hoist.
Fig. 1.42
1. Emergency lever for ascent/
descent.
2. Insertion hole for emergency

1 lever.
3. Brake and emergency lever

3
for descent of the service hoist
4
4. Power plug for the motor.
2
• The brake is activated when there is no power for the motor. this will be the
case if the emergency stop (G.Fig. 3.42) has been activated, if one of the safe-
ty switches are active, when knobs (D.Fig. 3.42) are released in case of power
failure.
• The Service hoist is equipped with an automatic overload detector in order to

prevent the Service hoist to be used to raise or lower the cabin if the maximum
load is exceeded. In this case, a signal lamp (F. 3.42) inside the cabin will light
up until the overload has been removed.
• The Service hoist is equipped with a fastening safety device which rides on a
separate safety wire. If the car speed exceeds the maximum allowed speed,
the fastening safety device clutch the secondary safety steel wire and stop.
The fastening safety device can be operated manually using the red lever on
the Safety brake. (B. Fig. 3.42)
The Safety brake Fig. 2.42

A. Safety brake.
D.
A. B. Safety wires.
C.
C. Driving wires.
D. Anchor bolts.
D. B.

Rev: 28.08.08 / ECN 28833

The safety brake must only be manually activated in case of an emergency.
(fig. 2.42)
External safety equipment Safety areas.

At safety railing, fencing and similar on areas near the service hoist which are
considered to be a work area or areas, where a person is expected to be present,
it is important to comply with safety regulations.
Emergency precaution Activating the emergency stop device (G.Fig. 3.42) will cut off the current to the
motor. the current can only be reinstalled by deactivating the emergency stop de-
vice.
The cage-arresting device If the driving wire breaks, the fastening safety device detects the increased speed
and automatically catches on to the safety wire, and thereby stop the downward
direction of the service hoist.
When the service hoist has come to a full stop, the service hoist must be aban-
doned by using the emergency ladder.
After replacement of the broken driving wire, the “safety brake” of the cage-
arresting device and its attachments must be inspected.
During normal operation, the manual release lever of the Safety brake (B.
Fig. 3.42) may NOT be activated in any way. It is possible to raise the service
hoist while the brake is activated, but this will cause wear on the internal safety
parts. A red signal lamp (E.Fig. 3.42) inside the cabin will indicate if the safety
brake is activated.
Fig. 3.42
A. Safety brake reset lever.
B. B. Red activation handle of the
C.
Safety brake.
D. C. Driving wires.
D. Red overload indicator. The

E. pilot light will be on if the brake is
activated.Max. wight of 250 kg
A. E. Red pilot light. Will be on

when the brake is activated.
F.
F. UP/DOWN operating switch.
H.
G. G. Emergency stop push button.
H.Safety wires.
• In addition, all anchor bolts (see Fig 3.42) must be checked.NB: If the lock nuts
can be turned without the use of tools, the lock nuts must be replaced.
• If the bolts are to be replaced, only bolts of similar quality and size must be
used.
WARNING! The cage-arresting device “Safety brake” may only be removed and dis-
mounted by trained persons. It might cause a safety risk exposing both
user of the service hoist as well as persons near by the service hoist to dan-
ger.

Rev: 28.08.08 / ECN 28833

1. Installation of service hoist
Short description • The service hoist must be placed in bottom/middle/top section or as (option)
where it gets lowered separately into the tower on site.
• The Service hoist is mounted onto a back profile and two horizontal profiles in
the bottom of the service hoist. There are 8 guide wheels mounted on back
profiles. The rollers are connected to the front and back of the profile on the
emergency ladder making the service hoist hold onto the profile as guide rails
(emergency ladder).
• Both driving/safety wires are to be attached to the top console before the roll-
out of wires.
• The service hoist power cable is connected.
• The hoist and the motor are bolted onto the back profile and “drives” up the
wire, which is hanging from the top to the bottom of the tower.
• As a safety precaution to prevent the service hoist from going downwards at a
too high speed, the Safety brake will operate on a separate safety wire.
• The cabin is equipped with windows for tower inspection. In order to establish
if the stop position has been reached, the access door has a window in the bot-
tom. The directional manoeuvre switch for the direction is the type “hold-to-
run”.
Placing of service hoist The service hoist can be placed in the top/between or bottom section.
Bottom tower section Fig. 4.42

1 Service hoist placed in the
bottom section.
1.

Rev: 28.08.08 / ECN 28833

Service hoist mounted in bot- Fig. 5.42
tom tower 3.6MW 1 The service hoist placed in
1. the bottom tower top.
(Off shore) 3.6 MW.
Service hoist mounted in bot- Fig. 6.42

tom tower 2.3MW The service hoist placed in bot-
2. tom tower fastened with trans-
port brackets transverse spindle
at the ladder steps at the service
hoist bottom, surring clamp.
(On shore) 2.3MW
Service hoist mounted in Top Fig. 7.42

tower. 1 The service hoist placed in
1. top tower fastened with
transport brackets trans-
verse spindle at the ladder
steps at the service hoist bot-
tom, surring clamp.
A.

Rev: 28.08.08 / ECN 28833

Fig. 8.42
The top console fordriving- and
1. 2. safety wire .
3.
1. Climbing safety wires.
2. Safety wires for Service hoist.
3. Driving wires.
• “The suspension and reference position for the driving wire and safety wire
must be in place in the tower top before start.
Fig. 9.42
1 The 2 plugs for start-up of
1. Service hoist.
Cable bearer is placed in the • If cable bearer is not fitted in advance, the cable bearer must be fitted along
tower middle with the towers when these are assembled.
Initial work • Fit and adjust all ladders, making them ready to be used down the tower.
Fig. 10.42
Ladder assembly.

Rev: 28.08.08 / ECN 28833

Fig. 11.42
1. Power cable.
2.
1. 2. Control box for the service
hoist as well as hour meter.
3. The window in the access

door, to see the stop position.
3.
NOTE! • Connect the 2.3MW turbine to power cable (690 V) in the bottom section, in
A1cabinet terminal block.(Follow the instruction diagrams).
Connect also power cable in Fig. 12.42

A1 (3.6MW) 1. Connect the power cable to
the service hoist in A1 under the
1.
power unit. (Follow instruction di-
agrams).
(A1 cabinet in 3.6MW)
NOTE ! • Connect 3.6MW turbine to power cable (690 v) in the bottom section under the
power unit in A1cabinet, in terminal block.(Follow the instruction diagrams).
Placement of control cabinets 1 A1 placed in the bottom section)

in 2.3MW and 3.6MW
Fig. 13.42
A18 A9 G A5 G1
A5
A6 A6
A3 A3 A13
A4
1. A4
1.
2.3MW 3.6MW
A14
A1
A14
A2
A1 A12
A12
A11
A2 A11

Rev: 28.08.08 / ECN 28833

Lower service hoist into the tower in site (option)
Service hoist is attached Fig. 14.42

1 Attach the service hoist in 2
pcs. shackles in the service
hoist top.
1.
Fig. 15.42
Lift up the entire service hoist to
the bottom tower top.
Fig. 16.42
Place the service hoist over the
ladder.

Rev: 28.08.08 / ECN 28833

The service hoist bottom Fig. 17.42
wheels are lowered down the
ladder
• Lower the service hoist bottom wheels carefully over the ladder until they en-
gage with the ladder.
Fig. 18.42
Lower carefully.
• Lower the service hoist further down the ladder until the top wheels engage
with the ladder.
Fig. 19.42

Rev: 28.08.08 / ECN 28833

Fig. 20.42
Lower the service hoist down to
ground level when the top
wheels are wheeled on the lad-
der.
Fig. 21.42
Lower the service hoist carefully
down to ground level.
• When the service hoist is at ground level, mount the transverse spindle in
through the ladder steps as stop for the service hoist.
Fig. 22.42

Rev: 28.08.08 / ECN 28833

2. Roll-out of steel wire
IMPORTANT! • Always use gloves when handling steel wires.
driving/safety wires Fig. 23.42

Wires are coiled up on winch
barrel.
Wires may not be thready.
It must be a hard bullet-shaped

end in order to pull it through the
system.
Wire ends Fig. 24.42

Wires may not be thready.
It must be a hard bullet-shaped

end in order to pull it through the
system.
• 3. The steel wire end must be equipped with a bullet-shaped wire end.
Winch barrel Fig. 25.42

Winch barrel.
IMPORTANT! • Steel wires must be coiled up on a winch barrel with the sw-end on the inside
of the roll.
• Sw must be rolled out by means of a winch barrel and must manually be low-
ered carefully to ground level.

