G 5.1 GP - bh.01 A A en Operating Manual

Operating manual
Wind turbine
Doc.-ID: G-5.1-GP.BH.01-A-A-EN 2008-10-06

Table of contents Wind turbine 5M
Table of contents
Operating manual
Revision service
This operating manual has been prepared in cooperation with the suppliers and
on the basis of recommendations by the regulatory authorities. This operating
manual is also continuously revised with regard to modifications and gained
experiences in order to ensure the optimum operation and a high level of
availability of the wind turbine.
The performed changes and the respectively affected replacement pages are
listed together with the corresponding revision index and the associated issue
date for the revision in the following table.
List of changes
Revision Issue date Replaced pages Changes
A 2008-10-06 - First edition
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Wind turbine 5M Table of contents
Operating manual
Table of contents
1 General...........................................................................................................................9
1.1 Information about the operating manual ........................................................................................... 9
1.2 Address of the manufacturer ........................................................................................................... 10
1.3 Customer service ............................................................................................................................ 10
1.4 Copyright ......................................................................................................................................... 10
1.5 Explanation of the symbols ............................................................................................................. 11
1.6 Associated documents .................................................................................................................... 12
1.7 Limitation of liability ......................................................................................................................... 12
1.8 Warranty .......................................................................................................................................... 13
1.9 Guarantee conditions ...................................................................................................................... 13
1.10 Declaration of conformity................................................................................................................. 13
1.11 Spare parts ...................................................................................................................................... 13
2 Safety ...........................................................................................................................15
2.1 Responsibility of the operator.......................................................................................................... 15
2.2 Intended use.................................................................................................................................... 16
2.3 Personnel requirements .................................................................................................................. 17
2.3.1 Qualification........................................................................................................................ 17
2.3.2 Access to the wind turbine ................................................................................................. 18
2.4 Complete personal protective equipment........................................................................................ 18
2.4.1 General personal protective equipment ............................................................................. 18
2.4.2 Complete personal protective equipment against fall ........................................................ 19
2.4.3 Check the protective equipment!........................................................................................ 20
2.5 Special dangers............................................................................................................................... 20
2.6 Securing against reactivation .......................................................................................................... 27
2.7 Fire protection and explosion protection ......................................................................................... 27
2.7.1 Behavior in case of fire....................................................................................................... 28
2.8 Hazard identification and labeling ................................................................................................... 29
2.8.1 Identifications and labels in the tower ................................................................................ 29
2.8.2 Identifications and labels in the nacelle.............................................................................. 33
2.9 Ascending and descending in the tower ......................................................................................... 40
2.9.1 Securing individuals ........................................................................................................... 40
2.9.2 Securing the wind turbine................................................................................................... 41
2.9.3 Elevator system.................................................................................................................. 41
2.10 Log entries....................................................................................................................................... 42
2.11 Behavior in case of hazardous situations and accidents ................................................................ 42
2.11.1 Preventive measures.......................................................................................................... 42
2.11.2 Correct actions ................................................................................................................... 42
2.11.3 Emergency measures and rescue measures..................................................................... 43
2.12 Environmental protection................................................................................................................. 44
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3 Safety mechanisms ......................................................................................................45

3.1 Emergency stop pushbutton............................................................................................................ 45
3.1.1 Emergency stop pushbuttons in the nacelle ...................................................................... 46
3.1.2 Emergency stop pushbutton in the tower base.................................................................. 48
3.1.3 Reactivating following an emergency stop......................................................................... 49
3.2 Rotor lock ........................................................................................................................................ 49
3.2.1 Permissible environmental conditions and wind turbine states.......................................... 50
3.2.2 Locking and releasing the rotor.......................................................................................... 51
3.2.3 Moving drive ....................................................................................................................... 52
3.2.4 Rotor lock ........................................................................................................................... 54
3.3 System management mechanisms ................................................................................................. 55
3.3.1 Control system ................................................................................................................... 55
3.3.2 Control of the pitch system................................................................................................. 56
3.3.3 Self-monitoring ................................................................................................................... 56
3.4 Safety chain..................................................................................................................................... 57
3.5 Pitch system .................................................................................................................................... 58
3.6 Rotor holding brake ......................................................................................................................... 59
3.7 Sensors ........................................................................................................................................... 61
3.7.1 Speed and direction of rotation .......................................................................................... 61
3.7.2 Power ................................................................................................................................. 63
3.7.3 Blade pitch.......................................................................................................................... 63
3.7.4 Wind speed and wind direction .......................................................................................... 64
3.7.5 Vibrations............................................................................................................................ 64
3.7.6 Oscillations ......................................................................................................................... 65
3.7.7 Additional sensors .............................................................................................................. 66
3.7.8 Brake wear signaling mechanism of the rotor holding brake ............................................. 67
3.7.9 Clearance signaling switch of the rotor holding brake ....................................................... 68
3.7.10 Hydraulic units.................................................................................................................... 68
3.7.11 Nacelle position, cable twist ............................................................................................... 71
3.7.12 Grid monitoring................................................................................................................... 71
4 Design and function......................................................................................................73

4.1 General............................................................................................................................................ 73
4.2 Module overview ............................................................................................................................. 74
4.3 Brief description of the main components ....................................................................................... 75
4.3.1 Rotor................................................................................................................................... 75
4.3.2 Pitch system ....................................................................................................................... 76
4.3.3 Brake systems.................................................................................................................... 77
4.3.4 Drive train ........................................................................................................................... 77
4.3.5 Generator / converter system............................................................................................. 78
4.3.6 Wind adjustment (yaw system) .......................................................................................... 79
4.3.7 Nacelle................................................................................................................................ 80
4.3.8 Air dehumidifier .................................................................................................................. 82
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4.3.9 Nacelle cooler..................................................................................................................... 83

4.3.10 Deck crane ......................................................................................................................... 85
4.3.11 Helicopter rappelling platform ............................................................................................ 86
4.3.12 Tower.................................................................................................................................. 86
4.3.13 Corrosion protection ........................................................................................................... 87
4.3.14 Lightning protection ............................................................................................................ 87
4.3.15 Fire protection system ........................................................................................................ 87
4.3.16 Control system ................................................................................................................... 89
5 Description of the operating modes ..............................................................................91

5.1 Automatic operation ........................................................................................................................ 91
5.1.1 Requirements for the automatic operation ......................................................................... 91
5.1.2 System test......................................................................................................................... 92
5.1.3 Start-up............................................................................................................................... 92
5.1.4 Production mode ................................................................................................................ 92
5.1.5 Reduced operation ............................................................................................................. 93
5.1.6 Deactivating........................................................................................................................ 93
5.1.7 Notifying customer service ................................................................................................. 99
5.2 Manual operation........................................................................................................................... 100
6 Transport, packaging, storage....................................................................................101

6.1 Safety notices for the transport ..................................................................................................... 101
6.1.1 General safety requirements ............................................................................................ 101
6.1.2 Personnel requirements ................................................................................................... 102
6.1.3 Personal protective equipment......................................................................................... 102
6.2 Transport inspection...................................................................................................................... 103
6.3 Hoisting, lowering, transporting, and storing ................................................................................. 103
6.3.1 Operating the chain hoist ................................................................................................. 103
6.3.2 Operating the deck crane ................................................................................................. 104
6.3.3 Transporting loads............................................................................................................ 105
6.3.4 Storing accessories, modules, and spare parts ............................................................... 106
6.3.5 Handling packaging materials .......................................................................................... 106
7 Installation and initial commissioning..........................................................................107
8 Operation....................................................................................................................109
8.1 Safety notices for the operation..................................................................................................... 109
8.2 Activating ....................................................................................................................................... 111
8.2.1 Preparations ..................................................................................................................... 111
8.2.2 Starting the wind turbine................................................................................................... 111
8.3 Stopping the wind turbine.............................................................................................................. 112
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8.4 Manual wind adjustment................................................................................................................ 112

8.4.1 Wind adjustment via touch panels ................................................................................... 112
8.4.2 Wind adjustment via switch settings ................................................................................ 113
8.5 Closing the rotor holding brake ..................................................................................................... 114
8.6 Resetting the safety chain ............................................................................................................. 114
8.7 Using the elevator system, ascent support ................................................................................... 116
9 Control........................................................................................................................117
9.1 Safety notices for the control......................................................................................................... 117
9.2 Concept and technical principles................................................................................................... 118
9.3 General.......................................................................................................................................... 118
9.4 Active status and priority rules ...................................................................................................... 119
9.5 Touch panels ................................................................................................................................. 120
9.5.1 Design of the touch panels............................................................................................... 120
9.5.2 Activating the touch panel ................................................................................................ 120
9.5.3 Function keys ................................................................................................................... 121
9.5.4 Line editor......................................................................................................................... 122
9.5.5 Wind adjustment at the touch panel................................................................................. 124
9.5.6 Adjusting the touch panel brightness ............................................................................... 124
10 Menus.........................................................................................................................125
10.1 Structure of the menus .................................................................................................................. 125
10.2 Handling the menus ...................................................................................................................... 125
10.3 Display area of the touch panel..................................................................................................... 126
10.4 Error messages ............................................................................................................................. 126
10.5 Start menu ..................................................................................................................................... 127
10.6 Login at the system ....................................................................................................................... 128
10.6.1 Requesting active status .................................................................................................. 128
10.6.2 Deactivating active status................................................................................................. 128
10.7 Status menu .................................................................................................................................. 129
10.7.1 System submenu.............................................................................................................. 130
10.7.2 Oil submenu ..................................................................................................................... 131
10.7.3 Yaw submenu................................................................................................................... 131
10.7.4 Temperatures submenu ................................................................................................... 132
10.7.5 RPM submenu.................................................................................................................. 132
10.7.6 Controller submenu .......................................................................................................... 133
10.7.7 Lennord+Bauer submenu................................................................................................. 133
10.7.8 Pitch motor submenu ....................................................................................................... 133
10.7.9 Wind submenu ................................................................................................................. 133
10.7.10 Operating timers submenu ............................................................................................... 134
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10.7.11 Communication submenu................................................................................................. 134

10.7.12 Inputs submenu................................................................................................................ 135
10.7.13 Outputs submenu ............................................................................................................. 135
10.7.14 I/O abbreviation submenu ................................................................................................ 135
10.7.15 Analog signal status submenu ......................................................................................... 135
10.7.16 Wind farm power control submenu .................................................................................. 136
10.7.17 Availability submenu......................................................................................................... 137
10.8 Grid menu...................................................................................................................................... 139
10.8.1 Grid, common submenu ................................................................................................... 139
10.8.2 Grid, individual submenu.................................................................................................. 140
10.9 Parameters menu.......................................................................................................................... 140
10.9.1 Control panel submenu .................................................................................................... 141
10.10 Status code list menu .................................................................................................................... 142
10.10.1 Status list point submenu ................................................................................................. 143
10.11 Status counter menu ..................................................................................................................... 144
10.12 Event list menu .............................................................................................................................. 145
10.13 Access list menu ........................................................................................................................... 146
10.13.1 Access list point submenu................................................................................................ 147
10.14 Serial number menu ...................................................................................................................... 148
10.14.1 Product code and serial number submenu ...................................................................... 149
10.15 Maintenance menu........................................................................................................................ 150
11 Maintenance...............................................................................................................151
11.1 Safety notices for the maintenance............................................................................................... 151
11.1.3 Complete personal protective equipment......................................................................... 152
11.1.4 Working in the rotor hub ................................................................................................... 152
11.1.5 Working at the drive train ................................................................................................. 152
11.1.6 Working at the yaw brakes and the yaw drives................................................................ 153
11.1.7 Log entries........................................................................................................................ 153
11.2 Reporting damage......................................................................................................................... 154
11.3 Measures in case of an unscheduled standstill of the wind turbine .............................................. 155
11.4 Measures in case of a longer standstill of the wind turbine .......................................................... 156
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12 Disassembly and disposal ..........................................................................................157

12.1 Safety notices for the disassembly and disposal .......................................................................... 157
12.1.3 Complete personal protective equipment......................................................................... 159
12.2 Disassembly .................................................................................................................................. 159
12.2.1 Dismantling....................................................................................................................... 159
12.2.2 Rotor blades ..................................................................................................................... 159
12.2.3 Nacelle and rotor hub ....................................................................................................... 159
12.2.4 Tower................................................................................................................................ 160
12.2.5 Switching equipment ........................................................................................................ 160
12.2.6 Foundation ....................................................................................................................... 160
12.2.7 Transfer station with transformer ..................................................................................... 160
12.2.8 Crane setup area and access path .................................................................................. 160
12.3 Disposal......................................................................................................................................... 161
13 Technical data ............................................................................................................163

13.1 Design data ................................................................................................................................... 163
13.2 Rotor.............................................................................................................................................. 163
13.3 Pitch system .................................................................................................................................. 163
13.4 Gearbox......................................................................................................................................... 164
13.5 Generator ...................................................................................................................................... 164
13.6 Tower............................................................................................................................................. 164
13.7 Wind adjustment............................................................................................................................ 165
13.8 Weights.......................................................................................................................................... 165
13.9 Safety systems .............................................................................................................................. 165
13.10 Type label ...................................................................................................................................... 166
14 Annex .........................................................................................................................167
14.1 Escape and rescue plan................................................................................................................ 167
15 Index...........................................................................................................................169
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Wind turbine 5M General
Operating manual
1 General
1.1 Information about the operating manual
This operating manual contains important notes with regard to handling the
wind turbine as well as its modules and components. The operating manual
informs about the correct use and operation of the wind turbine and provides
knowledge regarding the safe, intended, and economic operation of the wind
turbine.
The operating manual exclusively focuses on the operating phase of life.
Adhering to all specified safety notices and directives is a requirement for the
safety at work. In addition, the accident prevention regulations and general
safety instructions applicable for the field of use and the location of the wind
turbine must be observed at all times.
This operating manual does not replace duly qualified technical

personnel.
The assembly, commissioning, and removal stages may only be realized by

trained specialized companies.
At the same time, this operating manual provides the service personnel of
REpower Systems AG as well as other specialized staff working at the wind
turbine with a work of reference and a reference manual.
The chapters are sorted by numbers. The document name and the chapter
name are located in the header. The pages are consecutively numbered. The
page number is displayed in the footer on each page and is aligned on the left
or right.
In the interest of technical advancement, REpower Systems AG reserves the
right to make changes and realize expansions while maintaining the essential
characteristics of the described wind turbine without simultaneously updating
the present operating manual.
The operating manual must be thoroughly read prior to commencing the work!
It constitutes a product component and must always be stored in such a manner
that it is accessible for the personnel and in close proximity to the wind turbine.
The figures in this operating manual are not necessarily true to scale and may
deviate from the actual design in order to better display the matter at hand.
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1.2 Address of the manufacturer

