Alignment Instructions

Maintenance instructions
Generator, generator frame, coupling

Wind turbine class K08 gamma
Types: N80/2500, N90/2500, N100/2500, N117/2400
I401_1008_EN
Revision 05 / 2014-10-27
- Translation of the original instructions -

Document is published in electronic form.
Signed original at Nordex Energy GmbH, Engineering department.
2014 by Nordex Energy GmbH

Technical modifications
This document was created with utmost care, taking into account the currently
applicable standards.
However, due to continuous development, the figures, functional steps and
technical data are subject to change without prior notice.
Copyright
Copyright 2014 by Nordex Energy GmbH.
This document including its presentation and content is the intellectual property
of Nordex Energy GmbH. The information in this document is intended
exclusively for Nordex employees and employees of trusted partners and
subcontractors of Nordex Energy GmbH and Nordex SE and must never (not
even in extracts) be disclosed to third parties.
Any disclosure, duplication or translation of this document or parts thereof in
printed, handwritten or electronic form without the explicit approval of Nordex
Energy GmbH is explicitly prohibited.
All rights reserved.
Contact details
For questions relating to this documentation please contact:
Nordex Energy GmbH
Langenhorner Chaussee 600
22419 Hamburg
Germany
http://www.nordex-online.com
info@nordex-online.com
2014 by Nordex Energy GmbH

Table of contents Revision 05 / 2014-10-27
1. Conventions ........................................................................................................ 4
1.1 Symbols and notes ............................................................................................... 4
1.1.1 Hazard of personal injury.................................................................................... 4
1.1.2 Warning of material damage .............................................................................. 4
1.1.3 Notes and information ........................................................................................ 4
1.1.4 Integrated safety notes and information ............................................................. 4
1.2 Lists and work steps ............................................................................................. 5
1.3 Italic text................................................................................................................ 5
2. Scope ................................................................................................................... 6
3. Maintenance of the generator, generator frame and coupling ....................... 7

3.1 Visually inspecting the generator frame................................................................ 8
3.2 Checking the automatic lubrication unit (ALU) ...................................................... 9
3.3 Emptying the grease collectors ........................................................................... 10
3.4 Checking the generator alignment ...................................................................... 10
3.4.1 Checking the axial alignment............................................................................ 12
3.4.2 Determining offset with a laser alignment system ............................................ 13
3.4.3 Checking the generator alignment with the Prüftechnik-alignment system ...... 16
3.4.4 Correcting the alignment of the generator ........................................................ 24
3.5 Checking the screw connections of the clamping sets ....................................... 30
3.6 Checking the screw connections and the condition of the coupling.................... 30
3.7 Checking the screw connections generator frame / machine frame ................... 31
3.8 Inspecting the screw connections of the generator supports .............................. 31
3.9 Inspecting the cable glands on the generator ..................................................... 31
3.10 Checking the tightening torques in the generator terminal boxes ....................... 31
3.11 Checking the tightening torques of the equipotential bonding ............................ 32
3.12 Inspecting the slip ring tracks.............................................................................. 32
3.13 Inspecting the carbon brushes and brush holders .............................................. 33
3.14 Cleaning the slip ring box.................................................................................... 38
3.15 Replacing the air filter mats in the generator ...................................................... 39
3.16 Electrical test measurements .............................................................................. 40
3.16.1 Checking the insulation resistance ................................................................... 40
3.16.2 Checking the protective ground conductor ....................................................... 40
4. Revision index................................................................................................... 41
I401_1008_EN Page 3 of 42
Revision 05 / 2014-10-27 Maintenance instructions
1. Conventions
1.1 Symbols and notes
1.1.1 Hazard of personal injury
DANGER
Failure to comply with the instructions and notes will result in life-threatening
injury.
WARNING
Failure to comply with the instructions and notes may result in serious injury.
CAUTION
Failure to comply with the instructions and notes will result in injury.
1.1.2 Warning of material damage
NOTICE
Warning of damage to components or material
1.1.3 Notes and information
NOTE
Additional information, notes and hints
OBSERVE DOCUMENT
Reference to information in other documents
1.1.4 Integrated safety notes and information

Information and safety notes integrated into the text. Indicated by the signal word
in bold: Note, Notice, Caution, Warning.
Page 4 of 42 I401_1008_EN Symbols and notes

Maintenance instructions Revision 05 / 2014-10-27
Example
Notice: To prevent damage to the paintwork, the tower sections must not
touch the ground.
1.2 Lists and work steps

Ŷ Work step
Ź Result of a work step
Ɣ List
- Subordinate list
1.3 Italic text

Identification of proper names: e.g., manufacturer names, document titles.
Lists and work steps I401_1008_EN Page 5 of 42

2. Scope
OBSERVE DOCUMENT
• Safety manual NALL01_011010 Rules of conduct on, in and around wind
turbines
• HSE 12 Documented procedure for work in and around WTGs
for Nordex employees and for employees of contractual companies
These maintenance instructions describe all work steps for the maintenance of
the described system of the K08 gamma wind turbine class.
This document was created for employees of Nordex Energy GmbH and
commissioned companies only and must not be disclosed, even in extracts, to
third parties.
The tasks described in this document must only be carried out by qualified
specialized personnel.
General safety instructions (e.g., how to handle respective tools and hoists),
references to corresponding guidelines and occupational health and safety
regulations, as well as generally accepted handling procedures are not
mentioned.
The safety manual NALL01_011010 as well as the above-mentioned safety
instructions must have been read and understood. Observe the safety notes.
The extensive health and safety regulations implemented at Nordex Energy
GmbH form the basis of occupational health and safety and environmental
protection.
The valid accident prevention regulations must be observed.
If operating materials are used, always observe and adhere to the
manufacturer's information on existing health risks.
In addition to these maintenance instructions, the supplier's maintenance
instructions mentioned in the respective chapters must be observed.
Only electrically skilled persons are authorized to carry out some parts of the
maintenance. These persons must meet at least the requirements of DIN VDE
1000-10
Page 6 of 42 I401_1008_EN
3. Maintenance of the generator, generator frame

