NORDEX N-54

Technical description

© 1997–2000 NORDEX GmbH

Technical information is subject to change. All rights reserved.

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NORDEX N-54 Technical description

Table of contents
1 Design............................................................................................................................................... 2
2 Rotor ................................................................................................................................................. 3
3 Main shaft ......................................................................................................................................... 3
4 Gearbox ............................................................................................................................................ 4
5 Generator.......................................................................................................................................... 4
6 Braking system ................................................................................................................................. 4
7 Hydraulic system .............................................................................................................................. 5
8 Nacelle.............................................................................................................................................. 5
9 Yaw system ...................................................................................................................................... 5
10 Tower and foundation....................................................................................................................... 6
11 Controller .......................................................................................................................................... 6
12 Lightning protection .......................................................................................................................... 7
13 General reservations ........................................................................................................................ 7

1 Design
The NORDEX N-54 is a wind turbine with a 3-bladed horizontal-axis rotor. The turbine is stall-
regulated with the rotor mounted up-wind and turning clockwise seen from windward. This wind
turbine was the first megawatt class turbine in serial production and ranks among the most successful
wind turbines of its class on the international markets.
All NORDEX wind turbines are manufactured according to ISO 9001 quality standards. For all main
components NORDEX cooperates with a number of qualified suppliers.
Information on the certificates available can be found in document ‘Certificates’ (N54-601-en).
Nacelle overview NORDEX N-54

1 2 3 4 9
6 10
7 8

13 14
5 11 12

1 Hub 5 Yaw drive 9 Wind sensors 13 Yaw brakes

2 Main shaft 6 Gearbox 10 Cooler 14 Generator
3 Main bearing 7 Disc brake 11 Yaw bearing
4 Nacelle cover 8 Generator coupling 12 Tower

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NORDEX N-54 Technical description

Overall data
Type 3-blade horizontal-axis rotor mounted up-wind
Power regulation Stall
Rated power 1,000 kW/200 kW
Start wind speed 3…4 m/s
Nominal power at wind speed 14 m/s
Stop wind speed 25 m/s
Calculated lifetime 20 years

Climatic design conditions

Class GL 1
Operating temperature range – 20…+ 40 °C

2 Rotor
The NORDEX N-54 is a stall-regulated wind turbine.
The rotor blades are made of high-quality glass fibre-reinforced plastic (GRP). The blade tips are
pivotable and can be swivelled 85 degrees relative to the main blade, in this position acting as
aerodynamic brakes. Lightning receptors are integrated into the blade tips, diverting a lightning strike
to the hub.
Rotor main data
Rotor diameter 54 m
2
Swept area 2,290 m
Maximum tip speed 60.79 m/s
2
Specific power 437 W/m
Rotor speed 21.5 rpm/14.3 rpm
Rotor tilt angle 3.5°
Rotor cone angle 0°
Tip to tower distance 3.9 m
Total weight c. 18.6 t

Rotor hub
Material Spheroidal graphite cast iron GGG 40.3
Weight c. 5.4 t

Rotor blades
Material Glass fibre-reinforced plastic (GRP)
Total length 26 m
Tip length 3.7 m
Twist 15°
Weight c. 4.2 t

3 Main shaft
The main shaft is forged from high-quality tempered and quenched steel. Towards the rotor the main
shaft is supported by a solid self-aligning roller bearing absorbing the axial thrust from the rotor. It is
again supported in the gearbox.
Main Shaft
Material 42 CrMo 4V
Weight c. 6.2 t
Main shaft bearing Self-aligning roller bearing
Bearing housing Spheroidal graphite cast iron

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NORDEX N-54 Technical description

4 Gearbox
The gearbox is a three-stage design, with the first stage as a high torque planetary stage and the
other two stages as spur stages. The planetary gear makes the construction very compact, yet
allowing for the high torque from the rotor to be transferred with a high gear ratio.
The gearbox oil is kept in its optimal temperature range by a double cooling circuit (primary circuit oil,
secondary circuit water). The water air cooler is located in the top part of the nacelle and cooled by air
from the outside.
The gearbox is supported by two strong rubber bushings fixed to the nacelle frame structure. This way
a mechanical decoupling and thus a reduction of noise emission is attained and torsional peaks are
reduced.
Gearbox
Type 3-stage planetary and spur gear
Nominal effect 1,080 kW
Ratio 1 : 70
Lubrication Splash lubrication
Oil-quantity 200 l
Oil-type VG 320
Oil changes Annual check, change as required
Main shaft bearing Cylindrical roller bearing
Weight (unfilled) c. 10.5 t

5 Generator
The generator is a double-winding, 4/6 pole water-cooled squirrel-cage asynchronous type. At low
winds the generator operates on the 6-pole 200 kW winding and at high wind speeds on the 4-pole
1,000 kW winding.
In both stages the generator is softly connected to the electrical network via a thyristor unit. This is
then bypassed by the main contactor.
The generator is connected to the gearbox by a tooth-type coupling. The solid rubber mounting
decouples the generator from the nacelle frame and thus reduces the transfer of machine noises.
Generator data 1,000 kW 200 kW
(G1) (G2)
Type of enclosure IP 54 IP 54
Nominal power kW 1,000 200
Nominal voltage V 690 690
Frequency Hz 50 50
Speed rpm 1,513 1,014
Poles 4 6

6 Braking system
The primary brake system of the NORDEX N-54 is the aerodynamic blade tip brake. The secondary
brake is a disc brake situated on the high-speed shaft.
Both systems are able to decelerate the wind turbine from any state in order to reach a safe status
independent from each other. Both braking systems are fail-safe, i.e. braking is guaranteed even if
components, systems or power supply should fail.
Aerodynamic brake: The centrifugal force causes the blade tips to swivel to their braking position.
Disc brake: The brake will operate automatically by its spring in case of a power or a system failure.
For a normal braking the blade tips are rotated to their braking position by reduction of the hydraulic
pressure. When the rotating speed is at about 4.3 rpm the disc brake is activated and brings the wind
turbine to a standstill. The braking pressure is controlled in such a way that a sudden stopping is
prevented. This allows a soft braking procedure without load peaks.