REpower Systems AG
Überseering 10 / Oval Office
22297 Hamburg
Phone: +49-40-55 55 090 - 0
Fax: +49-40-55 55 090 - 39 99
E-mail: info@repower.de
Web: www.repower.de
1.3 Customer service

The customer service of REpower Systems AG is available to provide technical
details. Notes about regionally responsible contact persons may be accessed
via phone, fax, e-mail, or the Internet at any time.
In addition, the employees of REpower Systems AG are always interested in
information and experiences that result from the use and may be of value for
the improvement of the wind turbines.
1.4 Copyright
This operating manual is exclusively intended for the individuals working with
and at the wind turbine. Providing the operating manual to third parties is not
permitted without written authorization by REpower Systems AG.
The contained details, texts, drawings, figures, and other representations are
protected by copyright and subject to industrial property rights. Each
unauthorized utilization is liable to prosecution.
Copying of any type and style – even in extracts – and the utilization and / or
communication of the contents are not permitted without a written letter of
consent by REpower Systems AG. Failure to comply with this provision results
in an obligation to pay damages. We reserve the right to further claims.
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1.5 Explanation of the symbols

Warning notices are identified with symbols. They contain additional signal
words that indicate the scope of the danger.
Adhere to all notices under all circumstances!
While working, always exercise caution in order to avoid accidents, injuries, and
property damage!
… indicates an immediate hazard which, if not avoided, will result in death or

severe injury.
… indicates a potentially hazardous situation which, if not avoided, could result

in death or severe injury.
… indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.
… indicates a potentially hazardous situation which, if not avoided, may result in

property damage.
… highlights useful hints and recommendations as well as information

for an efficient and failure-free operation.
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1.6 Associated documents

The following documents are inseparable components of the system
documentation.
The annex of this operating manual contains:
Escape and rescue plan (also on placards: 1 x tower base, 1 x nacelle)
The following was also included in the set of documentations that was provided
to the operator upon the handover of the wind turbine:
Operating instructions for the control system
Hazard identification and labeling
Hydraulic plans
Status code description
Circuit diagrams
Schedule of required maintenance
Documentation elevator system
Documentation chain hoist
Documentation deck crane
Documentation dehumidification system
Documentation nacelle cooler
1.7 Limitation of liability

All specifications and notes in these instructions have been compiled while
taking the applicable standards and regulations, the state of the art, and long-
term findings as well as experiences into consideration. The liability is limited to
damage that occurs during proper use.
REpower Systems AG does not accept liability for damage due to:
y failure to observe the instructions
y improper use
y use of untrained personnel
y unsanctioned alterations
y technical modifications
y use of unapproved spare parts
The actual scope of supply may deviate from the explanations and
representations here in case of special designs, because of the utilization of
additional ordering options, or due to the latest technical modifications.
Other than that, the obligations agreed upon in the supply agreement, the terms
and conditions, and the terms of delivery of REpower Systems AG as well as
the legal provisions valid at the time of the conclusion of the agreement apply.
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1.8 Warranty
REpower Systems AG warrants the functionality of the utilized process
technology and the specified performance parameters.
The warranty period commences upon the defect-free acceptance.
1.9 Guarantee conditions

The guarantee conditions are provided as separate document in the sales
documents.
1.10 Declaration of conformity

The wind turbine complies in its design and construction as well as the model
put into circulation by REpower Systems AG with the fundamental safety
requirements of the EC machine directive,
the EMC directive, and the low voltage directive including the amendments
applicable at the time of declaration.
The declaration of conformity is attached as separate document to the
contractual documents.
1.11 Spare parts

Risk of injuries due to incorrect spare parts!
Incorrect or erroneous spare parts may greatly affect the safety of the personnel
and result in damage, malfunctions, or total failures of the wind turbine.
y Use original spare parts only.
Original spare parts may be acquired from REpower Systems AG.
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Wind turbine 5M Safety
Operating manual
2 Safety
This section provides an overview of all important safety aspects for the
protection of the personnel as well as the safe and failure-free operation of the
wind turbine.
Failures to observe the directives and safety notices detailed in this operating
manual may cause substantial dangers.
2.1 Responsibility of the operator

Each natural or legal person using or commissioning the use of the wind turbine
may be an operator.
The wind turbine is used in the commercial sector.
For that reason, the operator is subject to the legal requirements for
occupational health and safety.
The operator bears the system responsibility (EN 50110).
The safety, accident prevention, and environmental protection regulations
applicable for the field of use of the wind turbine and its components must be
observed in addition to the occupational health and safety notices in this
operating manual.
In particular, the operator:

y needs to gather information about the applicable occupational health and
safety regulations.
y needs to determine the additional dangers resulting from the special work
conditions at the location in a danger assessment.
y needs to implement the necessary behavioral requirements for the operation
of the wind turbine at the location in operating instructions, regulating in
particular:
• the instructions for visitors
• the access to the transformer room and the hub
• the use of the complete personal protective equipment against fall
• the escape and rescue plan
• the operation of the elevator system (optional equipment).
y needs to check whether the operating instructions he prepared conform to
the latest editions of the rulebooks at regular intervals during the service life.
y needs to adapt the operating instructions to new regulations, standards, and
conditions of use if required.
y needs to clearly assign the responsibilities for the installation, operation,
maintenance, and cleaning of the wind turbine.
y needs to ensure that all employees working at or with the wind turbine have
read and understood the operating manual.
y needs to train the personnel and inform them about possible dangers in the
context of handling the wind turbine at regular intervals.
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The operator is also responsible for

y ensuring that the wind turbine is always operated in a good technical
working order.
y observing the inspection and maintenance intervals and servicing the wind
turbine in accordance with the detailed maintenance regulations.
y ensuring that all protective systems and safety mechanisms are inspected
for completeness and functionality at regular intervals.
2.2 Intended use

The wind turbine has been exclusively designed for the purpose of the intended
use detailed below:
The wind turbine including all associated and neighboring mechanisms,
components, and modules (e.g. transformer, transfer station, wind farm
communication) is used to generate power in a fully automated operating mode
for the purpose of supplying it to the medium voltage grid of a power utility.
Danger due to improper use!

Each use of the wind turbine exceeding and / or differing from the intended use
may cause dangerous situations.
The following applies for that reason:
y Use the wind turbine in the intended manner only.
y Exactly adhere to all details in this operating manual.
y Particularly refrain from the following uses of the wind turbine, they are
considered improper uses:
• unauthorized access to the control system or switching activities that
have not been approved
• performance of maintenance work, service work, and / or repairs by
insufficiently trained and authorized personnel.
• the modification, conversion, or alteration of the construction or
individual equipment components in order to adjust the field of
application or the usability of the wind turbine
Claims of any type due to damage arising from improper use are excluded.
Damage due to improper use is the sole responsibility of the operator.
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2.3 Personnel requirements

2.3.1 Qualification
Risk of injuries in case of insufficient qualification!
An improper use may cause substantial injuries and property damage.
• Only commission qualified individuals with the performance of activities.
The following qualification requirements are defined for the various fields of
activities in the operating manual:
y Instructed individual
has been informed about the assigned duties and possible dangers in case
of improper behavior by the operator in the context of an instruction.
y Trained personnel
are able to perform the assigned tasks and independently recognize
possible dangers because of the professional training, knowledge, and
experience as well as the familiarity with the pertinent regulations.
y Skilled electrician
is able to perform work at electrical systems and independently recognize
experience as well as the familiarity with the pertinent standards and
regulations.
y Person instructed in electrical engineering (EUP)
is a person that has been informed and – if necessary – trained with regard
to the assigned duties and possible dangers in case of improper behavior
and has also been instructed about the necessary protection means and
protective measures by a skilled electrician.
y Personnel with switching authorization
are skilled electricians that have been specially trained for the switching
activities at the medium voltage switch gear that possess the required local
knowledge in the wind turbine. The operator must commission the person
with switching authorization for each individual case.
y Hydraulics expert
is able to perform work at hydraulic systems and independently recognize
experience as well as the familiarity with the pertinent standards and
regulations.
The personnel may only include individuals that may be expected to reliably
perform their work. Individuals with a diminished ability to respond, e.g. due to
drugs, alcohol, or pharmaceuticals, are not authorized.
In addition, the age and profession-specific regulations applicable at the site
must be observed when selecting personnel.
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2.3.2 Access to the wind turbine

Danger for individuals that have not been instructed!
Only persons with training in electrical engineering or skilled electricians may
access the wind turbine. All other individuals must be accompanied by a person
with training in electrical engineering or a skilled electrician.
• Keep unauthorized individuals away from the working area.
• Protect the entire wind turbine against unauthorized access.
• Always keep the door in the tower base locked. Unauthorized individuals
may not enter during maintenance and repair work either.
• In case of doubt, approach individuals and instruct them to leave the
proximity of the wind turbine. Interrupt the work as long as unauthorized
individuals are present in the danger zone.
2.4 Complete personal protective equipment

The entire personal protective equipment must be worn in order to minimize
hazards to health when working at or with the wind turbine or its components
.
y Properly put on the respectively specified protective equipment prior to any
work and wear it while working.
y It is also absolutely necessary to observe any signs regarding the complete
personal protective equipment that are attached in the working area.
y Do not wear rings, chains, jewelry, or untied long hair.
2.4.1 General personal protective equipment

The following protective equipment must generally be worn and/or carried in
order to access the wind turbine.
Protective work clothing – EN 50286
Tightly fitting work clothing with tight sleeves and no protruding elements.
Hard hat – EN 397

for protection against falling and flying components and materials.
Protective gloves – EN 420

for protection of the hands against contact with harmful substances and
touching hot or cold surfaces.
Safety boots – EN 345-347

for protection against heavy falling components and protection against slipping
on slippery ground. Use of boots with protective toe caps and anti-slip antistatic
soles.
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Safety glasses – EN 166

for the protection of the eyes when performing work that may damage the eyes.
Work at hydraulic systems, grinding work etc. Select the safety glasses in
accordance with the work to be performed.
Hearing protection – EN 352

for the protection of the hearing when performing work that may damage the
hearing. grinding work, drilling work etc. Select the hearing protection in
accordance with the work to be performed.
2.4.2 Complete personal protective equipment against fall

The following must be worn while being present and working in and at the tower
and in the nacelle:
Complete personal protective equipment against fall

in case of an increased risk of fall. An increased risk of fall exists whenever
bigger differences in height are exceeded and the workplace is not protected by
means of a railing. The entire personal protective equipment against fall must
always be considered a safety equipment system. Possible combinations may
be requested from REpower System AG.
The complete personal protective equipment against fall comprises:
Identification Standard
Safety belts with fall protection eye EN 361
Shock absorbers EN 355

Connection means with fall absorber (2 pcs. or Y-shape)
Fall protection slide EN 353-2
2 safety carabiners EN 362
Holding rope with rope shortener (rope, snap hook) EN 358
Hard hat with chin strap EN 397
Special training is required for properly wearing and correctly using safety belts.
For that reason, safety belts may only be used by individuals that have been
specially trained for that purpose.
y Perform a visual inspection prior to using the protective equipment.
y Check the functionality of the fall protection slide near the ground.
y Also perform a suspension test near the ground in order to test the correct
fitting of the protective equipment.
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2.4.3 Check the protective equipment!

Observe expiration dates of the material and care instructions in the instruction
manuals. Ensure that the required recurring inspections are performed by an
authorized specialist at regular intervals.
2.5 Special dangers

The following section details the remaining risks that have been determined by
means of a risk analysis.
The notes in this section and the safety notices detailed in the following
chapters of this manual must be observed under all circumstances in order to
reduce possible health hazards and avoid dangerous situations.
Risk of life due to electric current!

Touching live components poses a risk of life.
y Do not damage cables. If work may damage the cables, protective measures
must be implemented in coordination with the responsible skilled electrician
beforehand. Check for damage of the electrical systems when entering the
system. Damaged systems or system components must not be operated
further. The wind turbine must be decommissioned if applicable.
y Unauthorized individuals may not open switching cabinets or electrical system
components. Authorized individuals may open switching cabinets or system
components while observing the 5 safety rules. The 5 safety rules are:
1 – Establish the voltage-free state
2 – Secure against reactivation
3 – Determine the voltage-free state
4 – Ground and short-circuit
5 – Cover or block neighboring live components.
y Troubleshooting and repairs of the electrical system may only be performed
by authorized specialized companies under the supervision of a responsible
skilled electrician. Only spare parts approved by REpower Systems AG may
be used.
y In case of special system states, e.g. following water penetrations, longer
system standstills, medium and major technical defects etc., the system may
only be reactivated following a special evaluation by an authorized
specialized company.
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Risk of life due to high direct voltage!

The sets of rechargeable batteries of the blade pitch drives in the rechargeable
battery boxes are not protected against touch. Physical contact may cause
death! Bridging contacts may cause dangerous electrical arcs.
y Always handle rechargeable batteries, sets of rechargeable batteries, and
rechargeable battery boxes with special care.
y Disconnect the rechargeable batteries from the electrical system of the pitch
drive assemblies and secure them against reactivation prior to commencing
any work.
y Exclusively commission skilled electricians to perform the work.
Risk of life due to damaged electrical work equipment!

The use of damaged electrical work equipment may cause death.
y Always use the work equipment in the intended manner.
y Work equipment that is exclusively intended for use at home must not be
used.
y Only portable electrical work equipment supplied via an isolating transformer
or with safety extra low voltage may be used in tight areas with a conducting
environment, e.g. in the hub or below the machine base.
Risk of life due to lightning strikes!