Rev: 28.08.08 / ECN 28833

Uncoiling of wire Fig. 26.42
Uncoil the wire rope. Carefully
turn the coil while uncoiling in or-
der to prevent twists and kinks in
the wire rope.
Fig. 27.42
Carry out the uncoiling with great
care in order to prevent twists
and kinks from occurring.
The wire weight Fig. 28.42

1.Wire weight is fitted on steel
1 wire end.
• Attach a weight to the wire end while the wire from the winch barrel is carefully
rolled out.
The wire weight is lowered to Fig. 29.42
ground level 1. Wire weight.
2. The service hoist in the bottom

tower.
The wire weight helps the wire

end not to get caught between
ladder steps or the intermediate
1. alighting and boarding platforms
of the tower.
2.

Rev: 28.08.08 / ECN 28833

3. Feed-in of wire in the hoist
Feed-in of wire in the hoist Fig. 30.42

Lift up the wire from ground level.
Put wire in the hoist Fig. 31.42

Put the bullet end in the hole for
the hoist. Push down the wire in
the hole.
4
Let go of the wire when the hoist
starts pulling it.
Run wire through the hoist Fig. 32.42

Start the hoist at the platform
control box for the service hoist
by turning button in upward di-
rection.
1 Control box for the service

hoist.
Then run the wire down the hoist

by turning the button in upward
direction.

Rev: 28.08.08 / ECN 28833

Put wire in control bracket Fig. 33.42
When approx. 3 m wire has
come out through the hoist, it is
lead on, down through control
bracket.
1 Control bracket.
1
Fig. 34.42
1 Run through the control
bracket.
Run down wire to ground lev- Fig. 35.42

el Run the driving wire down
through the hoist until it reaches
ground level in the bottom sec-
tion.
Fig. 36.42
The wires at ground level.
1 Safety wires.
1
2 Driving wire.
(Off shore)

Rev: 28.08.08 / ECN 28833

4. Bottom console for safety/driving wires
(On shore) mounting Fig. 37.42

Mounting of bottom console for
safety/driving wires.
Fig. 38.42
4 Safety steel wire is prestressed
max. 150 kg. which corresponds
the proper weight of the service
hoist.
5 7
Weight for driving wires Fig. 39.42

In driving wires a weight of 6 kg
is to be fitted in order to stretch
out driving wires.
IMPORTANT! Fig. 40.42

Wire clamp is fitted whereafter
wires are pulled back through the
plummet hole.
The wire must not be cut by cut-

ting as the cone-shaped end
must be intact.

Rev: 28.08.08 / ECN 28833

Fig. 41.42
The wires are tied in order for
them to stay next to each other.
Fig. 42.42
The wires are tied in order for
them to stay next to each other.
Fig. 43.42
The cone-shaped end of the wire
must always be intact for possi-
ble future use.

Rev: 28.08.08 / ECN 28833

Offshore bottom console (option)
Bottom console (offshore) Fig. 44.42

Bottom console for the service
1 3 hoist.
1 Bracket for ladder.

2 Bracket for climbing wire.
3 Pipe for weight for driving
2 wire.
4 Safety wire bracket.
Warning line fitted Fig. 45.42

Fitting of warning line for the ser-
vice hoist driving area.
The service hoist driving area
Marking off for weight pipe Fig. 46.42

Marking the hole for weight for
driving wire.

Rev: 28.08.08 / ECN 28833

(Off shore) mounting Fig. 47.42
Mounting of bottom console for
safety/driving wires.

wire. The pipe is counter-
sunk into the floor.
(Offshore)
(Offshore) mounting. Seen Fig. 48.42

underneath the 1st platform Mounting of bottom console for
safety/driving wires. Seen under-
neath the 1st platform.
1
wire.
5
(Offshore)
IMPORTANT! The service hoist must be secured for falling down before the bracket is dis-
mounted.
Fig. 49.42
1 Service hoist bottom.
1. 2 A passing threaded spindle
going through inside the lad-
der.
3 Spindle.
2. 3.
Fig. 50.42
Dismount bracket for service
hoist, a passing threaded spindle
going through the ladder step to
the other side of the service
hoist.

Rev: 28.08.08 / ECN 28833

Make sure that wires are al- Fig. 51.42
ways tight 4 Seen from above.
1. The two wires must be tight-

e ned.
2. 2. Front for the service hoist.
1.
D.
Fig. 52.42
4
Seen from below.
1. F.
1.The two wires must be tight-
e ned.
2.
C. 2. Front for the service hoist.
D.
E
Fig. 53.42
Seen from above.
2. 1. Driving wires.
2. Safety brake.
3. Safety wires.
1.
3.
Fig. 54.42
4
Seen from above.
1.
1. Driving wires.
2.
2. Safety brake.
1.
D.
E

Rev: 28.08.08 / ECN 28833

5. Joining of power cables and operation boxes
• The main power cables of the Service hoist are inserted.
• “The external operation boxes or Send/Call stations (VN, V11, V12) are pre-
pared and connected according to the electricity plan (El diagram 1G.- 2G.).
Fig. 55.42
The cover of the external opera-
tion boxes are removed. Con-
nect miscellaneous electric lines
subsequently.
Fig. 56.42
The connection box is placed be-
hind connection cable trays.
Fig. 57.42
Central Control placed on top of
the cabin doorway.
• “Joining boxes (V10) are prepared and connected in accordance with the Elec-
tricity diagram.

Rev: 28.08.08 / ECN 28833

• “Perform “Installation check.

Rev: 28.08.08 / ECN 28833

Electricity diagram 1 G
~
~

Rev: 28.08.08 / ECN 28833

Electricity diagram 2 G

Rev: 28.08.08 / ECN 28833

6. Safety and driving wires in the service hoist
Top reference/fitting position • The Service hoist must be lead to assembly level at the tower bottom.
• Make sure that the cage-arresting device is open. This is indicated by

RED light in the safety brake signal light. (E, Fig. 58.42)
Fig. 58.42
A. Safety brake reset lever.
B. B. Red activation handle of the
C.
Safety brake.
D. C. driving wires.
D. Red overload indicator. Lamp

E. will light if the brake is activated.
Max. wight of 250 kg.
A. E. Red lamp. Will light when the

brake is activated.
F.
F. UP/DOWN knobs.
H.
G. G. Emergency stop push button.
H.Safety wires.
• Release the emergency stop push button. (G.Fig. 58.42)
• Lower the access door in order to connect the door switch.
Fig. 59.42
B. 1.Door switch.
A. 4
F.
C.
1.
• Chose driving direction knobs UP/

. DOWN. Keep it turned during the drive.
• If the total load exceeds the limit of 250 kg drastically, the “RED maximum load
signal lamp” light and stop the drive. The current to the motor will remain dis-
connected until the load has been reduced.

Rev: 28.08.08 / ECN 28833

Fig. 60.42
1. Operating switch UP/DOWN.
1.
2. Emergency stop push button.
2.
• When stopping at a entry and exit platforms between top and bottom, the door
is to be used to establish that the service hoist is in the correct position.
• Release the operated direction switch to stop the service hoist when the cor-
rect position is reached.
• Raise the sliding door.
• In order for the Service hoist to continue up or down, the cabin access door
must be completely shut and the emergency stop push button (G.Fig.
58.42 ) must not be activated.
• The fitters must attach the safety belts to the service hoist . Subsequently, drive
the service hoist down to assembly.
• The Service hoist must be in the bottom of the tower, at the lowest possible
driving position.
Fig. 61.42
Position for mounting of the ser-
vice hoist.
• Before activating the Safety brake, the service hoist is raised approx. 0.5 m
above bottom limit stop.
WARNING! • Before moving on, it must be checked that the Safety brake is attached to a
safety wire. The entire suspended load carried by suspension wires must now
be transferred to safety wires.
• Activate the Safety brake normally by turning the RED 'Manual Flipping'-han-
dle on the Safety brake counter-clockwise.