and coupling
Note on maintenance at low temperatures
- The maintenance can be performed down to temperatures of -20 °C.
- Heat the grease cartridges so that the grease can flow.
OBSERVE DOCUMENT
• K401_1025
• I401_1001
• K0801_026636 Lubrication Plan K08 gamma
NOTICE
CONSIDER THE TEMPERATURE
If the drive train is not completely enclosed the mechanical rotor brake must
not be used for assembly and maintenance activities at a temperature of 0°C
or below 0°C (rotor lock on the rotor shaft is not engaged).
Only then a sufficient friction coefficient between brake pad and brake disk is
ensured. This friction coefficient is needed to lock the drive train in a manner
that excludes slipping. Only in that case hazard to personal safety from
rotating parts can be excluded.
Before each actuation, the temperature of the brake pad must be read via the
analog value "TR52 RotBrk Temp".
Prerequisites
- The WT has been stopped.
- The generator is disconnected from the power supply and grounded.
DANGER
HAZARDOUS VOLTAGE
Exposed live components in the terminal boxes and in the slip ring box of the
generator.
Any contact with live parts may result in death or serious injury. Prior to
starting work on the generator, disconnect it, secure it against reconnection,
verify that the system is dead, and ground it.
- The 10-minute average wind speed is less than 12 m/s
I401_1008_EN Page 7 of 42
WARNING
MAXIMUM WIND SPEED
Work on the drive train and in the rotor hub is only permitted at 10-minute
average wind speeds of less than 12 m/s.
- The rotor is locked on the rotor shaft
DANGER
ROTATING PARTS
A sudden start-up of the rotor during maintenance work may lead to serious or
life-threatening injury.
Prior to performing any work on the drive train and in the rotor hub, always
lock the rotor at the rotor shaft. The rotor lock on the brake disk, if applicable,
must not be used for such work.
3.1 Visually inspecting the generator frame
Maintenance for type: 1 2 3 4

Visually inspecting the generator frame X X X
Ŷ Visually inspect the entire generator frame

Ŷ Visually inspect the weld seams for cracks or other damage
Ŷ Visually inspecting the generator

Visually inspecting the generator X X X
Ŷ Check the generator for cracks and damages

Ŷ Check the elastomer elements on which the generator rests and the
generator supports for cracks and brittleness
Ŷ Check the generator frame for cracks, especially in the area of the weld
seams at the flange to the machine frame
Ŷ Check the electrical connections for temper colors on screws, nuts and
terminal lugs (thermal overload)
Ŷ Visually inspect the weld seams for cracks or other damage
Page 8 of 42 I401_1008_EN Visually inspecting the generator frame

3.2 Checking the automatic lubrication unit (ALU)

Checking the automatic lubrication unit (ALU) X X X X
The generator bearings are equipped with an automatic lubrication system.
Automatic lubrication system type "Lincoln"

The electronically operated lubricator of the automatic lubrication unit of the type
Lincoln continually provides the two bearings of the generator with grease via
fittings.
Fig. 1 Automatic lubrication unit type "Lincoln"
The maintenance of the automatic lubrication system type "Lincoln" shall be

performed as follows:
Ŷ Check the lubricant supply unit for damage and tight fit
Ŷ Check fittings to the lubrication points for damage, leaks and correct
attachment
Ŷ Fill the lubricator with grease
Material: refer to Lubrication plan K0801_026636
NOTE
For changing the grease type proceed as described in chapter "Changing the
grease type"
Check for proper functioning:

Ŷ Bridge relay 156K8 using a wire jumper (refer to circuit diagram)
Ŷ Remove the hose from one of the lubrication points and check whether
grease escapes
Checking the automatic lubrication unit (ALU) I401_1008_EN Page 9 of 42

Ŷ If the automatic lubrication system does not function properly, inform Nordex
Service
Changing the grease type

If a change of grease type is required proceed as follows:
Ŷ Remove the hoses from the lubrication points on the generator and press a
quarter cartridge of the new grease into each lubrication point using a grease
gun.
In doing so, rotate the generator shaft to allow the grease to distribute
Ŷ If necessary, empty the grease collectors several times
Ŷ Completely empty the lubricator and fill it with new grease
Ŷ Press new grease through the hoses
3.3 Emptying the grease collectors

Emptying the grease collectors X X X
On both bearings of the generator:

Ŷ Remove the grease collectors
Ŷ Remove the old grease and dispose of it
Ŷ Re-install the empty grease collector
3.4 Checking the generator alignment

Checking the generator alignment X X X
The generator must be checked for axial alignment and for vertical and
horizontal parallel and angular offset.
The axial alignment can be determined with a measuring tape.
The parallel and angular offset is checked with a laser alignment system.
Prerequisites:
- Nacelle is turned into the wind
- The rotor blades are in the 90° position
- The rotor brake is applied
- The rotor is not locked
Page 10 of 42 I401_1008_EN Emptying the grease collectors