A risk of life exists for individuals in the wind turbine and its immediate
surrounding in case of lightning strikes.
y If a thunderstorm draws near, immediately stop the work at the wind turbine
and immediately exit the wind turbine.
y Maintain a minimum distance of 500 m to the wind turbine.
y After the thunderstorm has moved on, all individuals must keep away from
the wind turbine for one hour.
y If a cracking noise is audible from rotor blades, they are electrostatically
charged. Individuals may approach the wind turbine only if the cracking
noise can no longer be heard.
y In the case of offshore systems, a timely departure from the wind turbine
must be ensured by monitoring the weather and adapting the response
times of the transport means.
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Risk of life due to falling down or falling objects!

The tower and the nacelle are workplaces at height. A fall is deadly! Falling
objects pose a risk of life for individuals underneath.
y Only authorized individuals may be present in the wind turbine.
y Two individuals instructed for rescues at height and trained as first aiders
must be present at all times. A maximum of ?? individuals may be present in
the nacelle at the same time.
y Ascending to the nacelle roof is only permitted when wearing the entire
personal protective equipment against fall and with continuous safeguarding.
Exclusively use identified attachment points in that context.
y Use the roof hatches of the nacelle roof in accordance with their respective
designations only. Pay attention to the labeling on the hatches.
y Only persons trained and instructed in the safe use of the complete personal
protective equipment against fall may ascend the tower and the nacelle. The
instruction must include:
• the safe use of the PPE against fall
• the rescue of an individual from the PPE against fall
• the evacuation in case of an emergency
y Third parties may only ascend the wind turbine under the supervision of a
trained individual.
y Ascend the wind turbine only if the rescue from the PPE against fall is
ensured by a second trained individual.
y Wearing the entire personal protective equipment against fall is also
mandatory when using the elevator system.
y Visual and functional inspections of the complete personal protective
equipment against fall must be performed by the actual user and by the
users for each other prior to ascending the wind turbine.
y Only carry tools as well as small parts in closed transport cases and secure
them against falling out. Do not carry loose items on the body, on the
clothing, or in pockets of the clothes.
y Wear a hart hat while being present in the wind turbine and its immediate
surrounding.
Risk of life due to falling ice!

If iced rotor blades turn, small and large pieces of ice may chip off, be blown off,
and cause life-threatening injuries. Similar to other tall buildings, pieces of ice
may also fall down while the system is in standstill.
y If there is an ice warning, keep a distance of at least 400 m from the wind
turbine.
y If the distance to buildings or public paths is less than 400 m, deactivate the
wind turbine in case of an ice warning.
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Risk of life due to failures at the wind turbine!

Failures at the mechanical and / or electrical modules may cause life-
threatening situations.
y Immediately deactivate the wind turbine in case of a failure.
y Refrain from all working methods and activities that endanger the safety of
individuals, the wind turbine, or the power grid.
y Only commission trained personnel and skilled electricians with the
performance of troubleshooting and repair work.
y Do not retrieve status messages and operating states in the wind turbine,
but rather via remote access in a first step if possible.
y Do not release electrical or mechanical connections.
y Ensure that the failure has been fully resolved prior to the reactivation.
y Reactivate the wind turbine only if all protective mechanisms and safety
mechanisms have been properly reinstalled and there is no more danger for
individuals and / or property.
y Ensure that the wind turbine is inspected in accordance with the defined
inspection intervals by trained and authorized personnel at regular intervals.
Risk of life due to components arbitrarily flying around!

If all blade pitch systems simultaneously fail during extremely high wind speeds,
components may tear off, fly around, and severely injure persons.
y Immediately evacuate an area of 500 m around the wind turbine and protect
it against access in case of a severe overspeed of the rotor. Inform the
remote monitoring.
y Individuals must not approach the wind turbine in order to stop it from
uncontrolled overspeed under any circumstances.
Recognize failure indicators in due time!

The operator or his agent (e.g. operations manager) should be familiar
with the operating sequences and the typical noises of his wind turbine in order
to recognize failures at an early stage. This is the only way to ensure that the
customer service of the operator (e.g. REpower Systems AG) will be
immediately informed about minor particularities, thereby preventing more
extensive damage.
Danger following special system states!

Following water penetrations, longer system standstills, medium and major
technical defects as well as other severe system failures, the system may only
be reactivated following a special evaluation by an authorized specialized
company.
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Risk of injuries at hydraulic equipment!

Hydraulically operated components may unexpectedly move. If individual
components are damaged, hydraulic fluid may escape with high pressure and
cause severe injuries.
y Only trained hydraulics experts may be commissioned to perform the work at
the hydraulic system.
y Prior to commencing the work at hydraulic components:
• Deactivate the entire hydraulic system and release the pressure.
• Completely empty the accumulator.
• Check that the entire pressure has been released from the hydraulic
system.
y Use suitable personal protective equipment when working at hydraulic
equipment.
y Do not modify the pressure settings beyond the maximum permissible
values.
y Check the accumulator and the pressure tank in accordance with the
German Health and Safety at Work Regulations (BetrSichV).
Risk of poisoning with oil or grease!

Oil and grease contain harmful components and may cause poisoning or severe
skin irritations.
y Observe the safety data sheets of the manufacturers.
y Avoid spillages and fog formations.
y In case of inhalation, immediately move the affected person to the outside.
Seek medical advice!
y In case of swallowing, immediately consult a physician. Thoroughly rinse the
mouth with plenty of water.
y Avoid contact with the skin and the eyes:
• Apply suitable skin protection cream prior to working at containers,
lines, or utilities.
• Wear protective gloves made from a synthetic material or rubber and
safety glasses with side protection elements while working.
• Thoroughly wash and use skin care cream after the work.
y In case of contact with skin or eyes, rinse immediately with plenty of water.
Consult a physician!
y In case of splashes, immediately remove the affected pieces of clothing. Re-
move working area soilings in a professional and environmentally friendly
manner. Oil and grease may not be emptied into drains.
y Do not eat, drink, or smoke while working.
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Risk of injuries due to improper use of rechargeable batteries!

Installed rechargeable batteries may release harmful substances or explode if
handled improperly.
y Do not throw rechargeable batteries into the fire or expose them to high
temperatures. There is a danger of explosion.
y Wear protective gloves.
y Do not touch escaping fluids. After contact with skin, wash immediately with
plenty of water.
y In case of fluid contact with eyes, rinse eyes immediately with plenty of water
and seek medical advice.
y Carefully remove escaping fluid with a suitable absorbent cloth and dispose
of it in an environmentally friendly manner.
Risk of injuries due to moving components!

Driven, rotating, or unidimensionally mobile modules or components may cause
the most severe injuries! For that reason, the following applies during operation:
y The presence of individuals in danger zones or their immediate surrounding
is strictly prohibited!
y Remove covers, e.g. flaps, doors, hatches, or maintenance covers, only if
the rotor has been locked.
y Do not deactivate, disable, or circumvent protective mechanisms and safety
mechanisms.
y Never operate the wind turbine, components, or parts without closed covers
or functional safety mechanisms.
y Never reach into running modules or components.
y Prior to accessing danger zones:
• Deactivate the power supply and secure it against reactivation.
• Wait until components that are still running reach standstill.
• Wait for the automatic reduction and / or discharge of residual
energies.
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Risk of injuries due to the impeller in the ventilator!

Rotating components in the ventilator may cause the most severe injuries. The
impeller must not be accessible during operation.
y Never reach into the running ventilator.
y Do not open covers and maintenance covers during operation.
y Pay attention to the running time after deactivation: Ensure that there are no
more moving parts prior to opening maintenance openings.
Risk of burns due to hot operating materials!

Operating materials may reach high temperatures during operation and cause
burns on contact.
y Check whether operating materials are hot prior to handling them. Allow a
cooling down period if necessary.
Risk of injuries due to illegible symbols!

Stickers and signs may soil or become illegible over time. Illegible signs may no
longer warn against injuries.
y Always keep safety notices, warning notices, and operating notes in a highly
legible condition.
y Immediately replace signs or stickers that have been damaged or become
unrecognizable.
Risk of injuries at edges and corners!

Sharp edges and pointed corners may cause abrasions and cuts of the skin.
y Proceed with caution when working in the proximity of edges and corners.
y Wear protective gloves.
Risk of stumbling due to dirt and scattered objects!

Soilings and scattered objects pose slipping and stumbling risks and may cause
substantial injuries.
y Keep the working area clean at all times. Always remove oil, grease, and
similar materials or substances from the ladder steps, the platforms, and the
floor of the nacelle immediately.
y Remove objects that are no longer needed.
y Mark stumbling spots with yellow/black marker tape.
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2.6 Securing against reactivation

Risk of injuries due to unauthorized reactivation!
There is a risk of the power supply being activated in an unauthorized manner
which may injure individuals in the danger zone when working at individual
modules or components.
y Observe the notes for securing against reactivation in the chapters of these
instructions.
y Adhere to the procedure for securing against reactivation which is detailed
here whenever working at individual modules or components.
Securing against reactivation:

1. Deactivate the power supply.
2. Secure the main switch by means of a lock and have the employee working
at the wind turbine keep the key.
3. Attach the following warning sign in a clearly visible location above the
switch at the bottom box in the tower base.
Fig. 2.6-1: Warning sign

4. After completing the work, ensure that no further individuals are present in
the danger zone.
5. Properly reinstall all protective mechanisms and ensure their correct
function.
6. Only remove the warning sign after that.
2.7 Fire protection and explosion protection

The wind turbine is equipped with a fire protection mechanism (ref. section:
4.3.15 "Fire protection system").
The following measures reduce possible dangers due to fire or explosions. For
that reason, all individuals working in the danger zone must ensure the
observance of these measures at all times:
y Keep the work rooms clean at all times. Remove leftover materials, waste,
dirt, empty containers, cloths containing oil and other flammable cloths,
materials etc. upon completing the work.
y Smoking is prohibited in the entire wind turbine.
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y Sprays with flammable components may be used in areas with good

ventilation only.
y Do not store empty or filled packaging or loose materials between machines
or at individual components of the wind turbine.
y Keep dust deposits and dirt deposits away from motors and components
running hot.
y Check the perfect condition of electrical installations at system components
and required ancillary equipment, e.g. portable lamps and extension cables,
at regular intervals. Immediately commission skilled electricians with the
repair or replacement of defective installations and devices.
y Remove oil and grease from the workplace, arrange a protective screen, and
ensure an exhaust prior to working with warm or hot tools, e.g. soldering
irons, hot air units, welding torches, or grinding tools. Keep fire extinguishers
within easy reach.
2.7.1 Behavior in case of fire

y Immediately evacuate the wind turbine, disconnect the electrical connection
to the power grid at the converter switching cabinet, and inform the plant
manager of the responsible power utility.
y Make extinguishing attempts only if both the personal safety and a safe
escape route are ensured. Put on escape hoods and ensure that the escape
routes are unobstructed.
y Put on escape hoods and ensure that the escape routes are unobstructed
prior to extinguishing attempts.
y If the fire cannot be extinguished, block off an area of at least 500 m around
the wind turbine and alert the fire department.
y Extinguish fires by means of the fire extinguishers installed in the tower base
(1xCO2 and 1xABC) and in the nacelle (2xCO2 and 2xABC). If electrical
modules are on fire, initially use CO2 fire extinguishers in order to prevent
destroying all components. Use ABC fire extinguishers for all other fires.
y In case of hazardous smoke emissions, exit the nacelle via the rescue
device if a safe descent in the tower is no longer possible. Attach the rescue
device for the evacuation to the marked attachment points. A rescue device
is always attached to the crane carrier. The possible escape routes are
detailed in the escape and rescue plan (ref. section 14.1 "Escape and
rescue plan").
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2.8 Hazard identification and labeling

2.8.1 Identifications and labels in the tower
Fig. 2.8.1-1: Identifications and labels in the tower base
Pos. Identification Attachment point
Entrance door, outside

1 (at eye level)
(ref. section 13.10 "Type label")
Type label
Tower base, tower wall, near the

2
ladder
Instruction PPE against fall

3
ladder
Rescue – Emergency numbers
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4
ladder
Fire protection system – minimax

5
ladder
Ban for persons with pacemakers

6
ladder
Combo sign –
Requirement for PPE

7
ladder
Information (operating manual or
excerpt with safety notices)
8 1x per elevator system

Text label – Attention …
Requirement personnel, cell phone
Text label – PPE against fall

Text label –
Load-bearing capacity elevator
system
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1x per elevator system

11
1x cabinet in the entrance area
Text label –
Emergency hand torch
12 1x cabinet in the entrance area

Additional CO2 sign
Electrical fires
1x tower base, tower wall, near

the ladder
13
1x cabinet in the entrance area
Fire protection label – (CO2 extinguisher)
Firefighting equipment
14 Tower base
Prohibition sign – No access
15 Tower base
Warning sign – Electrical voltage
16 Tower base
First aid
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Fig. 2.8.1-2: Identifications and labels in the

tower/on platforms
1 1x per platform, tower wall,

eye level
Text label – Limited capacity
2 1x bottom of each platform access

hatch
Text label – reclose hatches ...
3 2x per platform, tower wall,

eye level exit elevator system
Text label – Do not stand …
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2.8.2 Identifications and labels in the nacelle
Fig. 2.8.2-1: Identifications and labels in the nacelle I
1 On the left, gearbox

Warning sign –
Risk of stumbling
2 Above the rotor lock

Text label –
Activation of the rotor lock ...
On the right, near the crane,

3
nacelle enclosure
Text label –
Emergency hand torch
1x on the right, crane base

4 1x on the right, nacelle enclosure,
Warning sign – near the crane
Risk of contusions
1x on the right, crane arm

5 1x on the right, nacelle enclosure,
near the crane
Warning sign – Hanging load
1x on the right, on top, nacelle

cooler, on the front right
6
1x on the right, on top, nacelle
Warning sign – Ventilator cooler, on the front left
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7 Helideck, at the railing
Combo sign –
Access to the nacelle roof
On the right, in the back, chain

8
hoist
Emergency rappelling
mechanism
In the back, above the transformer

9
room (upper deck)
Rescue stretcher
On the left, in the back, access

10
transformer room
Combo sign –
Gas and open light
In the back, cover plate loading