Rev: 28.08.08 / ECN 28833

The Safety brake (Red Flip- Fig. 62.42
ping handle) 1. The Red 'Manual Flipping-
handle is turned counter-clock-
wise.
• The RED 'Manual Flipping'-handle is turned counter-clockwise.
• Subsequently, the safety brake is released by turning the reset handle clock-
wise.
• Turn the safety brake reset handle clockwise, then turn up/down knobs up-
wards to max. 30 cm above bottom limit level.
Fig. 63.42
1.Release the safety brake by
turning the reset handle clock-
wise.
2. Turn up/down knobs upwards.
• Afterwards, drive the service hoist downwards by using the emergency handle
down to the bottom limit to loosen the wires.
Emergency handle for emer- Fig. 64.42

gency drive 1.Pull the emergency handle to-
wards the access door. As a re-
sult, the drive down is controlled
by the service hoist.
1
4
2

Rev: 28.08.08 / ECN 28833

7. Fitting of top & bottom power switch
• The Service hoist is equipped with safety power switches in top/bottom of the
service hoist in order to stop it at these locations.
• Make sure that the top and bottom power switch are able to activate.
Top power switch Fig. 65.42

1.Top power switch.
2. Safety stop.
1 Last Top and Bottom power
switch.
2
A.Bottom power switch.
Fig. 66.42
1.Top power switch.
1.
2.Safety stop.
Last Top and Bottom power
switch.
2.
A. Bottom power switch.
A.
Top safety stop Fig. 67.42

1. Top safety stop is at the top
right side of the service hoist be-
tween the emergency ladder .
2. Reset blue knobs.

1.
2.
D
• The Service hoist stops when the plate is forced down, e.g. if an object or a
person is on the emergency ladder.

Rev: 28.08.08 / ECN 28833

Top safety stop is reset Fig. 68.42
1.The blue reset knob of the top
safety stop is pulled out.
1.
• The blue reset knob is located on the right side between the emergency ladder
and the top part of the service hoist. The knob is pulled out if the top safety
stop is released.
Bottom power switch Fig. 69.42

1 Top power switch.
1 2 Top/Bottom power switch
stop.
A. Bottom power switch.

2
Fig. 70.42
Mounting of power switch brack-
et on emergency ladder in the
bottom of the tower.
Fig. 71.42
1 Top power switch.
1.
2 Top/Bottom power switch
stop.
2. A. Bottom power switch.
A.

Rev: 28.08.08 / ECN 28833

Bottom limit safety stop Fig. 72.42
1.In case of the emergency plate
being forced upwards, the safety
stop will be activated.
2.The safety stop will remain ac-

tivated until it has been reset.
Fig. 73.42
1.In case of the emergency plate
being forced upwards, the safety
stop will be activated.
2.The safety stop will remain ac-

tivated until it has been reset.
1 2
Fig. 74.42
Seen from one side.
2 1. Safety plate activating the

safety stop.
2. The safety stop.
By pushing the blue knob, the

1 safety stop will be reset again .
• As it must ensure that no persons or objects could get injured and if the service
hoist is blocked at descent, the bottom limit safety stop must stop immediately
if the bottom plate is forced upwards.

Rev: 28.08.08 / ECN 28833

8. Before use and operation of the service hoist
1. Wire procedure and preparation.
Wires are prepared for drive • Attach the safety belts to the service hoist when driving up.
• Any exceeding wire at ground level must be rolled up and tied in such a way
that no wires are touching the ground. The wire must be hanging FREELY ap-
prox. 20 cm above ground level (with exceeding wire rolled up), This allows
the tension built-up in the steel wire to “unreel” during the first ascent with the
service hoist to ground level.
• Operators of the service hoist will notice that the steel wire will twist a little dur-
ing ascent and descent of the service hoist, causing the tension in the steel
wire to release, which prevents the arising of “bird cages”. Thereby, it will re-
move the tension and untwist the wire.
• Fitters should drive the service hoist to the highest position of the tower and
thereafter return to ground level , stopping at each platform to inspect the steel
wires for signs of bid caging at the primary wire .
• Drive the service hoist up the tower to the highest possible driving position.
Check if the top power switch is mounted in the correct position and that the
service hoist will stop when the Top power switch is activated.
• This procedure should be repeated at least two times before the steel wire can
finally be used. This allows for wire to turn and removes possible twists and
tensions from the wires .
2. Wire procedure and preparation.
Attach the wires to bottom • Fitter must now attach the wires to bottom console for safety/driving wire be-
console neath the power unit. See , “4. Bottom console for safety/driving wires,” .
• The wire may NOT be cut as it must have the correct cone-shaped wire end
for future check of the service hoist.
• Fitters should drive the service hoist to the highest position of the tower and
thereafter return to ground level, stopping at each platform to inspect the steel
wires for signs of bird caging at the primary wire .
• If the wires are still showing” zz”. signs of bird caging, the above-mentioned
procedure must be repeated.
IMPORTANT! “Tension” must be released from the steel wire by following the above-mentioned
procedure. Neglect in carefully following this procedure will result in WIRE
BLOCKING AND/OR BIRD CAGING.
This procedure must be followed each time the service hoist is in use:

Rev: 28.08.08 / ECN 28833

WARNING! • Make sure that the safety steel wire is always tight and that both wires are free
above and below the service hoist. See, “Make sure that wires are always
tight.”
Emergency ascent/desent
In case of power failure or other incidents disconnecting the current to the motor,
the emergency stop is to be pushed. It is possible to raise the service hoist man-
ually a few cm. see pictures below.
Ascent/descent Fig. 75.42

1. Emergency hand wheel for as-
cent/descent. (to be unscrewed)

hand wheel.
1
3.Emergency lever brake loosen
for motor. (by pushing towards
the access door, the brake is
loosened).
Fig. 76.42
2. hand wheel ascent/descent. Sub-
sequently, turn counter-clock-
wise if the service hoist is to go
up/down, push the emergency
lever towards the access door.

Rev: 28.08.08 / ECN 28833

Fig. 77.42
1. Emergency lever for ascent/
descent.

1 hand wheel.
3. Brake will loosen for the motor

3
hoist.
4
4. Plug for motor.
2
Descent procedure • Emergency lever for descent (1. Fig. 75.42) is placed in the side of the motor
end cover , and can be operated manually through an opening in the top plate.
Emergency lever for descent Fig. 78.42

1. The emergency lever for de-
scent.
1.
• Pull the lever towards the access door in order to release the brake.
• The built-in condenser brake circuit of the motor prevents the service hoist
from exceeding the permissible speed.
WARNING! At manual descent, it is very important to make sure that no persons are using the
ladder below the service hoist. If the service hoist hits a person or an object, the
bracket mounted side frame attached to a safety switch will be released automat-
ically, preventing further descent.
After removal of the blocking person or object, and after resetting the lower reset
button of the safety switch See , “7. Fitting of top & bottom power switch,” ,
the descent can continue.

Rev: 28.08.08 / ECN 28833

Fig. 79.42
1.The blue reset button of the
1. bottom limit stop, under the ser-
vice hoist. The button is
pushed.
See , “7. Fitting of top & bot-

tom power switch,”
Fig. 80.42
1.The blue reset button of the top
limit stop, is located on the right
1.
side between the ladder and the
top part of the service hoist. The
button is pulled.
See , “7. Fitting of top & bot-

tom power switch,”
Emergency ascent It is possible to manually drive up the service hoist a few cm in order to release
the safety brake is this has been activated by mistake, and the current to the mo-
tor has been cut off. See , “Emergency ascent/desent,”
Procedure for manual ascent 1.Insert the handwheel in the motor rear See , “Emergency ascent/desent,”
of the service hoist
2.Release the motor brake by using the emergency descent lever “See , “Emer-
gency lever for descent,” and turn the hand wheel to release the safety wire.
3. Tighten the motor brake.
4. Place the hand wheel in its retainer after use.
5. If the safety brake is activated, push the RED release lever (B.Fig. 81.42) to
release driving wires , making it only drive on safety wires.
Evacuation If a person is forced to leave the service hoist between platforms, the per-
son must use a belt as well as follow the below-mentioned procedure:
1. Activate the emergency stop push button. (G.Fig. 81.42).
2. Attach the short safety line to the safety ring in the service hoist and to the safe-
ty cable.
3. Open the access door.
4. Attach the long safety line to the outer safety ring and loosen the short safety
line.
5. Crawl out to the emergency ladder and attach the safety shoes of the short
safety cable to the safety wire.
6. Loosen the long safety cable.