NOTE
Only the above additional prerequisites ensure that the WT is as steady as
possible. Otherwise the measurements for checking the generator alignment
could be affected.
Fig. 2 Vertical offset, parallel (generator right)
Fig. 3 Vertical offset, angular (generator right)
In Fig. 2, the overall generator is too high; there is a positive vertical parallel
offset.
In Fig. 3, the generator is inclined to the front (in the direction of the coupling);
there is a positive vertical angular offset
Fig. 4 Horizontal offset, parallel (generator right)
Checking the generator alignment I401_1008_EN Page 11 of 42

Fig. 5 Horizontal offset, angular (generator right)
In Fig. 4, the overall generator is too far to the right; there is a positive horizontal
parallel offset.
In Fig 5, the rear supports of the generator are too far to the right; there is a
positive horizontal angular offset.
3.4.1 Checking the axial alignment

Ŷ Measure the distance between the brake disk on the gearbox side and the
coupling flange on the generator side:
- Target value multi-disk coupling (KTR coupling: 570 mm ± 0.5 mm)
- Target value link coupling (Centa coupling: 550 mm± 0.5 mm)
Fig. 6 Axial alignment (example KTR coupling)
Ŷ Document the measured value in the appendix of the maintenance report

Ŷ If the result does not comply with the target value, the generator must be re-
aligned
Page 12 of 42 I401_1008_EN Checking the generator alignment

3.4.2 Determining offset with a laser alignment system
OBSERVE DOCUMENT
Operating Instructions I210_012_X Generator alignment using Fixturlaser
alignment system
The parallel and angular offset can be checked with different laser alignment
systems, always in accordance with the respective manufacturer's instructions.
The procedure is described with the example of the Fixturlaser alignment
system. For a detailed description refer to the document I210_012_X Fixturlaser
manual Only the most important work steps are mentioned below.
WARNING
LASER BEAMS
Laser beams can cause damage to the eyes.
The Fixturlaser alignment system operates with a laser beam. Before using
the system, thoroughly read the operating instructions and observe the safety
notes contained therein. Do not look directly into the laser beam.
Ŷ Attach the TD-M unit to the generator shaft using a chain and bars and align
it vertically above the shaft
Ŷ Attach the TD-S unit to the brake disk with the magnet and align it vertically
above the shaft
Fig. 7 Sensors
1 TD-M unit generator side

2 TD-S unit gearbox side
Ŷ Connect both TD units to the display
Ŷ Switch on the system and start the measuring program for horizontal shaft
alignment

Ŷ Use the laser beam to adjust the TD-S unit so that both sensors are equal in
height and parallel to each other
Ŷ Use the blue adjustment screws to adjust the TD units so that the laser beam
hits the exact center of the grid
Ŷ Use the default values:
Default setting
Resolution 0.01 mm
Measurement period 3s
Display filter 0
NOTE
In the case of strong and gusty winds, the measurement period must be
increased to 10 s.
Ŷ Select the "Tripoint" measuring method .

Ŷ Determine and enter the dimensions requested by the measuring program
Fig. 8 Dimensions for "Tripoint" measuring method
Ɣ The distance C between the generator supports is 1400 mm

Ɣ A and B depend on the measurement set-up and must be measured
Ɣ D = A/2 is a default setting and must also be checked and corrected, if
necessary.

NOTE
Since it is sometimes difficult to measure distance B, the distance between the
front generator supports and the front surface of the coupling flange (the side
facing away from the generator) is also specified.
It is for the
- Link coupling 695 mm Centa
- Multi-disk coupling 675 mm KTR
Ŷ Press the "Tripoint" icon.

The first measured value is stored.
Ŷ Rotate the shaft by at least 30°.
For that purpose, temporarily release and engage the rotor brake
Ŷ Store the second measured value by pressing the "Tripoint" icon
Ŷ Rotate the shaft in the same direction by at least an additional 30° and press
the "Tripoint" icon to store the third measured value
NOTE
Only turn the shaft in one direction during the measuring process. Changing
the rotating direction will falsify the measurement results.
Ŷ Read the values of vertical and horizontal parallel and angular offset from the
display and record them in the appendix of the Maintenance Report, including
the algebraic sign.
Switch between the display of vertical and horizontal offset by pressing the
corresponding icon.
Ŷ Compare the measured values for parallel and angular offset of the generator
with the permissible offset values
Permitted offset values

Parallel offset y (vertical and horizontal): ± 0.5 mm
Angular offset x (vertical and horizontal): ± 0.2 mm / 100 mm

Fig. 9 Vertical parallel and angular offset
x Angular offset
y Parallel offset
Ŷ If the offset values are within the permissible range, document them in the
appendix of the maintenance report. Save the measurement results with the
following designation:
- XXXX.serv.bbb.YY
The parts of the character string have the following meaning:
String Description
XXXX: Turbine number, e.g. "8010"
serv: As "service"
bbb: E.g., "pre" for prior to the generator alignment
YY: Average value
Ŷ If one of the permissible deviations is exceeded, the generator alignment

must be corrected
3.4.3 Checking the generator alignment with the Prüftechnik-

alignment system
Abbreviation Designation
ESW Engineering Service Web
WT Wind turbine
The generator alignment is checked by means of the Prüftechnik alignment

system ROTALIGN® Ultra iS, SAP-Nr. 43622.