11
hatch
Prohibition sign –
No access to the area
On the left, in the back, ascent

12
upper deck and helideck
Text label –
Exit only ... Fall protection

13
Requirement for safety belt

14
No drilling
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Fig. 2.8.2-2: Identifications and labels in the nacelle

II
1 On the left, access hub

Warning sign –
Risk of stumbling
On the left, next to the access

2
hatch to the hub
Text label –
Activation of the rotor lock …
1x on the left, in the middle,

nacelle enclosure
3
Text label – 1x on the left, on the inside,
Emergency hand torch switching cabinet top box
On the right, in the back, nacelle

4
enclosure
Emergency rappelling
mechanism
2x in the back, converter switching

cabinet, cover plate
2x on the left, in the back,
5
converter switching cabinet, cover
plate
No access to the area
1x slip ring element
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On the right, in the back, entrance

6
transformer room
Prohibition sign – No drilling
1x on the left, nacelle enclosure

next to the access hatch to the hub
1x on the right, nacelle enclosure
in the front
7
1x on the right, in the back
Fire protection label –
1x on the left, in the middle nacelle
firefighting equipment
enclosure
(CO2 fire extinguisher)
1x on the right, stairs above the

rotor bearing
8
2x on the left, stairs above the
Requirement sign – rotor bearing
Use the passage
1x on the left, in the front, next to

the access hatch to the hub
1x on the left, in the front, access
hatch to the hub
9
+ yellow paint! 1x on the left, in the back, ascent
Attachment point upper deck and helideck
1x on the right, in the back
1x at the generator
1x cover drive train, on the right

10
1x cover drive train, on the left
Warning sign –
Rotating drive train
1x in the middle, rotor switching

11 cabinet, side panel
Warning sign – 1x in the middle, generator top
Electrical voltage
On the right, in the back, nacelle

12
enclosure
Text label – Rescue device
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In the back, converter switching

13
cabinet, near the trolley
Text label – Max. 250 kg
On the left, in the back,

14
transformer room
Warning sign – High voltage
On the right, in the back,

15
transformer room
Prohibition sign – No access …
In the back, on the cover plate

16
Prohibition sign – loading hatch
Placing or storing objects
prohibited
On the left, in the back, above the

17 pump station converter (upper
deck)
Fire protection label – Ladder
On the left, in the middle, above

18
the window
Text label – Inspection hatch
On the left, in the middle, nacelle

19
enclosure, above the first aid kit
First aid
On the left, gearbox, vibration

20
sensor
Warning sign – Risk of fall
On the left, nacelle enclosure, next

21
to the access hatch (manhole)
Eye wash station with 2 bottles
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On the left, in the middle, nacelle

22 enclosure, below the fire protection
label
Additional sign – Fire protection
On the left, nacelle enclosure, next

23
to the access hatch (manhole)
Requirement sign –
Fire escape hood
On the left, nacelle enclosure,

24
above the access hatch (manhole)
Smoking prohibited
Fire protection system

25
Text label –
Notice! This is for your safety ..

26
Behavior in case of a fire

27
Overview extinguishing areas

28
Overview of the signaling units
Bottom side access hatch

29
(manhole)
Text label – reclose hatches ...
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On the left, nacelle enclosure, near

30
the access hatch (manhole)
Notice sign –
Emergency numbers

31
above the Minimax system
Information (operating manual
or excerpt with safety notices)
On the left, in the front, access

32
Text label – hatch to the hub
Access nacelle …
EMERGENCY STOP …
1x per ladder,
33
working platform rotor blade
Text label –
Load working platform
On the left, in the front access

34
hatch to the hub
Text label – Load spinner
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2.9 Ascending and descending in the tower

Risk of life due to the wind turbine in the active operating state!
There is a danger of life-threatening injuries due to component movements in
the tower and the nacelle during the operation of the wind turbine.
A wind turbine in standstill may be activated by means of remote access and
operations from the outside or automatically activate and consequently
endanger individuals.
y Stop the wind turbine prior to ascending. (ref. section 2.9.2 "Securing the
wind turbine")
y Lock the door of the tower prior to ascending the wind turbine.
y Always wear the entire personal protective equipment against fall when
ascending and descending. This also applies when using the elevator
system available in the tower (ref. section 2.9.3 "Elevator system").
y Never ascend while the ladder exhibits ice formations.
2.9.1 Securing individuals

y Never perform work alone. At least 2 instructed individuals (onshore) or
3 instructed individuals (offshore) must ascend the wind turbine on principle.
Each individual must always be able to inform the other persons about the
respective location and an imminent change of the location. The individual
must wait for the confirmation from the other persons prior to leaving the
location.
y Put on the entire personal protective equipment against fall in accordance
with the notes in the operating instructions provided by the manufacturer
prior to ascending.
y Visual and functional inspections of the complete personal protective
equipment against fall must be performed by the actual user and by the
users for each other.
• Check the functionality of the fall protection slide for the safety ladder
near the ground
• Test the correct fitting of the entire personal protective equipment
against fall by means of a suspension test near the ground
y Wear protective work clothing, a hard hat, protective gloves, and anti-slip
safety boots.
y Stop the wind turbine prior to ascending, activate the tower light, and attach
a warning sign to the bottom box.
y Only carry tools as well as small parts in closed transport cases and secure
them against falling out. Do not carry loose items on the body, on the
clothing, or in pockets of the clothes.
y Generally climb up the ladder in the tower alone. The following person must
delay the ascent until the previous person has exited the top of the ladder
and is separated by the hatch of the next platform.
y Use the roof hatches of the nacelle roof in accordance with their respective
designations only. Pay attention to the labeling on the hatches.
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y Close the hatch at the platform again after passing through. Prior to
transferring from the ladder, secure yourself by means of connection means
to a fixed attachment point. Only release the fall protection slide after that!
Upon reaching the end of the fall protection rail, generally only unhook after
the hatch at the upper platform has been closed again. During transfers,
always hook connection means with a fall absorber to a fixed attachment
point.
y Ascending to the nacelle roof is only permitted when wearing the entire
personal protective equipment against fall and with continuous safeguarding.
Use the marked attachment points (weather mast / rope safeguarding
system) in that context.
2.9.2 Securing the wind turbine

The wind turbine must be stopped and secured against reactivation prior to
ascending. Always perform the following steps to that end:
1. Register the ascent with the system control room/wind farm management.
2. Stop the wind turbine via the touch panel at the bottom box.
3. Request active status in order to prevent remote access and operations from
the outside (ref. section 10.6.1 "Requesting active status").
4. Attach a warning sign to the bottom box (ref. section 2.6 "Securing against
reactivation").
5. Deactivate the fire protection system.
Risk of life when ascending the running wind turbine!

The wind turbine is not deactivated after stopping the wind turbine and
requesting active status. The rotor may turn (idle). The nacelle may move (the
wind adjustment is active).
y Continuously monitor the condition of the wind turbine during the ascent.
y Refrain from any activities that may pose a danger. In case of doubt,
deactivate and shut down the wind turbine and secure it against
deactivation.
2.9.3 Elevator system

An elevator system has been installed in the tower of the wind turbine in order
to simplify the ascent. Further information about the elevator system is available
in the annex.
y Generally put on the entire personal protective equipment (PPE) against fall
when using the elevator system.
y Prior to using the elevator system, read the operating instructions available
in the cabin in order to be familiar with the operation of the elevator system
in case of a failure as well.
y Prior to activating the elevator system, ensure that no persons or objects are
present in the range of the elevator path.
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Danger due to the automatic operation of the elevator system!

Always monitor the condition of the elevator system while ascending and
descending in the tower. Deactivate the automatic mode when working in the
range of the elevator path.
2.10 Log entries

All activities at and in the wind turbine (assembly, maintenance etc.) must be
documented on principle (e.g. in the assembly report).
These documents are filed in the log of the wind turbine. This is the only way to
ensure comprehensive monitoring of the wind turbine.
The log is stored together with the operating manual in the entrance area in the
tower base of the wind turbine.
Data storage!
The user data and control activities are automatically recorded after
logging in by means of username and password at the touch panel. As a result, all
interventions by operators at the wind turbine may be retraced.
2.11 Behavior in case of hazardous situations and

accidents
2.11.1 Preventive measures
y Always be prepared for accidents or fires!
y Keep first aid equipment (first aid kit, blankets etc.) and fire extinguishers
readily available.
y A small first aid pack must be carried when ascending in the tower.
y Carry a portable radio and a cell phone while ascending in the tower.
y Make personnel familiar with rescue mechanisms and accident notification.
y Keep access routes free for rescue vehicles.
y Keep the helicopter platform accessible.
2.11.2 Correct actions

In case of an emergency:
y Immediately activate the emergency stop pushbutton.
y Initiate first aid measures.
y Remove individuals from the danger zone.
y Inform the responsible party at the site.
y Alert the physician and / or the fire department.
y Clear access routes for rescue vehicles.
y Make the helicopter platform accessible.
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2.11.3 Emergency measures and rescue measures

For the purpose of ensuring immediate emergency measures and rescue
measures:
y Always ascend the wind turbine with at least 2 instructed individuals
(offshore: 3 individuals). The individuals must be in constant contact with
each other.
y Immediately make an emergency call in case of an emergency (ref. posted
sign "Emergency call" in the tower base and in the nacelle). To that end,
always carry a cell phone!
y Immediately inform the system management that is responsible for the
location.
Two rescue devices are located in the nacelle. One is located on the upper
deck, and the other one has already been installed in the fall line above the
loading hatch. The rescue device is used for rescuing an incapacitated person
suspended in the personal protective equipment against fall and evacuating in
all emergency situations which are characterized by the fact that the wind
turbine cannot be exited in a safe manner via the ladder or the elevator system.
Fig. 2.11.3-1: Rescue device for 2 persons [the figure provides an

example]
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Risk of life due to suspension trauma!

Immobility in the personal protective equipment following a fall may cause a life-
threatening shock and severe injuries.
y Make an emergency call, request an emergency physician.
y Immediately take the incapacitated person suspended in the personal
protective equipment against fall to the next safe location.
y Properly position the person and do not leave the person alone until the
arrival of the rescue team.
y Inform the system management that is responsible for the location.
y It is imperative that you inform the treating physician or the emergency
medical technician about the situation of the injured person (suspension
trauma).
2.12 Environmental protection

Danger due to environmentally hazardous materials!
Incorrectly handling environmentally hazardous materials or incorrect disposal
may cause substantial damage to the environment.
y Particularly observe the following notes.
y If hazardous materials escape to the environment, immediately initiate
counter-measures.
y Immediately inform the system management that is responsible for the
location.
y Immediately inform the authorities that are responsible for the location.
Lubricants
Lubricants, e.g. grease and oil, contain poisonous substances. For that reason,
they may not pollute the environment. Their disposal must be realized by a
specialized disposal company.
Rechargeable batteries
Rechargeable batteries contain poisonous heavy metals. They are subject to
hazardous waste treatment and must be disposed of by a specialized disposal
company.
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3 Safety mechanisms
This chapter describes the safety mechanisms of the wind turbine. The safety
mechanisms are connected to the control system in order to facilitate the safe,
fully automated operation of the wind turbine. In addition, the wind turbine may
be manually deactivated with the emergency stop pushbutton in case of danger.
Risk of life due to safety mechanisms that are not functioning!

The safety will be ensured only if the safety mechanisms are functional.
y Check whether all safety mechanisms have been properly installed and are
functional prior to commencing the work.
y Never deactivate safety mechanisms.
y Ensure that the safety mechanisms are accessible at all times.
y Inspect all safety mechanisms at least once a year.
y Check safety mechanisms upon making modifications at the wind turbine.
3.1 Emergency stop pushbutton

Five emergency stop pushbuttons have been installed for the purpose of
stopping the wind turbine in case of an emergency. Four pushbuttons are
located in the nacelle, an additional one is arranged in the tower base. The
switches in the nacelle are located at the top box, the converter switching
cabinet, the hydraulic unit of the deck crane, and the portable switching unit.
The emergency stop pushbutton in the tower base is located at the bottom box.
y Activate the emergency stop pushbuttons in hazardous situations and for the
purpose of protecting against reactivation during the performance of service
work only.
y An emergency stop exposes the wind turbine to a severe load.
y A reset following an emergency stop of the wind turbine may only be
performed by authorized service personnel.
Risk of life due to high direct voltage!

The sets of rechargeable batteries of the pitch system carry high direct voltage!
This voltage remains connected to the rechargeable batteries, even after
activating the battery isolator at the converter boxes of the pitch system.
y Do not touch live components following an emergency stop.
Risk of injuries due to quick stop!

Strong vibrations due to sudden slow-downs of the rotor following an
activation of the emergency stop may cause injuries. Flying sparks and
formations of smoke as well as dust may cause dangerous situations.
y If an emergency stop has been activated, hang on tight!
y Warn other individuals in the system prior to the emergency stop activation.
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3.1.1 Emergency stop pushbuttons in the nacelle
Fig. 3.1.1-1: Emergency stop pushbutton (1) at the top box
Fig. 3.1.1-2: Emergency stop pushbutton (1) at the portable switching unit
1 Emergency stop pushbutton 2 Service switch wind turbine

3 Switch for the rotor holding 4 Start switch moving drive
brake
5 Switch for the direction of 6 Speed controller moving drive
rotation moving drive
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Fig. 3.1.1-3: Emergency stop pushbutton (1) at the

switching cabinet of the converter
Fig. 3.1.1-4: Emergency stop pushbutton (1) at the

hydraulic unit of the deck crane
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3.1.2 Emergency stop pushbutton in the tower base
Fig. 3.1.2-1: Emergency stop pushbutton (1) at the bottom

box in the tower base
The wind turbine is immediately deactivated upon activating an emergency stop
pushbutton. The circuit breaker opens and the power section of the wind turbine
switches to a voltage-free state.
However, the control system, the sensor system, the sets of rechargeable
batteries of the pitch system, and the hydraulic unit of the rotor holding brake
remain live.
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3.1.3 Reactivating following an emergency stop

Simply unlocking the emergency stop pushbutton is insufficient for
acknowledging an emergency stop and reactivating the wind turbine for safety
reasons.
y Notify the customer service of the operator after each emergency stop.
y Ensure that the cause for the emergency stop has been resolved prior to the
reactivation.
y Perform a reset of the safety chain (ref. section 8.6 "Resetting the safety
chain").
3.2 Rotor lock

The rotor lock is used to lock the rotor prior to accessing the rotor hub. The rotor
may also be locked by means of the rotor lock for the performance of
maintenance work.
The rotor lock consists of the rotor locking disk which is installed between the
rotor shaft and the gearbox as well as two locking cylinders that are bolted to
the machine base. The locking bolts in the cylinders are hydraulically operated
and may only be inserted while the rotor is in standstill.
For that reason, the rotor may only be locked in the environmental conditions
and wind turbine states detailed below.
Risk of life due to electric current and moving components!