Rev: 28.08.08 / ECN 28833

WARNING! For safety reasons, all persons must leave the service hoist during evacu-
ation.
The safety brake Fig. 81.42

A. Reset lever of the Safety
brake.
B.
C.
B.Safety brake red activation
handle.
D.
C. Driving wires.
E. D. Red over load indicator. The

pilot light will be on if the brake is
activated. Max. wight of 250 kg
A.
E. Red pilot light. Will be on
F. when the brake is activated.
H. F. UP/DOWN knobs.
G.
G. Emergency stop push button.
H.Safety wires.
Maintenance of wires/gearbox and motor
Gearbox (lubrication) Normally, the gearbox oil does not need to be changed as motor shaft gear and
the gearbox is replaced after 50 hours of running.
The gearbox standard oil has a running temperature range of -20 to +40 degrees
C°.
Below-mentioned product can be used:
• API specification: “Synthetic oil ISO VG 460
• SHELL Tivoli Øl SD 460
• Mobil Glughul HE460
• Klubber Syntheso D460EP
Steel wires The primary steel wire of the service hoist and the secondary safety steel
wire of the Safety brake must be kept clean. Consequently, never use a lu-
bricant.

Rev: 28.08.08 / ECN 28833

Replacement of wires/gearbox and motor
• The service hoist must be in the lowest possible driving position during reno-
vation or replacement of the above-mentioned.
• Drive the service hoist down by using the emergency lever for descent. (See
Fig. 84.42)
The Safety brake (Red handle) Fig. 82.42

1. The red 'Manual Release'-
handle is turned counter-clock-
wise.
• The red 'Manual Release'-handle is turned counter-clockwise.
• Subsequently, the safety brake is loosened by turning the reset lever clock-
wise.
• Turn the reset lever of the safety brake clockwise, then turn the up/down knobs
upwards to max. 30 cm above bottom limit level.
Fig. 83.42,
1. Loosen the safety brake by
turning the reset lever counter-
clockwise. t
• To loosen the wires, drive thereafter the service hoist down to bottom limit by
using the emergency lever.

Rev: 28.08.08 / ECN 28833

Emergency lever for descent Fig. 84.42
1.Pull the emergency lever to-
wards the access door, making
1 the descent controlled by the
service hoist.
IMPORTANT! Drive the service hoist all the way to the bottom limit.
Fig. 85.42
Position for mounting of the ser-
vice hoist.
WARNING! Before proceeding, check if the Safety brake is fastened to the safety-sw. The en-
tire suspended load is to be carried by the safety-sw.
• Uncouple the driving wires from the wire weight at wire console beneath the
power unit in order for the wire to be free .
Driving wire must not be tightened before wire cutting. Are to be cut above the
electric hoist to the entry hole of the service hoist at the electric hoist.
Fig. 86.42
1. The electric hoist.
1. 2. Is to be cut approx. here, the

wires must not be tightened.
2.
• Remove the old steel wire from the upper anchor point from the top of the tow-
er.

Rev: 28.08.08 / ECN 28833

• The new steel wire is lead to the upper tower section and rolled carefully to
ground level manually. Each steel wire must be fastened to its respective cen-
tre of suspension. Follow the procedure.
• See , “2. Roll-out of steel wire,”

• See , “3. Feed-in of wire in the hoist,”
• By using the knob “Up”, the wire is lead through the electric hoist to guide block
and down to wire console beneath the power unit.
Fig. 87.42
1. Ascent knobs Up/down.
• Take the new driving wire end and lead it to the entry hole of the electric hoist.
Fig. 88.42
1. The electric hoist.
2. The entry hole.

1.
2.
• When the steel wire leaves the exit hole of the electric hoist for personal hoist,
it must be lead through the hole on sw-guide block.
Fig. 89.42
1. Guide block.
1.
2. The exit hole.
2.
• Drive the service hoist in Up-direction until the entire suspended load is trans-
ferred to the driving wire.

Rev: 28.08.08 / ECN 28833

IMPORTANT! • Reset the safety brake by using the Reset lever, but not until the entire sus-
pended load is transferred from the electric hoist to the driving wire.
Fig. 90.42
1. Loosen the safety brake by
1. turning the reset lever clockwise.
2.
• Any exceeding wire at ground level must be rolled up and tied in such a way
that no wires are touching the ground. The wire must be hanging FREELY ap-
prox. 20 cm above ground level (with exceeding wire rolled up), This allows
the tension built-up in the steel wire to “unreel” during the first ascent with the
service hoist to ground level.
• Operators of the service hoist will notice that the steel wire will twist a little dur-
ing ascent or descent of the cabin, whereby the tension in the steel wire is re-
leased resulting in the avoidance of “bird caging”.
• Continue with steel wires before the first use of the service hoist to remove the
tension and untwist the driving wire.
Standard check
Driving wire & safety wire • Make sure that both wires have the correct tension and that they are anchored
(Standard check) in both top and bottom.
Inspect both wires in their total length by going through the entire hoist height. If
one of the wires is damaged in one of the following ways, it must be replaced:
• “Sharp bends.
• “Pinch damage.
• “Hoop formation
• “Bird caging.
• “Severe corrosion.

Rev: 28.08.08 / ECN 28833

• “Wire diameter is reduced to less than 7.6 mm, measured on a wire without
load.
• “Destroyed single thread. Max. 8 threads for each wire length of 240 mm.
• “Check that all bolts in the top anchor point are fastened.
The use of other kinds of steel wires will pose a significant safety risk to the per-
sonnel and to the operating safety.
Standard check If the service hoist has not been used within 6 months, the service hoist must be
checked according to the following list:
50 hour inspection Check the motor shaft gear and gearbox of the lifting motor for abnormal
wear after 50 hours of uninterrupted and intensive use. After this, the motor
shaft gear/gearbox and the safety brake are to be replaced and wires are in-
spected and remeasured, wires must not be reduced to less than Ø 7.6 mm
measured on a wire without load. Otherwise, the wires must be replaced.
Or replace when it is assessed to be necessary.
Fig. 91.42
A. Hour meter.
A.
Service hoist inspection 1. The access door should be easy to operate and the door switch must work in
(Standard check) accordance with safety standards.
2. The safety rings which the safety cable is attached to must be securely in po-
sition.
3. Upper and lower safety precautions must work.
4. Emergency descent must work.
5. All wheels must be able to be moved freely and the wheel surfaces must be
intact without seriously worn areas.
6. The limit switches must work (Upper limit, Lower limit, safety limit).
7. Cabin operation must work (Up, Down, Emergency stop).
8. External operation must work (Up, Down, Emergency stop).
Cage-arresting device (Stan- • Emergency brake handle must work.

dard check)

Rev: 28.08.08 / ECN 28833

By activating the safety brake, the brake must close in such a way that it is
impossible to pull the safety steel wire upwards.
WARNING! If the driving wire or safety wire is to be replaced, only original wires with a diam-
eter om max. 8.3 mm are to be used.
The use of other kinds of steel wires will pose a significant safety risk to personnel
and to the operating safety.
External equipment (Standard check)
Special check In case that the cage-arresting device has been used, a safety check must be per-
formed.
Cage-arresting device (Spe- 1. Loosen the safety steel wire from the bottom wire tension block and pull the
cial check) loosened safety steel wire upwards with a sudden movement. This should acti-
vate the cage-arresting device.
Fig. 92.42
1.Loosen the cage-arresting de-
1. vice by turning the reset lever
clockwise.