OBSERVE DOCUMENT
• Operating instructions K0805_054937 Prüftechnik ROTALIGN® Ultra iS
(Prüftechnik alignment system)
• Operating instructions K0805_058068 Shaft alignment – alignment center
manual
• Operating instructions K0805_058069 Alignment center Prüftechnik
software handbook
• Engineering drawing 07010-1055189 Sensor bracket generator alignment
WARNING
EYE HAZARD
The laser beam can cause damage to the retina.
Do not look directly into the laser beam.
Do not hold lenses or optical glasses into the laser beam.
Observe the safety notes in the operating instructions K0805_054937.
Assembling the Prüftechnik alignment system
NOTE
The rotor must be locked prior to the assembly of the Prüftechnik alignment
system.
Ŷ Applying the rotor brake

Ŷ Lock the rotor using the rotor lock bolt
Ŷ Disassemble the guard or cover in the area of the high-speed shaft, if
applicable
- K08 gamma: Disassemble the cover of the coupling completely
Ŷ Clean the rotor brake disk or remove the corrosion protection of the rotor
brake disk at a suitable position
WARNING
CRUSHING HAZARD
There is a crushing hazard when the magnetic bracket is attached to the rotor
brake disk.
Make sure that no body parts or objects are located between the magnetic
bracket and the rotor brake disk.

Ŷ Assemble the sensor bracket for generator alignment (magnetic bracket),

SAP no. 1055189-XX, to the rotor brake disk in a suitable position
Ź Place the magnetic bracket on the rotor brake disk in such a way that it
does not collide with the rotor brake when the rotor shaft is turned
Fig. 10 Positioning of the magnetic bracket with laser (similar to figure)
Ŷ Mount the chain-type bracket onto the generator shaft

Ŷ Place both measuring units on the provided support posts
- Laser on magnetic bracket (rotor brake disk)
- Sensor on chain-type bracket (generator shaft)
A B
Fig. 11 Measuring units (similar to figure)
A Magnetic bracket with laser

B Chain-type bracket with sensor
WARNING
EYE HAZARD
The laser beam can cause damage to the eyes.
Do not switch on the laser before it has been roughly adjusted to the sensor.

Ŷ Align the laser roughly with the sensor

Ŷ Switch on both measuring units and slide the protective cap of the laser to the
side
Note: Both measuring units are supplied with power via batteries.
Ŷ Position the laser beam using the hand wheels
Ź The laser beam strikes the center of the receiver cover
Ŷ Slide the protective cover of the sensor to the side
Measuring the generator alignment

Ŷ Select the respective shaft alignment template in the menu Templates
Note: If necessary, the shaft alignment templates can be retrieved from the
ESW server and uploaded to the device with the Alignment Center software.
Note: For K08 gamma, Centa couplings with different intermediate shaft
length are used. Take that into account when selecting the shaft alignment
template.
Fig. 12 Selecting the shaft alignment template
Ŷ Determine the dimensions requested by the ROTALIGN® Ultra iS computer,

enter them and confirm with the ENTER key
Enter the following dimensions, see fig.13
- Dimension A: Distance front generator support / rear generator support
- Dimension B: Distance of coupling plane on generator side / front
generator support *)
- Dimension C: Distance of coupling plane on generator side / sensor *)
Note: There is a marking on the sensor to determine dimension C.
- Dimension D: Distance of coupling plane on gearbox side / coupling plane
on generator side *)
*)
Note: For the multi-disk coupling (KTR coupling) the coupling plane
corresponds to the center of the disk pack. For the link coupling (Centa
coupling) it corresponds to the screw connection of the link.
Note: The speed does not have to be entered.

D B A
Fig. 13 Required dimensions for the Prüftechnik alignment system ROTALIGN®

Ultra iS
1 Dimension A
2 Dimension B
3 Dimension C
4 Dimension D
Table 1: Dimensions for the Prüftechnik alignment system ROTALIGN®
Ultra iS
Wind turbine class / Dimensions

coupling (manufacturer) A [mm] B [mm] C [mm] D [mm]
K08 gamma
Link coupling (all
*) *)
Centacouplings except of CL- 1400 434
28)
Link coupling (only *) *)
1400 470
Centacoupling CL-28)
*) *)
Multi-disk coupling (KTR) 1400 472
*) This dimension must be determined from the measurement set-up.

Ŷ Change to the measurement view by actuating the M key
Ŷ If necessary, carry out a fine alignment of laser and sensor with the
ROTALIGN® Ultra iS computer
Ź The red dot is located as close as possible to the crosshair

Fig. 14 Fine alignment of the laser
1 Crosshair and red dot
WARNING
RISK OF INJURY FROM ROTATING COMPONENTS
Find a safe place in the nacelle for the following works steps, which are
performed with released rotor lock:
- K08 gamma: On the left side in the front area (take the manual control unit
with you)
Do not stay in the proximity of the high-speed shaft.
Note: Take the ROTALIGN® Ultra iS computer to the safe place during
measurement.
Ŷ Release the rotor lock
Ŷ Start the measurement by actuating the ENTER key
Ŷ Release the rotor brake and let the WT run at idle
Notice: The speed of the high-speed shaft must not exceed 30 rpm.
Ŷ The measurement set-up at the high-speed shaft must turn by at least 360°
Notice: Have the high-speed shaft only turn in one direction during the
measuring process. Changing the rotation direction will falsify the
measurement result.
Note: In the case of strong wind, i.e. with wind speeds > 5 m/s, and/or gusty
wind, the high-speed shaft should ideally perform several turns.