High voltages in the rotor hub, the turning rotor, and starting yaw drives may
cause life-threatening situations.
y Accessing the area behind the locking doors to the rotor is strictly prohibited
for unauthorized individuals.
Danger of severe injuries and property damage!

The incorrect use of the rotor lock may result in overloads of the components
and cause severe injuries and property damage.
y Only use the rotor lock in the detailed environmental conditions and wind
turbine states.
y Never use the rotor lock to slow down the rotor.
y Only insert the locking bolts after the rotor has come to a complete standstill.
y Always insert both locking bolts all the way into conic boreholes of the
locking disk.
y After that, secure the locking bolts by means of the associated fastening
bolts and face covers (ref. figure 3.2.4–2).
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3.2.1 Permissible environmental conditions and wind

turbine states
General
y A weather forecast for the expected maintenance period must be obtained in
order to ensure that the permissible wind conditions will not be exceeded
(ref. section "Service work in the rotor hub and in the nacelle") prior to
commencing more extensive maintenance work which requires the rotor lock
to be engaged. In that context, observe the blade settings that exist or are
planned during the work as well as the respectively applicable wind
conditions.
y If the wind increases to wind speeds that are higher than permissible, the
entire work must be interrupted. If possible, release the rotor lock prior to
exiting the wind turbine.
y Only set the rotor lock to a value not exceeding the maximum average wind
speed of vavg = 25 m/s (10 minute average). If the rotor lock is set at higher
wind speeds, substantial damage may result at the wind turbine. For that
reason, it is absolutely necessary to release the rotor lock at higher wind
speeds.
y If releasing the rotor lock is technically impossible, ensure that as many rotor
blades as technically possible are in the van position (90° blade pitch) and
the wind adjustment has been activated.
Service work in the rotor hub and in the nacelle

y If all 3 rotor blades are in the vane position (90° blade pitch), working in the
rotor hub is only permissible up to a wind speed of vavg = 25 m/s (10 minute
average) and/or 35 m/s in gusts after setting the rotor lock and activating the
emergency stop pushbutton.
y If multiple rotor blades are not in the vane position (90° blade pitch) and
additionally exhibit different positions with regard to each other, working in
the rotor hub is only permissible up to a wind speed of vavg = 10 m/s after
setting the rotor lock and activating the emergency stop pushbutton.
y The adjustment of an individual rotor blade (2 rotor blades fixed in the vane
position) is only permitted up to a wind speed of vavg = 18 m/s (10 minute
average) and/or 25 m/s in gusts while the rotor is locked.
y The collective adjustment of all 3 rotor blades is only permitted up to a wind
speed of vavg = 14 m/s (10 minute average) and/or 20 m/s in gusts while the
rotor is locked.
y If the wind increases to wind speeds that are higher than permissible, the
entire work must be interrupted. If possible, release the rotor lock prior to
exiting the wind turbine.
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Danger of severe injuries and property damage!

If the 3 rotor blades are not in the vane position and the average wind speed
increases beyond 14 m/s, there is imminent danger for individuals and the wind
turbine.
y The rotor lock must remain set.
y Immediately evacuate the wind turbine and its close proximity.
3.2.2 Locking and releasing the rotor

General information about the rotor lock
y Set the rotor lock prior to accessing the hub area.
y Set the rotor lock prior to all work at the pitch system or the drive train.
y Observe the environmental conditions and the wind turbine states
(ref. section 3.2.1 "Permissible environmental conditions and wind turbine
states").
y Generally turn as many rotor blades as technically possible into the vane
position (90° blade pitch) in the first step.
y If the wind during the idle mode of the wind turbine is insufficient for properly
positioning the rotor locking disk in front of the locking cylinders, the moving
drive may be used.
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3.2.3 Moving drive

The moving drive is used to position the rotor locking disk in front of the locking
cylinders if this is impossible by means of the idling rotor. The following notes
must be observed under all circumstances while using the moving drive!
y Use the moving drive only if the drive train has come to a complete standstill.
Fig. 3.2.3-1: Moving drive
y Pull the locking knob (1) of the hand lever (2) at the moving drive
y Push the hand lever (2) approx. 30° in the direction of the slip ring and hold it
there. This couples the moving drive to the gearbox.
y If the hand lever cannot be engaged, release the hand lever again and
secure it by means of the locking knob. Activate the moving motor once
"empty" in order to align the drive wheels.
y If the hand lever has been engaged, use the switch "Turn motor start" (4) on
the portable switching unit to start the motor. Use the switch "Turn motor
counter-clockwise / clockwise" (5) to define the direction of rotation and the
turning knob "Potentiometer turn drive" (6) to control the turning speed.
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Fig. 3.2.3-2: Portable switching unit
1 Emergency stop pushbutton 2 Service switch wind turbine

3 Switch for the rotor holding 4 Start switch moving drive
brake
5 Switch for the direction of 6 Speed controller moving drive
rotation moving drive
y If the locking cylinders have been exactly positioned in front of the holes in
the rotor locking disk, stop the moving motor, close the rotor holding brake
by activating the switch "Service brake open/close" (3), and keep it closed.
y If the rotor lock has been fully activated and secured, the rotor holding brake
may be opened for required work at the brake system or the gearbox while
monitoring the environmental conditions and the wind turbine states.
y Prior to releasing the rotor lock, the rotor holding brake must be closed again
until the locking bolts have been fully removed from the locking disk.
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3.2.4 Rotor lock
Fig. 3.2.4-1: Switching cabinet for the operation of the rotor lock
Setting the rotor lock
y Insert the locking bolts all the way into the locking disk by activating the
pushbutton (1).
y Check whether the locking cylinders have reached the correct position.
Fig. 3.2.4-2: Fastening bolt and face cover
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y Screw the fastening bolts (1) (hexagonal bolt M 48) with the face covers (2)
into the locking bolts on the left and right side of the drive train. Manually
tighten them by means of the knob until the face covers touch the rotor
locking disk (3) without clearance.
Releasing the rotor lock

y The rotor holding brake must be closed.
y Remove the fastening bolts (1) (hexagonal bolt M 48) from the locking bolts
and remove the face covers (2).
y Completely retract the locking bolts by activating the pushbutton (2) at the
switching cabinet for the operation of the rotor lock again.
y Ensure that both locking bolts have been fully retracted from the locking disk
again by means of a visual inspection.
3.3 System management mechanisms

The safety mechanisms of the system management detailed below facilitate the
fully automated operation of the wind turbine. Manual interference by the
operator is not required.
3.3.1 Control system

The control system is located in the top box in the nacelle.
The touch panels in the top box and in the switching cabinet in the tower base
are connected to a fiber-optic data line.
The entire data that is relevant for the operation is displayed at the touch
panels. Among others, it is possible to retrieve the wind speed, speed values,
error messages etc.
The control system processes all incoming signals and maintains an optimized
and safe operating state for the wind turbine while taking these signals into
consideration.
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3.3.2 Control of the pitch system

The control of the pitch system continuously communicates with the control sys-
tem. The communication line and the lines for the voltage supply of the control
system are passed inside the drive train from the hub all the way through the
gearbox. The signals are collected by means of a slip ring connector and
transmitted to the top box.
Fig. 3.3.2-1: Slip ring connector {figure without cover}
1 Slip ring connector 2 Torque support

3 High speed shaft
3.3.3 Self-monitoring
Each module of the wind turbine includes a self-monitoring mechanism.
Malfunctions are signaled to the control system.
The control system responds with predefined procedures to these messages in
order to prevent hazardous situations for the wind turbine.
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3.4 Safety chain

The safety chain is a hard-wired circuit which is characterized by the fact that all
contacts which may trigger an emergency stop are connected in series:
Contacts of the Triggering conditions Note

safety chain
Emergency stop Manually (emergency stop *)

triggered pushbutton)
Overspeed switching The predefined speed has been

device rotor speed exceeded.
Overspeed switching
device gearbox
speed
Oscillation sensors Permissible oscillation amplitudes

have been exceeded
Cam switch More than 3 rotations of the Excessive cable

(rotation counter yaw nacelle in one direction twist
adjustment)
Key switch "Service" Manually activated *)

at thetop box
Hardware contact of Deviations from predefined The control

the control system parameters, e.g.: system triggers
excess power, overspeed, failure the automatic
of the pitch system or brake fai- quick stop
lure, monitoring of the emergency
stop contacts redundant to the
safety chain
Power in excess of 1.3 times the Only in case of a

nominal power defect at the
generator system
Overspeed at the rotor Threshold =

1.3 times the
Overspeed at the gearbox maximum
operating speed
The control system signals a

failure of the pitch system or a
brake failure during the system
test or during operation.
Monitoring control Failure of the controller of the

system "Watchdog" wind turbine
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*) If an emergency stop pushbutton or the service switch has been manually

activated, a reset of the safety chain may be performed only upon the switches
being manually unlocked on site.
An interruption of the safety chain results in a drop of a self-supporting relay
and an immediate stop of the wind turbine. This relay may only be reset
manually.
If the relay has dropped due to a grid failure (an interruption of the power supply
from the power utility), it may be automatically reset by the control system.
y The reset of the safety chain is permissible only if the cause that led to the
safety chain being triggered has been resolved.
y A reset of the safety chain may only be performed by authorized specialists!
3.5 Pitch system

The pitch system is used to restrict the power and the speed and serves as
primary brake system.
It is based on three independent drives for each rotor blade that are
electronically synchronized. The direct current motors are controlled via
converters during the normal operation of the wind turbine. A synchronous
controller controls the converters. The nominal blade pitch value is externally
defined by the control system.
Danger due to pitch back operations in case of a grid failure!

If the power supply for the hub has failed or the Grid service switch of the blade
pitch system has been activated, one blade or multiple blades automatically
move to the vane position (pitch back operation).
y Ensure that no individuals are present in the danger zone prior to activating
the Grid service switch of the blade pitch system!
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3.6 Rotor holding brake

A brake disk (2) engaged by two brake calipers (1) is installed on the high
speed shaft in order to slow down the rotor. During operation, the rotor holding
brake is covered in order to protect the individuals working in the wind turbine.
The cover may only be removed by authorized specialists after the rotor has
come to a complete standstill.
Fig. 3.6-1: Rotor holding brake {figure without cover}

The brake calipers exhibit an active design type. The rotor holding brake is
closed and opened by the hydraulic system.
The rotor brake is part of the safety chain and used to bring the rotor to a
complete standstill in case of an emergency stop as well as for maintenance
work or service work. The brake is only activated in a soft manner below 500
min in order to protect the drive train. The full brake torque is reached a few
seconds after the rotor shaft has come to a standstill.
The manual operation of the rotor holding brake is realized via a switch at the
top box or via the portable switching unit.
The rotor brake should always remain activated if the rotor does not need to be
turned. The brake may only be opened as long as the environmental conditions
and the system state are observed when working directly at the brake system or
the gearbox. In that case, the rotor lock must have been set and secured
(ref. section 3.2 “Rotor lock”).
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Fig. 3.6-2: Hydraulic unit rotor holding brake

The rotor holding brake may be manually activated by means of the hand pump
at the hydraulic unit during a grid failure.
y To that end, use the hand pump (1) at the hydraulic unit to generate the
required hydraulic pressure in the accumulator.
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3.7 Sensors
3.7.1 Speed and direction of rotation
The direction of rotation of the rotor is determined by means of inductive
proximity sensors in a phase displaced manner. The control system determines
the direction of rotation on the basis of the temporal sequence of the signals.
Fig. 3.7.1-1: Speed determination at the rotor lock
Proximity sensors (2) at the rotor locking disk (1) are used for determining the
speed and the direction of rotation of the rotor. Up to 3 sensors may be
mounted in the sensor mount (3).
One of the proximity sensors is also connected to a speed switching device
which triggers the safety chain upon exceeding the permissible speed.
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The drive train includes an additional speed determination system. It is

characterized by the fact that an inductive proximity sensor (1) scans a sensor
disk (3) on the gearbox shaft (4). An additional proximity sensor (2) scans two
slotted holes in the sensor disk (3) and is used for detecting overspeed.
Fig. 3.7.1-2: Speed determination at the high speed shaft

The control system uses the speed signal to adjust the generator torque. In
addition, excesses of the permissible speed are detected.
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3.7.2 Power
The power is calculated from the signals of the voltage and current converters
by the control system. These signals are used for monitoring the grid.
The power determination of the converter is used for its control. This signal is
used for the purpose of redundant grid monitoring.
3.7.3 Blade pitch

The blade pitch of each individual rotor blade is redundantly determined by
means of two sensor systems. Each sensor system consists of three individual
sensors. The individual sensors of the active sensor system measure the
positions of the individual rotor blades and provide the measured values to the
control system.
One sensor system is arranged on the drive shaft of the direct current motor.
The signal of that sensor system is used to synchronize the blade pitch values.
The second sensor system directly engages the gearing of the rotor blade
bearing.
Both sensor systems are monitored by the control system. Accordingly, errors in
the blade pitch determination or failures in the drive train of the blade pitch
system are immediately detected.
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3.7.4 Wind speed and wind direction