2.
2. Reset the Safety brake by turning the reset lever (object 1).
When the safety brake is to be activated, the brake must close in such a way that
it is impossible to pull the wire upwards.
Troubleshooting
WARNING! Troubleshooting and repairs of electrical equipment must only be performed by

an qualified electrician.
Error Cause Solution

Rev: 28.08.08 / ECN 28833

The service hoist is not moving either Stop working immediately as it
up or down when the direction switch might damage the hoist unit and
is activated, even though the motor is pose a safety risk.
running
Wire is stuck in the hoist unit. Contact qualified personnel.
Wrong wire type
The service hoist cannot be moved Remove the obstacle and check
freely the service hoist for damages.
The service hoist is not moving. a. No control current a. Loosen the emergency stop
The motor is not running b. Power failure b. Find the cause.
c. Two phases have been replaced c. Replace phases.
d. Defect connection between the d. Check the main fuse

main current and the control box.
e. Remove the obstacle and reset
e. The safety device has been acti- the safety device.
vated.
Wrong connection Compare with diagram.
No neutral phase
Motor failure due to overheating a. Check fuses and connections
a. A phase is missing b. Clean the motor’s air inlet
b. Inadequate cooling c. Check tension and consumption

during operation.
c. Too high/low tension
d. Install a cable with more capaci-
ty.
The motor brake will not loosen. A a. Check cables and plugs.
click should be heard when the di-
rection switch is operated. b. Check brake coil.
a. Poor main current connection. c. Check the electric valve.
b. Defect brake coil. d. Send the motor for repairs.
c. Defect electric valve.
d. Worn brake rotor.
Error Cause Solution

Rev: 28.08.08 / ECN 28833

The service hoist can be moved down, but a. The service hoist is caught on a. Drive carefully a bit down and
not up. an obstacle. remove the obstacle.
b. The overload fuse has caused b. Reduce the load.

failure on the motor.
c. Check the switch.
c. The upper limit switch is de-
fect. d. Drive down to loosen the
switch.
d. The upper limit switch is acti-
vated. e. Check fuses and connections.
e. A phase is missing. f. Call an electrician.
f. Error in control circuit. g. Remove the cause and reset

the switch.
g. The upper safety device has
been activated. t.
Noise from the motor. Overheating. a. Check fuses and connections
b. Clean the motor’s air inlet.
c. Check tension and consump-

tion during operation.
d. Install a cable with more ca-

pacity.
Dirt in the drive. NB: Replace the motor.

Continued drive might damage
the wire and the drive.
The service hoist can drive up, but not The service hoist has reached an Drive carefully a bit upwards and
down. obstacle. remove the obstacle. Then reset
the safety switch in the bottom.
Cage-arresting device keeps the Loosen the cage-arresting de-

basket in the safety wire. vice and make sure that the wire
is tight up over the basket.
Damage of the driving wire. Leave the car. See this. Have the
wire replaced.
The speed exceeds the limit for Check the speed in comparison
the cage-arresting device. with the specifications. Replace
the hoist unit.
The lower safety device is acti- Remove the cause and reset the
vated. switch.

Rev: 28.08.08 / ECN 28833

- Chapter 28 MISCELLANEOUS TOOLS

Phone: (+45) 99 42 22 22
Telefax: (+45) 99 99 22 22
Chapter 28 MISCELLANEOUS TOOLS

SWT - 2.3 - 82VS/93/101
• Appendix - Data sheet

yyyy)

Document history

93/101

Appendix - Data sheet - Miscellaneous tools
See “AI-WI554222”
See “Pressure tool for tower flanges (all middle flanges) for 2.3MW”
See “Mounting and operating control box for use of crane, yaw and hydraulic
pressure in hub (Old type)”
See “Mounting and operation of control box in A6 (Rotorlift)”
See “Mounting and operation of control box/pitch adjustment of older type (Op-
tion)”


Arbejdsinstruktion
AI-WI554222
Work Instruction
Designer: SPE Beskrivelse: Betjening af hytorc
Description: Use of hytorc
Dato/Date: 05-08-05 Operation: Retrofit
ECN nr.: 17416 Værktøj/Tools:
Suppl. Dele/Parts: 200246 / 200247 / 200265
ECN Dato / Date: 09-08-05 Mølle/Turbine type: Standard
DK: Der henvises i øvrigt til CH
Vigtigt: Brug altid nødvendigt sikkerhedsudstyr, når der arbejdes med kemikalier, elværktøj og luftværktøj.
Der henvises iøvrigt til sikkerhedsdatabladene. Hold altid arbejdsområdet rent. Fjern spåner og snavs, når
disse findes. Der henvises til manualen generelle sikkerhedsregler.
GB: Refer also to CH
Note: Always use the necessary personal safety equipment when working with chemicals, electrical tools
and phneumatic tools. Also check the safety data sheets. Always keep the work area clean. Clean away any
swarf and dirt. Reference should be made to the general health and safety manual.
DK- Inden brug kontrolleres det at hytorc,

slanger og spændehoved ikke er defekt.
Slanger monteres på hytorc. Bemærk der
findes både slanger med lynkobling og
slanger med skruekobling.
UK- Before use, check that the hytorc, hoses

and tension head are not defective. Con-
nect the hoses to the hytorc. Note that
both quick acting couplings and screw
couplings exist.
Fig 38
829 / 836
AI-WI554222 - 17416

DK- På lynkoblingen drejes sikringsringen så
ringen kan trækkes tilbage og slangen
monteres.
UK- Turn the quick acting coupling to make it

possible to pull back the ring and fit the
hose.
Fig 39
DK- Efter montering af slange i lynkobling,

drejes sikringsringen tilbage så den låses.
UK- After fitting the hose in the quick acting

coupling the lock ring must be turned
back to lock.
Fig 40
830 / 836 AI-WI554222 - 17416

DK- Spændehoved monteres på slanger. Husk
at låse evt. lynkobling.
UK- Fit the tension head on the hoses,

Remember to lock any quick acting cou-
plings.
Fig 41
DK- Lokaliser ID nr. på spændehoved. Det

står indgraveret på spændehovedet.
UK- Find the ID number on the tension head.

The number in engraved on the tension
head.
Fig 42
831 / 836
AI-WI554222 - 17416

DK- Det kontrolleres at ID nr. på spænde-
hoved er det samme som på indstilling-
stabel. Når det er konstateret at
spændehoved og indstillingstabel hører
sammen, aflæses der i tabellen hvor
mange bar’s tryk hytorcen skal indstilles
til for at spændehovedet spænder det
antal moment man skal spænde.
UK- Check that the ID no. on the tension head

is the same as on the settings table. When
having checked that the tension head and
the settings table correspond, use the
table to find the setting pressure for the
hytorc which corresponds to the correct
Fig 43
torque.
DK- Hytorcen startes og aktiveres med spæn-

dehovedet fri. Når spændehovedet er i
bund aflæses trykket. Bemærk: Hvis
hytorcen er kold, køres der op i tryk og
slækkes et par minutter for at varme
olien op, da dette har indflydelse på
indstilling af tryk.
UK- Start the Hytorc and activate it with the

tension head free. When the tension head
is fully down, read the pressure. Note: If
the hytorc is cold build the pressure
and release it for a few minutes to heat
up the oil as this has influence on the
setting adjustment.
Fig 44
832 / 836 AI-WI554222 - 17416

DK- Hvis trykket skal sænkes, deaktiveres
spændehovedet, inden trykket skrues
ned.
UK- If the pressure needs to be lowered, deac-

tivate the tension head before turning
down the pressure.
Fig 45
DK- Trykket skrues ned ved at dreje regula-

toren mod uret. Spændehovedet aktiveres
ind imellem for at aflæse tryk.
UK- Turn down the pressure by turning the

regulator clockwise. Activate the tension
head now and then to read the pressure.
Fig 46
833 / 836
AI-WI554222 - 17416