Fig. 15 Active measurement
Ŷ Stop the measurement by actuating the ENTER key

Ŷ Apply the rotor brake and engage the rotor lock
Ŷ Call up the measurement result by actuating the RES key
Note: For a 2-level coupling the measuring instrument always indicates both
the vertical and horizontal angular offset on both coupling planes (D and E).
The absolute values of these 4 angular offsets must not exceed the maximum
permitted value, see "Maximum permitted angular offset per coupling plane".
Fig. 16 Displaying measurement result
1 Vertical measurement result: E = 5.47 mrad (maximum absolute

vertical angular offset, for E coupling plane)
2 Horizontal measurement result: E = 9.09 mrad (maximum absolute
horizontal angular offset, for E coupling plane)
Ŷ Store the measurement result under the following designation
Ź Wind turbine number/wind farm/date/before or after alignment
Ŷ Compare the measured values for the angular offset per coupling plane with
the maximum permitted value, see "Maximum permitted angular offset per
coupling plane"

Table 2: Maximum permitted angular offset per coupling plane

Note: The values depend on the wind turbine class and on the installed coupling
type.
Maximum angular offset

Wind turbine class Coupling
per coupling plane
K08 gamma KTR coupling
All Centacouplings
max. 3.05 mrad
except of CL-28)
or max. 0.175°
Only Centacoupling
CL-28)
Ŷ Correct the generator alignment if the value for the maximum permitted
angular offset per coupling plane has been exceeded
- Via the MENU button, select the Move function
Fig. 17 Menu Move
- Align the generator on basis of the displayed instantaneous values
Fig. 18 Aligning the generator in the move mode

Ŷ Finally, perform another measurement

Ź The value for the maximum permitted angular offset per coupling plane is
not exceeded
Ŷ Document the following measurement results in the report, print out the
measurement report and enclose it
- Maximum vertical angular offset for coupling plane D
- Maximum vertical angular offset for coupling plane E
- Maximum horizontal angular offset for coupling plane D
- Maximum horizontal angular offset for coupling plane E
Ŷ Disassemble the measuring units, chain-type bracket and magnetic bracket
Ŷ Assemble the guard or cover in the area of the high-speed shaft, if applicable
3.4.4 Correcting the alignment of the generator

The Fixturlaser alignment system can be used to align the generator. It displays
the required adjustments and updates them immediately during the re-
adjustment. Prerequisite for this is that the TD units for the correction of the
vertical deviations are in the 12 and 6 o'clock position and the horizontal
deviations in the 9 and 3 o'clock position.
If the generator alignment has been checked with dial gages, the corrections on
the generator supports must first be calculated from the measured values.
Calculate the vertical correction values for the front and rear generator supports
from the measured values of the vertical parallel and angular offset as follows:
Correction value
Front supports (mm) 1.1 wV + 0.5 (pV – B)
Rear supports (mm) 3.5 wV + 0.5 (pV – B)
where:
wV: Measured value for the angular offset in vertical direction
pV: Measured value for the parallel offset in vertical direction
B: Sag of the measurement stand
NOTE
The factor in front of the measured value for the angular offset is rounded and
only applies if the test prod of the dial gage for the angular offset was attached
as follows:
- On the front surface of the coupling flange (the side facing away from the
generator) and
- As far to the edge of the coupling flange as possible
Otherwise it must be redetermined according to the explanations below.
When inserting the measured values the algebraic signs must be considered.

Explanation:
The correction values for the vertical alignment of the generator supports are
calculated from the measured value for the parallel offset minus the determined
sag of the measurement set-up and a proportion resulting from the angular
offset.
A factor in front of the measured value for the angular offset is the quotient of
The
d , whereas
A: Distance between the respective generator support and the front side of the
coupling flange (the side facing away from the generator)
It is:
Distance between the generator support and the front side

of the coupling flange
Link coupling (Centa 695 mm, resp. 2095 mm
Multi-disk coupling (KTR) 675 mm, resp. 2075 mm
d: Diameter of the circle which is described by the test prod of the dial gage for
the angular offset while rotating the shaft; here it is equal to the diameter of the
coupling flange on the generator side.
If the actual position of the test prod is considerably different. "d" must be
corrected accordingly.
A positive result for the height correction means that the generator must be
lowered at this point.
Ŷ Calculate horizontal correction values for the front and rear generator
supports from the measured values of the horizontal parallel and angular
offset as follows:
Correction value
Front supports (mm) 1.1 wH + 0.5 pH
Rear supports (mm) 3.5 wH + 0.5 pH
where:
wH: Measured value for the angular offset in horizontal direction
pH: Measured value for the parallel offset in horizontal direction
NOTE
See the note on calculating the vertical correction values.
Explanation:
See the explanation on calculating the vertical correction values.

The sag of the measurement set-up must not be considered here.

A positive result for the horizontal correction means that in this position the
generator must be moved to the left (viewed from the rear).
Correcting the vertical alignment
Ŷ Install a securement against the shifting of the generator.
For this purpose, clamp the generator with a chain hoist to the generator
frame
Ŷ Loosen the nuts on two generator supports, left or right, front or rear.
Ŷ Use a wrench A/F 24 to secure the stud bolt while turning the nuts. The other
two nuts remain tightened so that the generator is secured against shifting
Fig. 19 Generator support for welded generator frame
1 Nut of the generator support

2 Adjustment nut
3 Generator support
Ŷ Relieve the load on the generator support using a suitable device, e.g., a
hydraulic cylinder, so that the adjustment nut moves freely
Fig. 20 Location for the hydraulic cylinder below the generator

Ŷ Manually correct the adjustment of the adjustment nut in accordance with the
calculated vertical correction values. If necessary, apply a marking
beforehand
NOTE
For this, position the hydraulic cylinder near the generator support below a
housing reinforcement.
NOTE
One turn is equal to a change in height of 2 mm.
NOTICE
GAP BELOW THE ADJUSTMENT NUT
The gap below the adjustment nut must not be greater than 10 mm.
If necessary, place shims on the adjustment nut.
Fig. 21 Generator support

Fig. 22 Generator support
1 Shims
2 Adjustment nut
Ŷ Hand-tighten the nuts on the generator supports
Ŷ Remove the device for relieving the load. Remove the chain hoist
Ŷ Proceed in the same way with the other two generator supports
Correcting the horizontal alignment
Ŷ Tighten the adjustment screws
Fig. 23 Adjustment screws
Ŷ Loosen 4 screws M16 per generator support, do not remove them.