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NORDEX N-54 Technical description

Only in case of an emergency braking both braking systems are activated at once.
Aerodynamic brake
Type Pivotable blade tips (85°)
Operation Centrifugal force and spring
Activation Reduction of the hydraulic pressure
Activation conditions Control, rotor overspeed, emergency stop

Mechanical brake
Type Disc brake
Location On the high-speed shaft
Disc diameter 880 mm
Number of brake callipers 2
Material of the brake pads Sintered metal

7 Hydraulic system
Hydraulic system
Hydraulic oil type VG 32
Oil quantity 60 l
Nominal power of the hydraulics pump 1.5 kW
Thermal protection Thermistor/Thermal relay

8 Nacelle
The nacelle consists of the cast nacelle main frame and the nacelle cover. The nacelle cover is made
of high-quality glass fibre-reinforced plastic (GRP). The nacelle roof is opened hydraulically. By the
shape of the nacelle and the cooler being placed in the top section the natural air flow is exploited for
cooling.
Nacelle
Type of nacelle frame Cast construction
Material Spheroidal graphite cast iron GGG 40.3
Type of nacelle cover Shell construction on welded frame
Material Glass fibre-reinforced plastic (GRP)

9 Yaw system
The wind direction and wind speed are constantly monitored by two mutually independent wind sensor
systems above the nacelle. When the wind direction is different from the direction of the wind turbine,
the wind turbine is yawed actively.
The yaw system is based on a ball-bearing type yaw ring between the tower and nacelle. The active
yawing is effected by two electrical drives connecting to the gearing of the yaw ring by pinions. Spring-
operated brakes are integrated into the drives.
The yaw system is additionally fitted with a disc brake with six hydraulic brake callipers. While yawing
these are only partly released in order to achieve a smooth movement. When there is no yaw
operation the nacelle is safely kept in its position by the disc brake and the brakes integrated in the
yaw drives.
Yaw bearing
Type Ball bearing
Material 42 Cr Mo 4
Weight c. 1.15 t

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NORDEX N-54 Technical description

Yaw drive
Motor Asynchronous motors with built-in brakes
Gear 4-stage planetary gear
Number of drives 2
Lubrication Oil
Yaw rate < 0.6 °/s

Yaw brakes
Type Hydraulic disc brake
Number of callipers 6
Material of brake pads Sintered metal

10 Tower and foundation

The NORDEX N-54 is erected on a tubular tower for 60 or 70 m hub height. The ladder and safety
rope, resting and working landings are located inside the tower.
Corrosion protection is achieved by sand-blasting and an epoxy coating of the tower surface according
to ISO 12944.
Tubular tower
Material S235 JRG2, S355 J2G3
Corrosion protection Epoxy coating
Tower-base connection details Flange and bolts cast in concrete

Hub height 60 m 70 m
Class DIBt 3 DIBt 2
Number of sections 2 3
The foundation of the NORDEX N-54 depends on the ground conditions at the intended site.
Anchoring of the tower is done by double flanges and anchor bolts. Further information can be found
in document ‘Foundations’ (N54-311-en).

11 Controller
The control system of the NORDEX N-54, together with switchgear and safety facilities, is located in
two switchboards, one in the bottom part of the tower, one in the nacelle.
On a control screen placed at the switchboard in the tower bottom all operational data can be
monitored and checked and a number of functions, such as starting, stopping and yawing, can be
controlled.
In addition, the NORDEX N-54 is equipped with a remote monitoring system that only requires a
telephone connection (ISDN). The appropriate communication software can be installed on any PC
and is provided by NORDEX.
The controller records a large number of operational parameters, such as energy production, wind
conditions, temperatures of the main components, hydraulic pressure, network connection, etc. In
case of a failure, an alarm is sent via the remote monitoring system. An event log is saved that can be
retrieved for fault analysis.
To ensure a smooth shut-down in case of a network failure the wind turbine is equipped with an
uninterruptible power supply (UPS) system.
Controller
Type of controller Microprocessor/PLC
Network connection and disconnection Via soft-power thyristor controller
Automatic restart:
– After grid drop Yes
– After cut-out wind Yes

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NORDEX N-54 Technical description

12 Lightning protection
During the development of the NORDEX N-54, the outmost attention has been devoted to lightning
protection. For all components a most reliable protection has been achieved. The lightning and over-
voltage protection of the wind turbine is based on the lightning protection zone concept and is accord-
ing to IEC 61024 and DIN VDE 0185. A detailed description can be found in document ‘Lightning and
overvoltage protection’ (N54-405-en).

13 General reservations
Deviation from the conditions specified above may have an adverse impact on the operation of the
wind turbine. In particular a performance reduction may occur.
Should icing occur on the rotor blades, the wind turbine must be stopped. At very low temperatures,
after e.g. a grid failure, some time for preheating some components of the wind turbine should be
allowed.
In connection with the continuous development and improvement of our products, we reserve the right
to make technical changes without prior notice.

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