DK- Når trykket er justeret ned under det
ønskede tryk eller trykket skal justeres
op, aktiveres spændehovedet og holdes
aktiveret imens der justeres på regulator.
UK- When the pressure is adjusted to below

the wanted pressure or the pressure needs
to be increased, the tension head must be
activated and stay activated while adjust-
ing the regulator.
Fig 47
DK- Regulatoren drejes med uret, mens

trykket aflæses på manometeret. Når det
ønskede tryk er opnået, deaktiveres
spændehovedet og aktiveres igen, og
trykket kontrolaflæses og justeres evt.
igen. Dette gentages, indtil det ønskede
tryk er opnået ved kontrolaflæsningen.
Hytorcen er nu klar til brug.
UK- Turn the regulator anticlockwise while

reading the pressure on the manometer.
When the wanted pressure has been
reached, the tension head must be deacti-
vated and reactivated, and the pressure
check read and readjusted. Repeat this
Fig 48
procedure until the wanted pressure has
been reached in the check read. The
hytorc is now ready for use.
834 / 836 AI-WI554222 - 17416

DK- Vigtigt: Ved brug af hytorc SKAL det
være samme person, der holder spæn-
dehovedet og aktiverer spændehove-
det. Sørg altid for at have et stabilt
modhold for spændehovedet og hold
altid spændehovedet, så der ikke er
fare for at klemme hånden eller fin-
grene ved aktivering.
UK- Note: When using the hytorc, the per-

son holding the tension head MUST
activate the tension head himself.
Always make sure to have a stable
backstop for the tension head and
always hold the tension head in a safe
Fig 49
way with no risk of jamming in hands
or fingers on activation.
DK- Vigtigt: Ved brug af hytorc SKAL det

være samme person, der holder spæn-
dehovedet og aktiverer spændehove-
det. Sørg altid for at have et stabilt
modhold for spændehovedet og hold
altid spændehovedet, så der ikke er
fare for at klemme hånden eller fin-
grene ved aktivering.
UK- Note: When using the hytorc, the per-

son holding the tension head MUST
activate the tension head himself.
Always make sure to have a stable
back stop for the tension head and
always hold the tension head in a safe
Fig 50
way with no risk of jamming in hands
or fingers on activation.
835 / 836
AI-WI554222 - 17416

DK- Ved spændehoved med justerbart mod-
hold drejes denne altid i den mest stabile
position. I tilfælde hvor modhold går
mod malede overflader lægges der en
klud mellem modhold og malet over-
flade.
UK- For tension heads with adjustable back

top, always turn it to the most stable
position. In case the back stop rests on
painted surfaces, place a piece of cloth
between the back stop and painted sur-
face.
Fig 51
DK- Efter brug afmonteres slanger og spæn-

dehoved. Husk at monterer støvhætter
igen for at undgå snavs i systemet.
UK- After use, remove hoses and tension

head. Remember to refit dust caps to
avoid dirt in the system.
Fig 52
836 / 836 AI-WI554222 - 17416

Pressure tool for tower flanges (all middle flanges) for 2.3MW
Pressure tool for tower flanges (all middle flanges) for

2.3MW
Assembly and mounting of (See the table for choice of middle section).
pressure tool
Fig. 0.42
Assembled pressure tool.
1 2
3 1. Middle section for tool.
2. Pressure rod (fixed end).
4 3. Pressure rod (cylinder end).
4. Flange bracket (fixed end / cyl-

inder end).
Fig. 0.43
Pressure tool disassembled
Part list no. 56 88 59.
Fig. 0.44
Pressure tool disassembled.
Fig. 0.45
1. Flange bracket (cylinder end).
4 1
2. Assembled hydraulic cylinder
and flange fixture.
3. Bushing (long).
4. Fixing pin.
3 2
(See the table for choice of bush-
ing).
Siemens Wind Power A/S / Pressure tool for tower flange / AS 557327 / 25.10.2005 837 / 840
Rev: 22.08.06 / ECN 21824

Fig. 0.46
1. Pole split pin.
3
2. Flange fixture/assembled hy-
draulic cylinder
3. Bushing (long).
4. Bushing (short).
4
1 2
(See the table for choice of bush-
ing).
Fig. 0.47
Pressure tool fitted on the tower
flange.
1. Always place the split pin be-

tween the tower flanges (under
the joint), and position it where it
is easy to remove when the tow-
er flanges are assembled.
The flange bracket can be

pushed out of the way to make
1
room for flange bolts.
Fig. 0.48
Assembled pressure tool
IMPORTANT!
The tool must be placed in the

centre holes (equal number of
holes to each side).
• When the pressure tool has been fitted, connect the hand pump at press the
flange out to fit the bolts in the flange connection.
WARNING! • Always keep the tool under observation when applying pressure.
• If the tool bends, stop the process and find a better position for the tool before
applying pressure again.
838 / 840 Siemens Wind Power A/S / Pressure tool for tower flange / AS 557327 / 25.10.2005
Rev: 22.08.06 / ECN 21824

Table of matching middle sec- The tower type is site specific.

tions and bushings
Each tower has two flange connections - the flanges in each flange connection
correspond, except tower type D (Rev.0).
Tower Flange connec- Tool combination with Long bushing Short bushing
Type tion middle section
TM = Top section - Find the right bushing for the right flange on the
Middle section tower sections below:
BM = Bottom sec- B = Middle flange on bottom section

tion - Middle sec- M = Middle flange on middle section
tion.
A og B TM Middle - (866mm) 50mm 10mm

BM Short - (746mm) 40mm 0mm
C (Rev. 0) TM Long - (946mm) 50mm 10mm

BM Middle (866mm) 40mm 0mm
C (Rev. 1) TM Middle - (866mm) 50mm 10mm

D (Rev. 0) TM Long - (946mm) 50mm 10mm

BM Middle - (866mm) M = 50mm, B = 40mm M = 0mm, B = 0mm
D (Rev. 1) TM Middle - (866mm) 50mm 10mm

BM Middle - (866mm) 50mm 10mm
E (Rev. 0) TM Long - (946mm) 50mm 10mm

E (Rev. 1) TM Middle - (866mm) 50mm 10mm

F (Rev. 0) TM Middle - (866mm) 50mm 10mm

Siemens Wind Power A/S / Pressure tool for tower flange / AS 557327 / 25.10.2005 839 / 840
Rev: 22.08.06 / ECN 21824

840 / 840 Siemens Wind Power A/S / Pressure tool for tower flange / AS 557327 / 25.10.2005
Rev: 22.08.06 / ECN 21824

Mounting and operating control box for use of crane, yaw and hydraulic pressure in hub (Old type)
Mounting and operating control box for use of crane, yaw

and hydraulic pressure in hub (Old type)
In general The erection box is used when; The turbine is not yet connected to the grid. The
erection box enables use off; The service crane, the yaw switch in the A18 cabi-
net, and the hydraulic station in the nacelle (Necessary to use the pitch function
on the blade bearings/Blades).
Fig. 0.49
Control box.
1 Cable from the A3 controller

to be connected here.
Connection of the cable for If the cable for the erection box is not mounted in the A3 controller from the fac-
erection box in the A3 tory, this must be done on site as described in the following pages.
Pass the cable through an M20 gland at terminal 607.X1 in the A3 box.
Fit wires No. 1 and No. 3 in the Wire 1: Supplies the hydraulic pump, when the user takes control from the A9
A3 controller box.
Wire 3: Controls the hydraulic pump with the PR module in the control box.
Fig. 0.50 (Page 71 in A3 controller diagram)
SWT- 2.3 - 82/93 / Erection box SWT-2.3-93 / OM 575343 / 31.05.2007 841 / 848
Rev: 21.04.2008 ECN 27625

Fit wire No. 1 Wire 1: Activates the emergency contactor both in A3 and A18
Fit wire No. 1 Wire 1: Supplies the A9 box with 230V
842 / 848 SWT- 2.3 - 82/93 / Erection box SWT-2.3-93 / OM 575343 / 31.05.2007
Rev: 21.04.2008 ECN 27625

Fit wire No. 2 Wire 2: Supplies the neutral, it maybe connected differently but as long it is con-
nected to a N6 in the A3 box is OK.
Fit wire No. 4 Wire 4: Powers the 230V to the A18 box
Rev: 21.04.2008 ECN 27625

Fit wire No. 5 Wire 5: Supplies 24VDC to the A9 box (CRANE/HATCH)
Fit wire Nos. 5 and 7 Wire 5: Supplies the Pressure transducer.