The wind turbine exhibits two anemometers and an ultrasound wind measuring
instrument which are installed at the weather mast and facilitate measuring the
wind speed and the wind direction. One anemometer is unheated. As a result,
the formation of ice can be detected.
The weather mast is grounded and includes a lightning arrestor. The cables are
arranged inside the tubes and accordingly shielded in an ideal manner. In
addition, the inputs at the control system are protected with surge suppressors.
3.7.5 Vibrations
Vibrations are determined by means of a spring lever switch (1). The spring
lever switch is arranged below the generator at the machine base and directly
integrated in the safety chain.
Fig. 3.7.5-1: Spring lever switch
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3.7.6 Oscillations
In addition to the spring lever switch at the machine base, tower oscillations and
drive train oscillations are determined by means of two separate acceleration
sensors. The acceleration sensor for the tower oscillation monitoring consists of
two sensors for monitoring the tower oscillations on two axes. These two
sensors are combined in the displayed housing (2). The housing is arranged in
spatial proximity to the spring lever switch at the machine base (1).
Fig. 3.7.6-1: Sensor for monitoring the tower oscillations
The acceleration sensor for monitoring the oscillations at the drive train is
arranged at the torque support of the gearbox.
Fig. 3.7.6-2: Acceleration sensor for monitoring the

oscillations at the drive train
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3.7.7 Additional sensors

Gearbox
Location Variable Sensor type
Oil sump Temperature PT 100
Bearing 1 high speed shaft Temperature PT 100
Bearing 2 high speed shaft Temperature PT 100
Cooling oil intake gearbox Oil pressure Analog pressure sensor
Oil pump Oil pressure Analog pressure sensor
Oil filter Oil pressure Pressure switch
Fig. 3.7.7-1: Sensors at the gearbox
1 PT 100 2 Pressure sensors

3 Manometer
Generator
Bearing A Temperature PT 100
Bearing B Temperature PT 100
Stator winding Temperature PT 100
Stator winding Temperature PTC

(2 sets of three)
Slip ring element Brush wear Wear signaling

mechanism
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Miscellaneous sensors
Bottom enclosure Temperature (outside) PT 100
Top box Temperature (inside) PT 100
Rotor bearing Temperature PT 100
3.7.8 Brake wear signaling mechanism of the rotor holding

brake
Wear signaling mechanisms (1) at the brake calipers monitor the wear of the
brake pads. If the permissible wear has been exceeded, a signal is transmitted
to the control system. The control system provides a warning.
Fig. 3.7.8-1: Brake wear signaling mechanism of the rotor holding brake
After the control system has generated this warning, the wind turbine may
perform a maximum of three more start procedures or remain operational for no
more than three days. Once these conditions have expired, the wind turbine
deactivates with a failure message.
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3.7.9 Clearance signaling switch of the rotor holding brake

The clearance signaling switch signals the complete opening of the rotor
holding brake for the purpose of preventing the pads from dragging.
The clearance signaling switch (pressure switch) is installed at the hydraulic
aggregate.
3.7.10 Hydraulic units

Hydraulic unit rotor holding brake
The hydraulic unit for the rotor holding brake is installed on the gearbox. The oil
level and the oil pressure are continuously determined and provided to the
control system.
Fig. 3.7.10-1: Hydraulic unit rotor holding brake
1 Pressure connection brake 2 Lever for the hand pump
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Hydraulic unit yaw brake

The oil level is monitored at the hydraulic unit. At the same time, the system
pressure is determined by means of a pressure sensor and provided to the
controller.
Fig. 3.7.10-2: Hydraulic unit yaw brake

The pressure connections (1) and (2) are used to charge the yaw brakes with
the brake pressure defined by the control system.
Hydraulic unit rotor lock and nacelle roof
Fig. 3.7.10-3: Hydraulic unit rotor lock and nacelle roof
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The position "Rotor lock active" or "Rotor lock inactive" is determined at the
hydraulic unit.
The hydraulic system of the roof is activated by means of the hand levers (1,4),
the valve (3), and the reducing valve (2) (ref. section 4.3.7 "Nacelle"). The
operation of the rotor lock (ref. section 3.2.2 "Locking and releasing the rotor") is
realized via the switching cabinet (5) or by means of the portable switching unit.
Hydraulic unit deck crane
Fig. 3.7.10-4: Hydraulic unit deck crane
1 Hydraulic unit 2 Lever for the hand pump

3 Control lamp motor 4 Control lamp failure
5 Emergency stop wind turbine 6 Main switch deck crane
7 Operating unit deck crane
The operation of the deck crane is realized by means of the operating unit (7) or
by means of the operating panel at the deck crane (ref. section 6.3.2 "Operating
the deck crane").
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3.7.11 Nacelle position, cable twist

The flexible lines between the nacelle and the conductor rails may be twisted
due to the wind adjustment of the nacelle. This twist is determined via a cam
switch (1) and inductive sensors (cog counters) that scan the yaw gear rim (2).
The inductive sensors (3) simultaneously monitor the direction of rotation of the
nacelle.
An automatic cable untwisting procedure is performed at less than 2 turns in a
period of little wind (less than 3 m/s).
The wind turbine is stopped (brake program 52) and an automatic cable
untwisting procedure is performed at 2 turns.
An additional turn (total of 3 turns) triggers the safety chain and causes a stop
of the wind turbine (failure message).
Fig. 3.7.11-1: Sensors for the wind adjustment
3.7.12 Grid monitoring

The control system recognizes frequency deviations, voltage deviations, brief
interruptions, and current asymmetries. Suitable reactions have been stored for
a number of possible failures in the control system of the wind turbine.
The respective thresholds are adapted to the requirements of the locally
involved power utility.
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Wind turbine 5M Design and function
Operating manual
4 Design and function

This chapter provides an overview of the design and the function of the wind
turbine REpower 5M. The most important components are illustrated in figures
and briefly described.
4.1 General
The wind turbine REpower 5M is a pitch-controlled wind turbine with variable
speed and an installed nominal power of 5,000 kW. It converts wind energy into
electric energy and supplies it to the electric grid.
The wind turbine has been developed for offshore applications and is used with
various hub heights that depend on the site conditions and the foundation
design. The rotor exhibits a diameter of 126 meters.
Variable speed and power limitation are achieved by means of a combined
control of generator moment and blade pitch.
The operation with variable speed facilitates a high degree of grid compatibility
and an optimized energy yield with minimized noise emissions.
Fig. 4.1-1: Wind turbine 5M
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4.2 Module overview
Fig. 4.2-1: Module overview
Pos. Identification Pos. Identification
1 Tubular tower 14 Deck crane
2 Yaw brake 15 Gearbox
3 Yaw drive 16 Rotor holding brake
4 Yaw bearing 17 Coupling
5 Machine base 18 Weather mast
6 Rotor blade bearing 19 Generator
7 Rotor hub 20 Converter
8 Spinner mount 21 Rappelling platform
9 Pitch system 22 Nacelle enclosure
10 Rotor blade 23 Transformer
11 Rotor bearing 24 Slip ring connector
12 Rotor shaft 25 Moving drive
13 Rotor arrester disk 26 Torque support
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4.3 Brief description of the main components

4.3.1 Rotor
The rotor consists of three rotor blades that are flanged via double-row four
point bearings to the rotor hub. The rotor blades may be adjusted as a function
of the wind conditions by means of associated rotary pitch drives around their
longitudinal axes (pitching).
The rotor operates with operating speeds between 6.9 and 12 rpm.
The wind turbine operates with a constant blade pitch and variable speed in the
partial load range, i.e. while operating the wind turbine below the nominal
power, in order to utilize the best rotor aerodynamics.
The wind turbine is operated with almost constant nominal moment in the
nominal load range, i.e. while operating the wind turbine above the nominal
speed. Speed changes due to changing wind speeds are compensated by
modifying the blade pitches.
Wind energy from strong gusts of wind is stored by accelerating the rotor and
only afterwards converted in a damped manner via the pitch system into
electrical energy and supplied to the grid.
The use of the "tilted cone" concept with a 4.0° cone angle of the rotor hub and
precurved rotor blades in connection with a 6° slant of the rotor shaft facilitates
an extremely short projection between the rotor and the tower axis.
The rotor hub may be reached directly from the nacelle via a protected access
inside the spinner in order to simplify maintenance work at the rotor hub.
Technical data rotor
Diameter of the rotor 126 m
Coated area 12,470 m2
Number of rotor blades 3
Material Glass-fiber reinforced plastic (GRP)
Nominal speed 6.9 through 12.1 +15% rpm
Blade tip speed 80 m/s
Axis slant of the rotor shaft 6°
Cone angle of the blades 4.0°
Direction of rotation Clockwise

(looking with the wind at the rotor)
Arrangement to the tower Windward
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4.3.2 Pitch system

The rotor blades are connected in a rotary manner via double-row four point
bearings to the rotor hub and may be individually adjusted via associated rotary
pitch drives around their longitudinal axes. The pitch drives are designed as
direct current motors. These interact via a planetary gear set and a pinion with
the external gearing of the four point bearing.
Spring-activated, electromagnetically ventilated brakes are integrated in the
pitch drives. A quickly operating synchronous controller is used to synchronize
the individual pitch systems.
Fig. 4.3.2-1: Pitch system unit 5M
Technical data pitch system
Principle Individual pitch adjustment by means

of electric motors
Power control Blade pitch and speed control
Speed of blade pitch adjustment Approx. 7°/s

during safety deactivations
Drive Direct current motors with battery

buffer
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Each rotor blade exhibits a separate associated rotary set of rechargeable

batteries in order to ensure the continued operation of the pitch system, even in
case of a grid failure or a failure of the wind turbine. The sets of rechargeable
batteries and the controller are arranged in a completely shielded manner in the
rotor hub and consequently protected against climatic influences. The pitch
drive assemblies are located outside the rotor hub. They are protected against
climatic influences by means of the spinner and the spinner retaining bracket.
4.3.3 Brake systems

The wind turbine is slowed down by shifting the rotor blades to the vane position
(primary brake system). Each of the three adjustment mechanisms is realized in
an entirely independent manner at the rotor blade. The drives are supplied via
the associated rotary sets of rechargeable batteries in case of a grid failure.
The adjustment of one rotor blade is sufficient for shifting the wind turbine to the
safe speed range. This results in a safety system with triple redundancy.
The primary brake system has been designed as "fail-safe" function. The wind
turbine immediately switches to the safe state upon a malfunction or a failure of
a single component of the brake system.
The rotor holding brake is used as service brake to temporarily hold the rotor
until the rotor lock is set. In addition, the rotor holding brake is used to take the
rotor to a standstill in case of an emergency stop in order to provide protection
against injuries.
Technical data brake system
Main system Individual blade pitch adjustment

(triple independent)
Holding brake Disk brake on the high speed shaft
4.3.4 Drive train

The rotor loads are directly transmitted via a rotor shaft arranged in two ball
bearings into the machine base. This keeps the gearbox mostly free of
additional external additional loads.
The low constraint torque support also reduces rotor loads at the gearbox. The
elastic suspension achieves effective noise decoupling and oscillation
decoupling from the machine base.
The lubrication has been optimized with regard to oil distribution in the gearbox
as well as oil cooling and oil filtering.
The gearbox and the generator are connected via a resiliently flexible and
torsion-proof friction coupling. The friction coupling prevents the transmission of
moment peaks and is gentle on the gearbox. In addition, the design as GRP
component ensures the static decoupling between the gearbox and the
generator.
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4.3.5 Generator / converter system

The wind turbine is equipped with a variable speed generator / converter sys-
tem. This facilitates an operation of +/- 40% of the synchronous speed. The
variable speed operation offers in connection with the pitch system very good
results with regard to the energy yield, degree of efficiency, mechanical load,
and quality of the power output.
The system prevents overvoltages and load peaks to the best possible extent.
The control of the generator facilitates an even power output with very little
fluctuations in the partial load range. The power output of the wind turbine is
almost constant in the nominal load range. The principal ability to generate
reactive power facilitates the (optional) targeted reactive power management in
accordance with the requirements of the customer and the grid operator.
The functional principle of this variable speed generator is based on the concept
of the so-called double-fed asynchronous slip ring generator with converter. The
system ensures the continuous power output by means of voltage and
frequency values that have been adapted to the grid independently from the
rotor speed. The speed and the power are continuously adapted to the
prevalent wind conditions by the system controller.
y The generator supplies 100% of the electric power to the grid in the sub-
synchronous range (partial load range).
y The generator directly supplies approx. 80% of the electric power to the grid
in the super-synchronous range (nominal load range). Management via the
converter is not necessary in that context. The remaining approx. 20% of the
power are fed from the rotor via the converter into the grid.
The generator exhibits protection class IP 54. The cooling is realized by means
of an air-to-air heat exchanger. As a result, outside air containing moisture and
salt cannot reach the inside of the generator. Temperature sensors are installed
in the bearings as well as the windings in order to monitor the machine
temperature.
Protection of moving parts against touch is ensured by covers. The housing of
the generator is grounded for potential equalization purposes. The generator is
arranged via noise-uncoupling and oscillation-uncoupling elements on the
machine base.
The converter and the transformer are also arranged in the nacelle. Both are
cooled via heat exchangers and consequently protected against entering
outside air.
Technical data generator
Nominal power Approx. 5,400 kW
Design Double-fed asynchronous generator
Protection class IP 54
Range of speeds 670 through 1,170 +15% rpm
Degree of efficiency at nominal Approx. 0.95

power
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4.3.6 Wind adjustment (yaw system)

The nacelle is connected in a rotary manner via a four point bearing with outer
gearing (1, yaw bearing) to the tower. The wind adjustment of the nacelle is
realized in accordance with the predominant wind direction via gearbox motors (2).
Fig. 4.3.6-1: Yaw drives