Ŷ Correct the adjustment of the adjustment screws in accordance with the
calculated horizontal correction values
NOTE
One turn is equal to a change in height of 2.5 mm.

After correcting the generator alignment
OBSERVE DOCUMENT
Maintenance report K401_1025
Color key I401_689
Ŷ Check the vertical and horizontal parallel and angular offset of the generator
again
Ŷ If the deviations are not within the permissible tolerances, repeat the
generator alignment
Ŷ Subsequently, check the axial alignment again
Ŷ If the deviation is not within the permissible tolerances, correct the axial
position of the generator in the same way as the horizontal alignment
Ŷ If a Fixturlaser alignment system has been used, store the last test
measurement under the following designation:
XXXX.serv.bbb.YY
where:
Code Description
XXXX: Turbine number, e.g. "8010"
serv: As "service"
bbb: E.g., "pre" for prior to the generator alignment
YY: Averaged value, e.g. "10"
Ŷ Retighten the nut of the re-adjusted generator support applying the required
tightening torque (see K401_1025).
For the generator frame:
Ŷ Retighten the four M16 screws per generator support with the required
tightening torque, see K401_1025
Ŷ Loosen the adjustment screws and tighten them again with 50 Nm
Ŷ Remove the securing mechanism which prevents the generator from slipping
to the rear
Ŷ Remove the measuring instruments
Ŷ Make sure that all torque-tightened screws are provided with the required
color marking (see I401_689).

3.5 Checking the screw connections of the clamping sets

Checking the screw connections of the clamping sets X X X
OBSERVE DOCUMENT
NALL01_040698 Quality Notes on the Assembly
Ŷ Check the screw connections as described in K401_1025.

Ŷ Now assemble the coupling pipe if still disassembled.
Comply to the tightening torques for the screws that are mentioned in
K401_1025
3.6 Checking the screw connections and the condition of

the coupling

Checking the screw connections and the condition of the
X X X
coupling
OBSERVE DOCUMENT
NALL01_040698 Quality Notes on the Assembly
Ŷ Check the coupling for visible damage.

Especially, check the disk packs of the KTR coupling.
If individual disks are broken, exchange the disk packs of the coupling
Ŷ Check the screw connections as described in K401_1025.
NOTE
Skip this check if the coupling has been previously removed and re-installed.
NOTE
Do not check the tightening torque of the screw connections on the integrated
slip unit in the KTR coupling. They are preset by the manufacturer.
Page 30 of 42 I401_1008_EN Checking the screw connections of the clamping sets

3.7 Checking the screw connections generator frame /

machine frame

Checking the screw connections generator frame / machine
X X X
frame
Depending on the type of generator frame, check the following screw

connections as described in I401_619 and K401_1025 :
Welded generator frame:
Ŷ Screw connection between generator frame and machine frame
3.8 Inspecting the screw connections of the generator

supports

Inspecting the screw connections of the generator supports X X X
Ŷ Check the screw connections as described in I401_619 and K401_1025.
Ŷ Hand-tighten the adjustment screws under the generator base plate.
3.9 Inspecting the cable glands on the generator

Inspecting the cable glands on the generator X X X
Ŷ Visually inspect the cable glands on the stator terminal box and the rotor
terminal box of the generator for leaks and for correct fit.
Only for cable glands with MTC frames (Brattberg):
Ŷ Retighten the rubber insert blocks if required.
To this end, remove the last segment
Ŷ Replace the rubber insert blocks if retightening is no longer possible
3.10 Checking the tightening torques in the generator

terminal boxes

Checking the tightening torques in the generator terminal boxes X X X
Checking the screw connections generator frame / machine frameI401_1008_EN Page 31 of 42

Ŷ Check the tightening torques of the electrical connections in the stator

terminal box as described in I401_619 and K401_1025.
Ŷ Check the tightening torques of the electrical connections in the rotor terminal
box as described in I401_619 and K401_1025.
3.11 Checking the tightening torques of the equipotential

bonding

Checking the tightening torques of the equipotential bonding X X X
Ŷ Check the tightening torques of the screw connections for the equipotential
bonding
- At the base of the generator and
- on the equipotential bonding bar below the brake disk on the machine
frame
as described in I401_619 and K401_1025.
3.12 Inspecting the slip ring tracks

Inspecting the slip ring tracks X X X X
The slip ring tracks are electrical contact areas and have a highly polished
surface under normal operating conditions. Their appearance is an indication of
the running characteristics of the carbon brushes.
Ŷ Open the slip ring box of the generator
Fig. 24 Slip ring box of the VEM generator
Page 32 of 42 I401_1008_EN Checking the tightening torques of the equipotential bonding

Ŷ Visibly check the slip ring tracks.