Wire 7: Is the Sense from the pressure transducer.
Rev: 21.04.2008 ECN 27625

Fit wire No. 5 and No. 8 Wire 5: Helps supplying the A9 box (24VDC)
Wire 8: Can control the By-pass valve (V25)
Fit wire No. 5 and No. 6 Wire 5: Supplies the yaw converter IO module (24 VDC)
Wire 6: Supplies the yaw converter IO module (0 VDC)
Rev: 21.04.2008 ECN 27625

Fit wire No. 6 Wire 6: Powers up the 0VDC.
IMPORTANT! Connect the joint cables A3-808.W3 /Yaw twist), A3-509.W1 (supply for hub),
A4-809.W5 (230 V supply from A2) and A4-801.W1 (Feedback from A2) in or-
der to avoid voltage feedback through the tower.
Operating crane, yaw and hy- When the cable is mounted connect the multiple plug to the control box and con-
draulics nect the 110 V/230 V plug to the service plug on the side of the A3 box.
NOTE: The emergency contactors will close as soon as the box is connect-
ed.
Starting up the hydraulics Fig. 0.60

The green "Start" button is used
for starting up the hydraulic
1 pump; it will stop automatically
after 10 min. or when the red
stop button is pressed.
1 Press the green button for

starting up hydraulics.
Rev: 21.04.2008 ECN 27625

Yawing of nacelle Fig. 0.61

In order to yaw the nacelle turn
the button called "Krøje" (Yaw) to
1 position "1". After that it is possi-
ble to yaw by means of the
switch in the A18 box.
1 Turn the button to "1".
Fig. 0.62
After that it is possible to yaw by
means of the switch in the A18
box.
1
1 Yaw switch in A18.
Operating the service crane. Fig. 0.63

Use the ordinary buttons on the
A9 box and on the crane for
1 craning.
NOTE: Start up the hydraulics by

using the green button on the
erection box.
Fig. 0.64
Use the ordinary buttons on the
A9 box and on the crane for
1 craning.
NOTE: Start up the hydraulics by

using the green button on the
erection box.
Rev: 21.04.2008 ECN 27625

Rev: 21.04.2008 ECN 27625

Mounting and operation of control box in A6 (Rotorlift)
WARNING ! At pitch of the blade bearing with electrical control box it is important to be
aware of following:
WARNING ! The electrical control box activates “emergency pitch” on all 3 blade bear-
ings at net failure and at “Power off”. Therefore, it is very important that the
twin valves (108) are closed. Only open the twin valve (108) where the blade
bearing must be pitched.
When you do not pitch, then close for the twin valve(108).
Fig. 0.65
1.Twin valve (108) on valve
block.
The valve is shown in closed

position.
Mounting of control box for At rotor mounting the blades and hub are assembled on a special foot (“elephant
pitch of blade bearing in A6 foot”) before mounting on the nacelle. Therefore, the control box for pitch of blade
bearings must be mounted in the control box A6 of the hub. The control box con-
sists of 2 parts:
1. part is a cable split in two: A plug for fitting in the control and a plug for fitting in
the 230 V voltage part of the control in one end and a large multi plug in the other
end.
2. part is the box with cables for: Fitting on the cable fitted in the control and a 230
V cable for fitting in the socket respectively.
Fig. 0.66
The cable split in two for the con-
trol box is fitted in the hub control
A6.
1 The cable for control.

2 The cable for 230V.
1 2
SWT- 2.3 - 93 / Opstillingsmanual / OM 575343 / 31.05.2007 849 / 854

Rev: 31.05.07 / ECN 24168

Cable for control is fitted Fig. 0.67

Before the cable for control can
be fitted in A6, a transition piece
must befitted.
1 Transition piece.
Fig. 0.68
Before the cable for the control
can be fitted in A6, the blind plug
1 No. X23 must be removed from
the printed circuit board.
1 Blind plug No. X23 is placed

here.
2 Remove the blind plug.
2
Fig. 0.69
The plug from the transition
piece is fitted in the control on
position X23.
1 Plug is fitted.
Cable for 230V is fitted Fig. 0.70

Cable for 230V.
1
1 BLUE = 0
2 BROWN = PHASE
3 BLACK = PHASE
2
850 / 854 SWT- 2.3 - 93 / Opstillingsmanual / OM 575343 / 31.05.2007

Rev: 31.05.07 / ECN 24168

Fig. 0.71
Cable for 230V is fitted in termi-
nal strip 509.X1.
NO. 1 = PHASE
NO. 2 = PHSE
NO. 3 = O
1
Control box for pitch of blade Fig. 0.72

bearing is connected. The plug from the control box is
assembled with the cable fitted in
the control.
1
1. The plug is locked with the 2
locks.
Fig. 0.73
The power supply for the control
box is connected to the socket.
1

Rev: 31.05.07 / ECN 24168

Functions of the control box Fig. 0.74

1. Red lamp “Error” is alight to-
gether with a green lamp if
1 2 3 there is an error in the sys-
1
tem.
2. Yellow lamp “Init” flashes at
start up until the system is
started up and checked.
3. Green lamp “Ready” is
alight when the system is
4 5
ready for use.
2 3 4. Power button. ON/OFF.
5. Vibrate button. ON/OFF.
When the button is on “ON”
6 7
The vibrate function is acti-
vated with the “Enable but-
ton”
6. Enable button.
7. Pitch button. CW = Clock-
wise CCW = Opposite
8 NB: The pitch button
works when the Enable
button is hold down. Both
with and without connection
of the vibrate function
8. Be aware of the fact that: If
the power button is turned to
OFF position, the emergency
pitch is activated on all 3
blades.
Fig. 0.75
“Power ON”
1 The yellow lamp is activated and

is alight until the system is
checked.
The green lamp is alight when

the system is ready for use.
NB: If both the green lamp and red lamp are alight after the yellow lamp, there is
an error in the system. If this is the case, a fault finding must be carried out.

Rev: 31.05.07 / ECN 24168

Hydraulic pressure for hub Fig. 0.76.

When only the green lamp on the
control box for pitch of blade
bearing is alight, pressure must
be pumped on the hydraulic sys-
tem.
Pressure on the system is

checked from the portable hy-
1 draulic unit.
1 Manometer
Fig. 0.77
Mount the hoses from the porta-
ble hydraulic unit in the hub.
A. Pressure hose.
B. Return hose.
A B
Fig. 0.78
2 1 Pressure side and pressure

filter.
2 Return side.
NOTE: Some oil spillage may

occur, have a cloth ready, in
1 case it does.

Rev: 31.05.07 / ECN 24168

Pitch the blade bearing Fig. 0.79

Start up the pump using the
breaker on the portable hydraulic
unit, and open the valve in order
to send hydraulic pressure to the
blade valves in the hub.
WARNING ! Before any pitching of the blade bearings, it must be checked that no per-
sonnel or components can be crunched by the pitch cylinders.
Fig. 0.80
When there is pressure on the
system, and the green lamp is
1
alight, the bearing/blade can be
pitched with the control box.
NB: The system starts sud-

denly.
Tip: If you want a calm start up,

the twin valve (108) can be
opened partially with advantage.
WARNING ! If no pitching is to be performed, the double valve (108) must be positioned

in closed position.
Fig. 0.81
NOTE: After pitching the blade
bearing, let the portable hy-
draulic unit pump pressure on
to the accumulators in the
hub, for no less than 3 min-
utes, with the valve on the
hose and the double valve
(108) open. This way it can be
avoided to overfill the portable
hydraulic unit.
1
1 Valve on hose open.
IMPORTANT! Check the oil level on the portable hydraulic unit regularly!