Hydraulic brake calipers hold the nacelle in the wind direction and the
adjustment motors in normal mode free of loads that may, among others, result
from an offset incoming flow of the rotor. The brakes are active in the condition
without current. In addition, spring-activated brakes that may be ventilated in an
electromagnetic or manual manner are integrated in the yaw drives.
When moving the nacelle, the brake pressure is reduced to a lower pressure
level; the brakes are not completely opened in that context. The residual
pressure causes a constant brake moment which counters the changing yaw
moment of the nacelle. This prevents reversing the drive gearing and facilitates
a low-load wind adjustment. In addition, the brake disk is kept in a clean and
ground in condition. The spring-activated brakes in the yaw drives are fully
opened during movements.
Electronic wind direction sensors with corresponding software control the
activation times and the direction of rotation of the yaw motors. If the wind
turbine has repeatedly turned in the same direction due to changing wind
directions, the control system also controls an automatic cable untwisting
procedure – by turning the nacelle (ref. section 3.7.11 "Nacelle position, cable
twist").
Technical data wind adjustment
Principle Electric motor via cog wheel
Design 8 gearbox motors, 8 brake calipers
Pitch speed 0.3°/s
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Stabilization Mechanical brake
Storage Four point bearing with external gearing
4.3.7 Nacelle
Glass-fiber reinforced plastic (GRP) is used as material for the enclosure. The
design of the nacelle defined nacelle dimensions even sufficient for optimum
service and maintenance conditions. Maintenance work may be performed
while the nacelle is closed.
A hatch in the machine base is used for the entry from the tower into the
nacelle. A maintenance platform has been installed in the upper tower segment
in order to facilitate accessing the components below the machine base.
All components, e.g. the yaw system or the hydraulic system, may be operated
by means of the control system in the nacelle. The control system is housed in
a switching cabinet, the top box. Emergency stop pushbuttons are installed for
safety reasons (ref. section 3.1 "Emergency stop pushbutton").
Fig. 4.3.7-1: Hydraulic unit rotor lock and nacelle roof

The wind turbine exhibits a nacelle roof which may be hydraulically opened in
halves. The hydraulic system for the right half of the roof is operated by means
of the hand lever (1), and the hydraulic system for the right half of the roof is
operated by means of the hand lever (4).
The operation of the rotor lock (ref. section 3.2.2 "Locking and releasing the
rotor") is realized via the switching cabinet (5) or by means of the portable
switching unit.
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Open the valve (3) to operate the hydraulic system of the roof only!
The required hydraulic pressure is provided via the reducing valve (2) by
opening the valve (3). If the valve (3) has been opened, the rotor lock can no
longer be activated. In addition, the system loses energy in the form of heat. For
that reason, the valve (3) must be closed again immediately after activating the
hydraulic system of the roof.
Fig. 4.3.7-2: Interlock nacelle roof

The nacelle roof exhibits multiple mechanical locks that provide security
against unintentional opening. It is imperative for the interlock to be released
prior to activating the hydraulic system in order to open the nacelle roof.
Opening the nacelle roof:
y Open the mechanical interlock (1) of the nacelle roof.
y The pump motor (6) is activated.
y Completely open the check valve (3) by turning it counter-clockwise.
y Push the hand lever for the respective half of the roof in the direction of the
drive train. It is vital to take the overlap of the halves of the roof into
consideration in that context.
y Completely close the check valve (3) by turning it clockwise after
completing the opening procedure.
Closing the nacelle roof:
y The pump motor (6) is activated.
y Completely open the check valve (3) by turning it counter-clockwise.
y Push the hand lever for the respective half of the roof in the direction of the
operator. It is vital to take the overlap of the halves of the roof into
consideration in that context.
y Mechanically lock the nacelle roof.
y Completely close the check valve (3) by turning it clockwise after
completing the closing procedure.
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4.3.8 Air dehumidifier

Air dehumidifiers that prevent corrosion at mechanical and electric components
by reducing the relative air humidity to values around 50% are used in offshore
wind turbines. The wind turbine 5M by REpower Systems AG is equipped with
two dehumidifiers for the nacelle and the tower that operate independently from
each other and in accordance with the sorption rotor principle.
The relative air humidity to be maintained is permanently set to 50% at the
respective 2 hydrostats of the dehumidifiers. The dehumidifiers operate in an
autonomous manner; the control system only receives operating or failure
messages from the dehumidifiers.
Air dehumidifier nacelle

Passing it through a filter of class F5, the dehumidifier takes in air via a defined
intake opening in the nacelle for the purpose of absorbing the moisture. This air
is heated by means of a heater that is integrated in the dehumidifier, passed
through the rotor for the purpose of absorbing the moisture, and pushed by
means of a ventilator via a defined exhaust opening from the nacelle. The dried
air is distributed via a pipe / hose system in the nacelle.
Fig. 4.3.8-1: Installation situation nacelle dehumidifier
Nacelle dehumidifier
1 Machine base 2 Aggregate
3 Yaw drive 4 Pipe/hose system
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Air dehumidifier tower

The air dehumidifier system in the tower functions similar to the system in the
nacelle. The air dehumidifier is located on the top platform of the tower. There
the room air is freely taken in via a filter of class F5, dehumidified, passed via a
pipe in the direction of the foundation, and blown out near the ground. The
humid air is passed from the tower to the surrounding. Similar to the nacelle
dehumidification, the tower exhibits defined intake and exhaust openings.
Fig. 4.3.8-2: Installation situation dehumidifier tower
Air dehumidifier nacelle
1 Room air (blue) 2 Dehumidified air (brown)
3 Humid air (pink) 4 Aggregate
5 Top platform 6 Pipe/hose system
7 Bottom platform
4.3.9 Nacelle cooler

Offshore wind turbines are equipped with a nacelle cooler. The nacelle cooler
cools the air inside the nacelle which is heated by the main aggregates and the
auxiliary aggregates. It is designed as air-to-air heat exchanger and operates in
accordance with the cross flow principle. There are two air streams that are
separated and independent from each other:
y Inside air circuit: The warm inside air is drawn by means of a ventilator into
the nacelle cooler and cooled by means of a heat exchanger. The cooled
air is returned to the interior. The air is diverted downward and to the center
of the nacelle at the exhaust opening. The inside air circuit exhibits a
nominal volume flow of 12,000 m3/h.
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y Outside air circuit: Outside air is drawn by means of a ventilator into the
heat exchanger. There it absorbs the amount of heat passed from the
inside air circuit to the heat exchanger. The warmed air is passed via an
exhaust opening to the surrounding. The outside air circuit exhibits a
nominal volume flow of 15,000 m3/h.
The air streams are separated from each other by means of the heat
exchanger. It is impossible for the inside air and the outside air to mix. This
ensures that no maritime outside air will penetrate the nacelle.
If the nacelle interior overheats, the nacelle cooler will switch to an emergency
mode. It is characterized by the fact that warm inside air is taken in and
dispensed into the surrounding.
The nacelle cooler is installed on the right side below the nacelle roof in the rear
section of the nacelle.
Fig. 4.3.9-1: Nacelle cooler, air stream, and installation situation
Nacelle cooler
1 Warm air (red) 2 View nacelle cooler at the installation

location
3 Outside air stream 4 Nacelle cooler
5 Cooled air (blue)
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4.3.10 Deck crane

In addition to the chain hoist, the wind turbine includes a hydraulic deck crane
for lifting and lowering loads in the rear part of the nacelle. It is installed to the
right of the drive train (viewed in the direction of the rotor hub) on the machine
base. The deck crane may be used inside the nacelle and even beyond the
footprint of the nacelle after opening the nacelle roof (ref. section
4.3.7 "Nacelle"). For notes regarding the operation of the deck crane, please
refer to section 6.3.2 "Operating the deck crane".
Fig. 4.3.10-1: Deck crane (view via the gearbox in the direction of the hub)
Fig. 4.3.10-2: Deck crane while the nacelle roof is opened
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4.3.11 Helicopter rappelling platform

The REpower 5M is equipped with a platform that may be approached by
helicopters in order to facilitate alternative wind turbine access for offshore
locations, especially for the purpose of rescuing persons.
Fig. 4.3.11-1: Rappelling exercise
Risk of life while the system is active!

Unexpected movements of the wind turbine may cause life-threatening
situations for individuals in the wind turbine or the helicopter. The approach
conditions applicable to the respective location must be observed under all
circumstances.
4.3.12 Tower
The tower is designed as steel pipe tower. Depending on the hub height and the
design of the foundation, it consists of 3-5 segments. A door opening is
arranged in the tower base. A weatherproof ascent to the nacelle is possible in
an elevator system or via a ladder with a fall protection system inside the tower.
Platforms that are closed with hatches are located at the transitions of the tower
segments.
The second platform is used as access platform for the elevator system and the
ladder with the fall protection system
The energy output from the transformer is passed via shielded conductor rails
that also contribute to the minimization of electromagnetic disturbances to the
tower base. The control signals from the control system in the top box of the
nacelle to the control cabinets in the tower base are transmitted via cables that
are installed on the inside wall of the tower.
A lighting system which ensures a complete illumination of the platforms and
the ascent is installed in the tower. The wind turbine also includes battery-
powered emergency lighting in order to ensure the safe departure from the wind
turbine in case of a grid interruption.
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4.3.13 Corrosion protection

All system components are protected by means of a special multi-layer coat
against corrosion and other environmental influences. The coating system
fulfills all requirements as specified in DIN EN ISO 12944.
4.3.14 Lightning protection

The wind turbine is equipped with a lightning protection system and fulfills
protection class I as required by international standard IEC 61024-1. The bolt of
lightning is received via receptors in the rotor blades and passed via slip rings
and spark gaps from the rotor to the tower. The current of the bolt of lightning is
discharged via foundation and/or deep grounding mechanisms into the ground.
4.3.15 Fire protection system

The fire protection system must be deactivated upon entering the wind
turbine and reactivated prior to exiting the wind turbine.
The wind turbine exhibits a fire protection system for the protection of
components in the nacelle that are endangered by fire. The fire protection
system must be deactivated upon entering the wind turbine and reactivated
prior to exiting the wind turbine. The system is divided into 6 extinguishing and
7 monitoring areas. The fire protection system includes a fire detector and
extinguishing agent control center which is independent from the control system
and arranged in the nacelle. The monitoring system of the fire protection system
is based on a 2 detector dependence. The detection of a fire is realized by
means of 2 detector units per monitoring area that operate in a self-sustaining
manner. If the first detector has been triggered, an advance alarm is optically
and acoustically triggered and a corresponding signal is transmitted from the
fire detection system to the control system of the wind turbine. The wind turbine
is automatically deactivated. If a main alarm is detected within a time period, a
corresponding message (fire alarm) will be transmitted from the fire detection
system to the control system of the wind turbine while the extinguishing
procedure will be triggered simultaneously. The medium voltage switch gear
and the uninterruptible power supply will be automatically deactivated at the
same time.
A manual triggering touch pad with 6 pushbutton detectors and a service switch
is arranged in the proximity of the fire detection system. An additional service
switch is located in the tower base. The extinguishing function of the fire
protection system may be deactivated via these service switches for
maintenance and repair work. While a fire would still be signaled, the
extinguishing function would be suppressed in that case. The extinguishing
procedure may be manually triggered for each extinguishing area by means of
the pushbutton detectors. However, this is also possible only if the system has
not been deactivated via a service switch. In that context, it is absolutely
necessary to keep in mind that the fire protection system cannot be activated
from the nacelle if the fire protection system has been deactivated via the
service switch in the tower base!
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The supply voltage of the fire protection system is maintained by a buffer

battery for a period of time in order to ensure the fire protection, even in case of
a grid failure and/or in case of an interruption of the power supply of the wind
turbine.
Fig. 4.3.15-1: Manual triggering touch pad fire protection system
1 LB5 NSV/UPS/BAT/TBS 2 LB3 GSF/STF/FIF

3 LB1 converter D + C 4 LB2 converter B + A
5 LB4 TSS/GRF 6 LB6 TRA
7 Service switch
The extinguishing areas are displayed in an overview drawing. The overview

drawing is installed on a carrier plate near the fire detection system in the
nacelle (ref. section 2.8.2 "Identifications and labels in the nacelle").
4 portable fire extinguishers are installed for manual firefighting in the nacelle,
2x CO2 and 2x ABC (ref. section: 2.7 "Fire protection and explosion protection").
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4.3.16 Control system

All functions of the wind turbine are monitored and controlled by the control
system. The control system is connected to all control sensors. The use of fiber-
optic cables ensures that the communication is protected from
electromagnetically interfering fields.
The control system defines nominal values for the blade angles of the rotor
blades as well as the torque of the generator and consequently functions as
superordinate controller for the decentralized control units of the electrical
system and the pitch system. The control algorithm optimizes the energy yield
without exposing the wind turbine to unnecessary dynamic loads.
The following data is continuously checked:

y Grid voltage, grid frequency, grid phase position
y Rotor speed, gearbox speed, generator speed
y Various temperatures
y Vibrations, oscillations
y Oil pressure
y Wear of the brake pads
y Cable twist
y Meteorological data.
The most critical functions are controlled in a redundant manner and may
trigger a quick stop of the wind turbine via a hard-wired safety chain in case of
an emergency – even without control system and external power supply. This
means maximum security, even during failures, e.g. a complete grid failure,
lightning strikes etc.
The operating data may be retrieved remotely. Accordingly, the entire
information about the status of the wind turbine is available to the operator as
well as the service team at any time. Various password-protected levels have
been set up to that end. Subject to the respective access rights, these even
facilitate a remote control of the wind turbine.
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Wind turbine 5M Description of the operating modes
Operating manual
5 Description of the operating modes

2 operating modes are distinguished:
Mode of Function
operation
Automatic All processes run in a fully automated manner and are

operation monitored by the control system. Operator interventions
are not required.
Manual operation Some functions may be manually activated at the

operating elements of the screens.
Additional functions may be executed by means of
switches in the wind turbine.
The following sections explain the process sequences and the differences
between the two operating modes.
5.1 Automatic operation

The control system checks whether the necessary requirements have been
fulfilled prior to the start of the wind turbine. After that, the control system
checks the functionality of the systems that are relevant to safety. This
functional test of the safety systems is referred to as system test.
5.1.1 Requirements for the automatic operation

The following conditions must be fulfilled prior to the start-up of the wind turbine:
y No error messages are active at the control system.
y The wind speed has remained above the value for the start-up wind speed
and/or below the deactivation wind speed for a defined time period.
y The wind turbine is aligned in accordance with the wind direction.
Activation / deactivation wind speeds (onshore / offshore)
Activation wind speed 3.5 m/s
Nominal wind speed 12 m/s
Deactivation wind speed 25/30 m/s
Design in accordance with the DIBT and GL guidelines:
Hub height in m Identification Fulfills the requirements in accordance

with
117 - 120 Onshore DIBT WZ III; IEC 61400-1 TC 2A, TC 1B
84 - 94 Offshore IEC 61400-3; DNV-OS-J101
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Operating manual
5.1.2 System test