The metal must be bright and smooth and there must be no stains or burn
marks
Ŷ If necessary, re-machine the slip rings in the direction of rotation or clean with
a dry, lint-free cloth
Ŷ For re-machining use a piece of pulp wood and fine emery cloth (500 grit).
The pulp wood must be adapted to the radius of the slip rings
NOTE
If there is a patina layer, do not grind it down, if possible. It ensures the best
electrical contact between the slip ring surface and the carbon brush.
3.13 Inspecting the carbon brushes and brush holders

Inspecting the carbon brushes and brush holders X X X
Inspecting the carbon brushes:

Ŷ Remove all carbon brushes, one after the other, from the brush holder
Ŷ Inspect the running surface of the carbon brushes
- Even wear
- Burn marks from brush sparking
achten.
Ŷ Measure the usable residual length and document it in the Maintenance
Report K401_1025
Fig. 25 Carbon brush
1 Residual length
2 Marking notch
Inspecting the carbon brushes and brush holders I401_1008_EN Page 33 of 42

Designation Target value:

Main brushes > 40 mm
Grounding brushes > 15 mm
Ŷ Replace the carbon brushes if the remaining length is shorter than the
permitted residual length or burn marks are found
Inspecting the brush holders:
Ŷ Check the inner surfaces of the brush holder box, and, if necessary, clean
them and carefully grind down the current traces
Ŷ Measure the distance between the bottom edge of the brush holder and the
slip ring surface
Target value: 2 mm + 0.5 mm
Ŷ Check whether the pressure lever can be moved
Ŷ If necessary, lubricate the joints with 1 to 2 drops of acid-free oil.
NOTICE
RISK OF DAMAGE TO COMPONENTS
Grease or oil on the running surface of the slip rings may result in severe
damage to the generator or converter.
Do not allow any oil drip onto the slip rings.
Ŷ Check the fastening of the brush holder and the flexible wires
Ŷ Carbon brushes that must not be replaced must be reinserted into the same
brush holder from which they were removed
When doing so:
- Do not twist the flexible wires of the carbon brushes
- Insert the grounding brushes with the arrow pointing into the direction of
rotation of the generator rotor
Ŷ Check the free movement of the carbon brushes in the brush holder
Ŷ Check the brush wear monitoring.
To do so, manually operate the micro switch and check the response of the
corresponding relay in the Topbox
Page 34 of 42 I401_1008_EN Inspecting the carbon brushes and brush holders

Replacing the carbon brushes
NOTICE
RISK OF DAMAGE TO COMPONENTS
Only use the same carbon brush type. The slip ring system of the generator
may get damaged.
Depending on the generator type the new carbon brushes have the following
different lengths:
Brush length [mm]

Generator type
Main brushes Grounding brushes
Winergy 100 50
VEM 50 30
ELIN 80 50
NOTE
Always replace carbon brushes in pairs.
To replace the carbon brushes, proceed as follows:

Material: Refer to K401_1025, Material for maintenance
Ŷ Remove the old carbon brushes and unscrew the flexible wires
Ŷ If not already completed, pre-machine the new carbon brushes outside of the
generator to match the curve of the slip rings
Ŷ Insert the pre-machined carbon brushes into the brush holder and screw on
the flexible wires
NOTICE
CONSIDER THE MOUNTING DIRECTION
The arrows on the grounding brushes must match the direction of rotation of
the generator rotor.

Fig. 26 Grounding brush layout
Ŷ Check the carbon brushes for good guidance and flexibility

Next, the carbon brushes must be run in. This can be achieved using different
methods:
- Manual run-in by pulling emery cloths between carbon brushes and slip
ring
- Running-in by turning the rotor with emery cloth glued to the slip ring
Page 36 of 42 I401_1008_EN Inspecting the carbon brushes and brush holders

A B
Fig. 27 Running in the carbon brushes
A Manual running-in
B Running-in by turning the rotor
1 Carbon brush
2 Direction of rotation of the rotor
3 Slip ring
4 Emery cloth
NOTE
Always run in the carbon brushes as a group per slip ring.
Manual running-in
Ŷ Place emery cloth around the slip ring.
Width of the strip: Slip ring width + 20 mm on both sides
Ŷ Move the emery cloth back and forth under the carbon brushes until approx.
90 % of the carbon brush contact surface comes into contact with the slip ring
Ŷ Finally, withdraw the emery cloth in the rotational direction of the rotor
Running-in by turning the rotor

Ŷ Attach strips of emery cloth to the slip ring in rotational direction using double-
sided adhesive tape.
Width of the strip: Slip ring width + 20 mm on both sides
Ŷ Release the rotor lock
Ŷ Manually turn the rotor blades into the wind until the rotor turns slowly

WARNING
ROTATING PARTS
Entanglement hazard due to rotating parts.
Keep a safe distance from rotating parts.
Ŷ After approx. 90 % of the carbon brush running surface comes into contact
with the slip ring, stop and lock the rotor
Ŷ Remove the emery cloth
Ŷ Thoroughly remove any adhesive tape residue from the slip ring
Final step:
Ŷ Thoroughly clean the running surfaces of the carbon brushes with a dry,
grease-free, lint-free cloth
Ŷ Thoroughly clean the slip ring box as described below
Ŷ Document the replacement of the carbon brushes in the appendix of the
maintenance report K401_1025
3.14 Cleaning the slip ring box

Cleaning the slip ring box X X
NOTICE
Severe damage to generator and converter
The abrasion product of the carbon brushes in the slip ring box and grease or
oil on the running surfaces of the slip rings may cause severe damage to the
generator and converter. Always clean the slip ring box thoroughly.
CAUTION
DAMAGE TO HEALTH FROM INHALING RESPIRABLE DUST AND
CLEANING AGENT VAPORS
Use breathing protection when cleaning the slip ring box.
Ŷ Ensure that the rotor is locked on the rotor shaft

Ŷ Remove the carbon brushes before using the cleaning agent
Ŷ Clean the slip rings and brush holders with a grease-free brush
Page 38 of 42 I401_1008_EN Cleaning the slip ring box