Rev: 31.05.07 / ECN 24168

Mounting and operation of control box/pitch adjustment of older type (Option)
Mounting and operation of control box/pitch adjustment of

older type (Option)
WARNING ! When pitching the blade bearing with the electric controller box, it is impor-
tant to be aware of:
The electric controller box activates “Emergency pitch” on all 3 blade bear-
ings at grid failure. Consequently, it is extremely important that the double
valve (108) is closed.
Only open the double valve (108) after checking that no personnel can get
trapped by the pitch cylinder, etc.
Close the double valve (108) when no pitching is taking place.
Fig. 0.82
The valve handle illustrated in
closed position.
1 Double valve (108) on the

blade valve block.
2 Check that the lock pin is in-

terlocked.
2
1
Mounting of controller box in Fig. 0.83

hub. 1. Electrical controller box.
2. Pitch button with scale.
1 (Neutral setting = approx.
“5”)
3. ON (1) / OFF (0) button.
Note: Pitch pawls and emergen-

cy valves are not disconnected
by the ON / OFF button.
2 3
Place the box in the hub. Only lift the box in the handle, not in the cables. Fit the
cables as shown below.
OM 557347 / 30.01.2006 / 18.02.02 855 / 860

Rev: 29.06.07 / ECN 24469

Important! Use the proper cables (9V - dark grey and 24V - light grey):
A: Proportional valve (102) - (9V) use two plugs.
B: Drop valves (109) and (119) - (24V).
C: Emergency stop valves (103) and (120) - (24V).
Fig. 0.84
Fit the plugs from the electrical
controller box to (A) - Proportion-
al valve (102) - (9V).
Fig. 0.85
3
controller box to (B1) - drop valve
1 (119) - (24V).
2 1. pos. 108 - Double valve
2. pos. 111 - Test nipple
3. pos. 116 - On / off valve
B1. pos. 119 - Drop valve

B1
Fig. 0.86
controller box to (B2) - drop valve
B2 (109) - (24V).
1. pos. 101 - Pressure relief

valve
B2. pos. 109 - Drop valve
856 / 860 OM 557347 / 30.01.2006 / 18.02.02

Rev: 29.06.07 / ECN 24469

Fig. 0.87
controller box to (C) - Emergency
1 stop valves (103) and (120) -
(24V).
1. pos. 130 - Pitch pal
2. pos. 117 - Manuel on / off

3
C
3. pos. 107 - Pressure switch
Important! Connect and tighten all plugs.
Hydraulic pressure for hub Use a portable hydraulic unit (Example) illustrated below.
Fig. 0.88.
Pressure must be pumped on
the hydraulic system.
Pressure on the system is con-

trolled.
1. Manometer.
Fig. 0.89
A. Pressure hose.
B. Return hose.
A B
OM 557347 / 30.01.2006 / 18.02.02 857 / 860

Rev: 29.06.07 / ECN 24469

Fig. 0.90
2 1 Pressure side and pressure

filter.
2 Return side.
NOTE: Some oil spillage may

occur, have a cloth ready, in
1 case it does.
Pitch the blade bearing Fig. 0.91

Start up the pump using the
breaker on the portable hydraulic
unit, and open the valve in order
to send hydraulic pressure to the
blade valves in the hub.
WARNING ! Before any pitching of the blade bearings, it must be checked that no per-
sonnel or components can be crunched by the pitch cylinders.
Controller box operation. Fig. 0.92.

Before activating the ON / OFF
button, the pitch button must be
on “5”. Neutral setting.
2 1
1. ON (1) / OFF (0) button.
2. Pitch button
Pitch the blade bearing by turn-

ing the pitch button either to the
right or the left.
858 / 860 OM 557347 / 30.01.2006 / 18.02.02

Rev: 29.06.07 / ECN 24469

Fig. 0.93
Pitch the blade bearing in ques-
tion with the knob on the control-
ler box until the blade bearing is
in position.
WARNING ! If no pitching is to be performed, the double valve (108) must be positioned

in closed position.
Fig. 0.94
NOTE: After pitching the blade
bearing, let the portable hy-
draulic unit pump pressure on
to the accumulators in the
hub, for no less than 3 min-
utes, with the valve on the
hose and the double valve
(108) open. This way it can be
avoided to overfill the portable
hydraulic unit.
1
1 Valve on hose open.
IMPORTANT! Check the oil level on the portable hydraulic unit regularly!
OM 557347 / 30.01.2006 / 18.02.02 859 / 860

Rev: 29.06.07 / ECN 24469

860 / 860 OM 557347 / 30.01.2006 / 18.02.02

Rev: 29.06.07 / ECN 24469

Siemens 2.3 Service Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Siemens 2.3 Service Manual PDF

Uploaded by

Copyright:

Available Formats

Siemens Wind Power A/S

Borupvej 16 - Box 171

Document no.: ZSM1005840 Workgroup level:

Issued by: E R WP EN 212 Confidentiality class:

Approval no.: ECN50015 Language: US English

Revision. no.: R5. / edition 1 Country of installation: INT

Revision date: (dd-mm-yyyy) 01-11-2009 Applicable law: Country specific

SWT - 2.3 - 82VS/93/101 INT. (US) / ZSM1005840 / ECN50015

© Siemens Wind Power A/S 2009. All rights reserved.

Document no. Title Chapter

ZSM1005840_01 Technical specifications 1

ZSM1005840_02 Service safety 2

ZSM1005840_04 Bolt tightening_general 4

ZSM1005840_09 Yaw system 9

ZSM1005840_10 Transmission system 10

ZSM1005840_11 Brake system 11

ZSM1005840_12 Pitch system 12

ZSM1005840_13 Components - diagrams 13

ZSM1005840_18 Paint repair 18

ZSM1005840_19 Turning gear 19

ZSM1005840_20 Fire detecting 20

ZSM1005840_21 Shadow detector 21

ZSM1005840_22 Ice dec equipment 22

ZSM1005840_23 Acoustic wind sensor 23

ZSM1005840_24 Visibility Meter 24

ZSM1005840_25 Aviation light 25

ZSM1005840_26 SALA fall protection system 26

ZSM1005840_27 SKY MAN servicelift TH250 27

ZSM1005840_28 Miscellanous tools 28

SWT - 2.3 - 82VS/93/101 INT. (US) / ZSM1005840 / ECN50015

© Siemens Wind Power A/S 2009. All rights reserved.

ECN no. Rev. no. Date Description for changes

ECN30446 R0 10-02-2009 Manual for SWT-2.3-82VS-93-101

ECN30997 R1 24-07-2009 Chapter 26-27-28 added.

ECN32228 R2 14-08-2009 Chapter 2 - page 23 - Fig 2.5 - torque

ECN32453 R3 09-09-2009 General update for ZSM1005840

ECN50015 R4 01-11-2009 Chapter 4 Bolt tightening_general

SWT - 2.3 - 82VS/93/101 INT. (US) / ZSM1005840 / ECN50015

© Siemens Wind Power A/S 2009. All rights reserved.

© Siemens Wind Power A/S 2009. All rights reserved.

Chapter 01 TECHNICAL SPECIFICATIONS .............................................................................. 7

Technical description ..............................................................................................................................................9

Components in the nacelle ...................................................................................................................................11

Technical specifications ........................................................................................................................................12

Weight List ............................................................................................................................................................14

Chapter 02 TURBINE SAFETY INSTUCTIONS ....................................................................... 17

Turbine safety instructions ....................................................................................................................................19

Opening and closing the nacelle hatches .............................................................................................................20

Locking the rotor on the high-speed shaft.............................................................................................................24

Locking the rotor on the low-speed shaft ..............................................................................................................25

Locking the yaw system........................................................................................................................................27

Hand braking by use of hand pump and test hose ...............................................................................................28

Position of emergency stop...................................................................................................................................32

Access to area underneath yaw section ...............................................................................................................34

Mounting of manhole hatches in the hub ..............................................................................................................35

Measuring de-energized condition of frequency converter ...................................................................................37

Procedure for låsning og skiltning - HS rotorlås /

Chapter 03 INSPECTION AND MAINTENANCE...................................................................... 69

Inspection and Maintenance Schedule .................................................................................................................71

Precautionary measures in case of long periods of standstill for wind turbines....................................................73

Chapter 04 BOLT TIGHTENING ONSHORE............................................................................ 75

Maintenance Schedule .........................................................................................................................................77

Bolt tightening .......................................................................................................................................................79