Ŷ Use a vacuum cleaner, cloth and brush to thoroughly clean the entire slip ring
box of the abrasion product of the carbon brushes over all maintenance
openings
NOTE
Additionally, the cleaning agent Rivolta SLX Top can be used to enhance the
cleaning process.
Do not spray the cleaning agent into the slip ring box. Do not apply it
extensively. Only use the cleaning agent with a cloth.
Provide for sufficient ventilation. The cleaning agent evaporates without
leaving any residue.
Ŷ Clean all covers of the maintenance openings

Ŷ Insert the carbon brushes after the cleaning agent has evaporated without
leaving any residue
Ŷ Close all maintenance openings
3.15 Replacing the air filter mats in the generator

Replacing the air filter mats in the generator X X X
Ŷ Remove the cap of the air filter by loosening the tommy screw
Ŷ Remove the air filter mats, beat out the dirt, check the condition and re-insert.
Fig. 28 Filter housing and positioning of the air filter mats
Ŷ Install the cap and hand-tighten the tommy screw

Ŷ Replace the complete set of air filter mats every two years.
Document the replacement in the maintenance report K401_1025.
Replacing the air filter mats in the generator I401_1008_EN Page 39 of 42

3.16 Electrical test measurements

Electrical test measurements X
3.16.1 Checking the insulation resistance

Ŷ Disconnect the generator from the converter and, if necessary, from the
surge arresters
Ŷ Measure the insulation resistance of phase-to-phase and phase-to-ground
Target value:
at 20 °C and a measuring voltage of 1000 V DC
Rotor winding 2.0 MOhm / M
Stator winding 1.5 MOhm / M
Ŷ Restore the operational condition of the generator
NOTE
If the target values are not reached, the windings must be dried.
3.16.2 Checking the protective ground conductor

Ŷ Check the protective ground conductor of the turbine using the insulation
tester
Page 40 of 42 I401_1008_EN Electrical test measurements

4. Revision index
Rev. Date Reason for revision AST Author

L. Ladwig
05 2014-10-27 Updates from NeMo 14-2 included 9220
S. Gastler
Ɣ Check for proper functioning ALU changed - forcing ST440 deleted

Ɣ Cleaning the slip ring box detailed
Ɣ Checking the generator alignment with the Prüftechnik alignment system
added
I401_1008_EN Page 41 of 42
Nordex Energy GmbH
Langenhorner Chaussee 600
22419 Hamburg
Germany
http://www.nordex-online.com
info@nordex-online.com

Alignment Instructions

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Maintenance instructions

Generator, generator frame, coupling

- Translation of the original instructions -

2014 by Nordex Energy GmbH

2014 by Nordex Energy GmbH

3. Maintenance of the generator, generator frame and coupling ....................... 7

1.1 Symbols and notes

1.1.1 Hazard of personal injury

1.1.2 Warning of material damage

1.1.3 Notes and information

1.1.4 Integrated safety notes and information

Page 4 of 42 I401_1008_EN Symbols and notes

1.2 Lists and work steps

1.3 Italic text

Lists and work steps I401_1008_EN Page 5 of 42

3. Maintenance of the generator, generator frame

- The 10-minute average wind speed is less than 12 m/s

- The rotor is locked on the rotor shaft

3.1 Visually inspecting the generator frame

Maintenance for type: 1 2 3 4

Ŷ Visually inspect the entire generator frame

Maintenance for type: 1 2 3 4

Ŷ Check the generator for cracks and damages

Page 8 of 42 I401_1008_EN Visually inspecting the generator frame

3.2 Checking the automatic lubrication unit (ALU)

Maintenance for type: 1 2 3 4

The generator bearings are equipped with an automatic lubrication system.

Automatic lubrication system type "Lincoln"

Fig. 1 Automatic lubrication unit type "Lincoln"

The maintenance of the automatic lubrication system type "Lincoln" shall be

Check for proper functioning:

Checking the automatic lubrication unit (ALU) I401_1008_EN Page 9 of 42

Changing the grease type

3.3 Emptying the grease collectors

Maintenance for type: 1 2 3 4

On both bearings of the generator:

3.4 Checking the generator alignment

Maintenance for type: 1 2 3 4

Page 10 of 42 I401_1008_EN Emptying the grease collectors

Fig. 2 Vertical offset, parallel (generator right)

Fig. 3 Vertical offset, angular (generator right)

Fig. 4 Horizontal offset, parallel (generator right)

Checking the generator alignment I401_1008_EN Page 11 of 42

Fig. 5 Horizontal offset, angular (generator right)

3.4.1 Checking the axial alignment

Fig. 6 Axial alignment (example KTR coupling)

Ŷ Document the measured value in the appendix of the maintenance report

Page 12 of 42 I401_1008_EN Checking the generator alignment

3.4.2 Determining offset with a laser alignment system

1 TD-M unit generator side

Checking the generator alignment I401_1008_EN Page 13 of 42

Ŷ Select the "Tripoint" measuring method .

Fig. 8 Dimensions for "Tripoint" measuring method

Ɣ The distance C between the generator supports is 1400 mm

Page 14 of 42 I401_1008_EN Checking the generator alignment

Ŷ Press the "Tripoint" icon.

Permitted offset values

Checking the generator alignment I401_1008_EN Page 15 of 42

Fig. 9 Vertical parallel and angular offset

Ŷ If one of the permissible deviations is exceeded, the generator alignment

3.4.3 Checking the generator alignment with the Prüftechnik-

The generator alignment is checked by means of the Prüftechnik alignment

Page 16 of 42 I401_1008_EN Checking the generator alignment

Assembling the Prüftechnik alignment system

2014 by Nordex Energy GmbH

2014 by Nordex Energy GmbH