The system test is performed once a week or after severe errors and comprises
the following steps:
y Activating the rotor holding brake.
y Checking the wear signal while the rotor holding brake is closed.
y Shifting the rotor blades with an adjustment speed of 2°/s to a blade pitch
of 70°.
y Checking whether the rotor holding brake holds the respective rotor moment
(slipping must not occur).
y Releasing the rotor holding brake.
y Cross-checking the idle speed and the wind signal in accordance with a
predefined routine (a discrepancy indicates an erroneous wind signal).
5.1.3 Start-up
If the conditions for the start-up have been fulfilled, and if the result of the
system test has been positive, the following start-up steps are performed:
y The rotor accelerates in a speed-controlled manner and the blade pitch is
slowly shifted in the operating position.
y The wind turbine quickly passes the tower resonance. If this procedure fails
due to a sudden lack of wind, the start-up program will automatically abort.
y If the start-up succeeds, the generator will be coupled upon the rotor
reaching the permissible speed range for the coupling, in particular ±10% of
the coupling speed.
y The condensers of the intermediate direct current circuit are charged and the
converter is connected to the electrical grid.
y Now the control system defines the nominal values for the blade pitch and
the torque of the generator system. These nominal values depend on the
wind speed and are accessed via ramp functions.
This concludes the start-up, and the wind turbine is connected in stationary grid
operating mode to the power grid.
5.1.4 Production mode

The speed manager of the control system determines the optimum generator
speed on the basis of variables that are relevant for control purposes and
adjusts the generator speed accordingly.
Partial load range

The wind turbine operates with a constant blade pitch (0° position) and variable
speed in the partial load range in order to utilize the best rotor aerodynamics.
The power output is predefined by the control system and accordingly only
depends on the wind speed as well as the resulting speed.
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Nominal load range

The wind turbine is operated with almost constant torque (nominal torque) in the
nominal load range. Speed changes (and consequently changes in power) due
to changing wind speeds are compensated by modifying the blade pitches.
5.1.5 Reduced operation

Operating data of the system, regulatory action, and external influences may
make a reduced operation of the wind turbine necessary. The reduced
operation may be achieved by reducing the speed and/or reducing the active
power.
Reduced operation in the following operating states (not complete):
• Noise optimized operation (lower rotor speed in order to reduce the sound
emissions)
• Gearbox warm-up stage (following a standstill)
• Gearbox run-in stage (in case of a new machine)
• An increased load at components of the wind turbine (e.g. when exceeding
permissible operating temperatures of the transformer, the generator, or the
gearbox)
• Strong gusts of wind (turbulences, >30° deviation of the wind direction)
• Over or under frequency of the grid voltage
• Definition of the active power by the grid operator (external power reduction,
so-called feeding management)
5.1.6 Deactivating
Different deactivation sequences with different adjustment speeds of the blades
are stored as brake programs in the control system. The following sequences
are distinguished during deactivations:
Deactivation sequence No. brake program
Emergency stop Safety chain
Safe stop 200
Quick stop IIa 180
Quick stop Ib 170
Quick stop Ia 75
Normal stop IIb 72
Normal stop IIa 70
Manual stop 60
Normal stop I 52
Idle stop 50
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Emergency stop
An emergency stop is initiated if a contact of the safety chain has been opened
(ref. section 3.4 "Safety chain"). The emergency stop runs independently from
the control system.
For example, an emergency stop is triggered by

• activating an emergency stop pushbutton
Sequence emergency stop

y The safety chain is interrupted.
y The generator is disconnected from the grid.
y The sets of rechargeable batteries are connected to the pitch drive
assemblies.
y The rotor blades are moved with maximum adjustment speed (approx. 7°/s)
to the 91° limit switches.
y The rotor blades are stopped upon reaching the 91° limit switches. (If the 91°
limit switches do not trigger, the adjustment procedure will continue until
reaching the 95° limit switches.)
y The rotor holding brake slowly falls in and supports the braking procedure
upon dropping below a generator speed of 500 rpm or no later than 15s after
triggering.
Following the completion of the procedure, the wind turbine is in standstill with a
stopped rotor and may only be restarted after a reset of the safety chain.
Safe stop
A safe stop is triggered by the following factors:
• Activating the spring lever switch
• Overspeed rotor
• Overspeed gearbox
• Cable twist in excess of 3 turns
• Triggering the watchdog circuit of the control system
Safe stop sequence

y The generator is disconnected from the grid.
assemblies.
y The rotor blades are moved with maximum adjustment speed (approx. 7°/s)
to the 91° limit switches.
y The rotor blades are stopped upon reaching the 91° limit switches.
y The rotor holding brake remains opened.
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Quick stop IIa

Quick stop IIa is initiated if at least one of the following criteria has been fulfilled:
y Triggering the watchdog circuit of the control system
y Voltage of the sets of rechargeable batteries outside the tolerance
y Triggering the main switch of the generator (short circuit due to overload or a
generator error)
Quick stop IIa sequence

y The generator is directly disconnected from the grid.
assemblies.
y The rotor blades are moved with maximum adjustment speed to the
91° limit switches.
y The rotor blades are stopped upon reaching the 91° limit switches.
Quick stop Ib
Quick stop Ib is initiated if one of the following criteria has been fulfilled:
y Grid error
y Converter error
Quick stop Ib sequence

y The pitch drive assemblies are activated.
y The rotor blades are moved with approx. 6°/s to the 91° limit switches.
y The safety chain remains closed.
Quick stop Ia
Quick stop Ia is triggered upon exceeding the maximum operating speed of the
converter.
Quick stop Ia sequence

y The pitch system is activated and the grid-supplied rotor blades are moved
with approx. 6°/s in the direction of the vane position (90°).
y The rotor blades are stopped upon reaching the vane position.
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Normal stop IIb

Normal stop IIb is triggered by an error in the pitch system which may have
been signaled by the control system or a position sensor.
Normal stop IIb sequence

assemblies.
y The rotor blades are moved with up to 7°/s to the 91° limit switches.
y The generator is disconnected from the grid at the defined power.
Normal stop IIa

Normal stop IIa is initiated if one of the following criteria has been fulfilled:
y The generator speed exceeds 1,260 rpm while the blade pitch speed = 0°/s
or the blades move in the direction of 0° at the same time
y The brake pressure is too low
Normal stop IIa sequence

y The pitch system is activated and the grid-supplied rotor blades are moved
with approx. 6°/s to the 91° limit switches.
Manual stop
Is triggered in case of a stop request activated via a display/touch panel/remote
monitoring system or by means of a brake switch at the top box/bottom
box/portable switching unit.
Manual stop sequence

y The rotor blades are moved with an adjustment speed of approx. 5°/s to a
blade pitch of approx. 70°; after that, they are moved with an adjustment
speed of approx. 1°/s to the 91° limit switches.
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Normal stop
A normal stop is performed in case of the following criteria (examples):
Criterion Automatic restart
Power in excess of 1.3 times the nominal

power
The generator power exceeds the nominal Three automatic restarts.

power (particularly strong gusts of wind or
incorrect settings).
The wind speed exceeds the permissible Automatic restart as soon as

operating range of the wind turbine. the wind speed drops below
the threshold for the restart.
Exceeding the threshold temperatures of Depending on the

the monitored components. components.
Surrounding temperature below -20°C Automatic restart as soon as

(deactivation criterion due to possible the surrounding temperature
material embrittlement). exceeds -20°C again.
Error at the hydraulic system. Possible No.

errors: Failure to achieve the pressure or
excessive pumping time, there is a
possibility of a leak.
Defect at the oil supply of the gearbox, e.g. No.

no pressure build-up.
Control system detects malfunction at the No.

yaw adjustment.
Anemometer error No.
Vane error No.
Direction of rotation of the rotor is incorrect. No.

Error only occurs in case of an extremely
incorrect alignment to the wind; it indirectly
indicates errors in the wind adjustment.
Cable untwisting procedure is necessary Automatic restart

immediately. Signal occurs if no suitable after untwisting procedure.
period of little wind occurred after
scheduling the cable untwisting procedure
and the cable has been twisted an
additional turn.
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Criterion Automatic restart
Acceleration sensors for monitoring the Conditional automatic restart

tower oscillations and the drive train (depending on the detected
oscillations have triggered. oscillation level, automatic
restart or manual reset
required).
The speed ratio between the slow rotor No.

shaft and the fast gearbox shaft does not
correspond to the nominal value.
Capacity of the rechargeable blade No.

batteries is below the tolerance.
Multiple identical errors occurring successively result in a block of the automatic

restart. The normal stop program is also triggered if the wind speed has
dropped below the activation wind speed (ref.: 13.1 "Design data").
Normal stop sequence

y The wind turbine is throttled in a controlled manner during operation at the
grid.
y The rotor blades are moved with an adjustment speed of approx. 2.5°/s to a
blade pitch of approx. 70°; after that, they are moved with an adjustment
speed of approx. 1°/s to the vane position (approx. 90° blade pitch).
y The generator is disconnected via a ramp from the grid at a defined power.
Idle stop
While idling, the rotor of the wind turbine turns with slow speed. The cause is
typically wind that is too weak for the power operation. An idle stop is initiated if
at least one of the following criteria has been fulfilled:
y Waiting for wind
y Wind is insufficient for quickly passing the tower resonance
y Wind is insufficient for connecting the generator
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Idle stop sequence

y The rotor blades are moved in a controlled manner with approx. 2.5°/s to the
70° pitch position.
y The generator is disconnected via a ramp from the grid at a defined power.
y The system continues idling with slow speed.
The uninterruptible power supply (UPS) is designed for a grid interruption of 6-8
hours (supply navigation mark, hazard beacon). The control system is
disconnected from the uninterruptible power supply and the safety chain drops
after 10 minutes ("fail-safe").
The data memory of the control system is sufficiently buffered. Accordingly, no
data will be lost.
Activation procedure after grid restoration

y The control system checks the current grid data ("system test").
y If the safety chain has been interrupted due to a longer grid failure, the
safety chain is reset.
y If no failure is active, the wind turbine will be automatically connected.
5.1.7 Notifying customer service

The wind turbine provides the possibility for automatically notifying the wind
turbine service via remote monitoring if a failure has occurred during the
(automatic) operation of the wind turbine.
If a failure occurs, it will be indicated via a corresponding warning message in
the "REguard Online Portal" to the wind turbine service.
The type of the notification depends on the parameters that have been set in
the control system of the wind turbine. The use depends on the provisions in the
agreement between the contractual partners.
Subject to the contractual provisions, the operator may generally be notified in
the following manner by the service control room (PMS):
y Error message by fax
y E-mail
y Phone
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5.2 Manual operation

The wind turbine is typically operated in a fully automated manner. System
management entries that are necessary to that end are typically entered via the
display keyboard.
Manual interference may also be necessary in a few cases. This may be
realized by a suitably qualified and authorized operator.
Always observe the special protective measures and safety requirements!

Manual operations always represent a special safety risk. The movable
and the live components as well as parts remain in a critical condition, even
after stopping the wind turbine. For that reason, it is vital for the safety notices
included in the directives (ref. chapter 8 "Operation") to be observed at all times.
The following manual interference may be realized by the operator:
Possible action Intended purpose
Stopping the wind turbine Prior to ascending to the nacelle,

inspecting damage, service work and repairs,
or other required manual activities
Starting the wind turbine For activating the wind turbine and shifting to
at the bottom box or remotely the automatic operating mode
Manual wind adjustment For special service work and

repairs at the wind adjustment mechanisms
For positioning the nacelle in order to use the
freight elevator
Closing the rotor holding For service work

brake
Resetting the safety chain Reactivation of the wind turbine following an

automatic safety stop or a manual
emergency stop
Activating the service switch For special service work and

repairs at the rotor hub as well as in the
nacelle
Operating the chain hoist For hoisting loads
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Operating manual
6 Transport, packaging, storage

This chapter contains important notes regarding the secure transport of
accessories, components, or spare parts that must be moved in the wind
turbine during the operating stage.
Transport of wind turbine equipment components by

REpower Systems AG only!
The transport, assembly, installation, and initial commissioning of the
wind turbine may only be performed by employees that have been
commissioned or authorized by REpower Systems AG.
If required, operators or maintenance personnel of the operator may participate
in accordance with the instructions provided by the commissioned individuals
while observing the following notes.
6.1 Safety notices for the transport

6.1.1 General safety requirements
Risk of life underneath hanging loads!
There is a risk of life due to falling or uncontrollably swinging components while
lifting, lowering, and moving loads.
y Never walk underneath hanging loads.
y Observe specifications for the designated attachment points.
y Do not use protruding machine components or loops of attached
components for connecting attachment means.
y Ensure the safe arrangement of the attachment means.
y Use approved hoisting means and attachment means with sufficient load-
bearing capacity only.
y Do not use damaged or worn ropes and belts.
y Do not arrange ropes and belts at sharp edges and corners, and do not knot
and twist them.
Risk of life due to uncontrolled movements!

Movable components and parts of the wind turbine may unexpectedly move and
cause life-threatening situations.
y Only use the chain hoist or the deck crane while the wind turbine is in
standstill or secured.
y Correctly position the nacelle prior to using the chain hoist or the deck crane.
y Check the immaculate condition of the guard door prior to opening the
loading hatch.
y Generally open and close the loading hatch from a safe position behind the
closed guard door only.
y Never stop on the loading hatch.
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y The operator of the chain hoist or the deck crane and the guide must be in
direct visual contact and voice contact (e.g. via radio) while hoisting and
lowering loads.
Risk of tilting in case of an offset center of gravity!

If the load has been incorrectly attached, it may tilt and cause life-threatening
injuries.
y Observe markings on the packaging or on the loads.
y Always arrange the attachment means in such a manner that the load-
bearing equipment is located perpendicularly above the center of gravity.
y Carefully hoist the load and monitor the load for tilting. Correct the
attachment if applicable.
Damage in case of improper transport!

Substantial property damage may occur in case of improper transport.
y Always act with the greatest diligence and care when unloading the loads
and performing transports within the company.
y Observe the symbols on the packaging.
y Use designated attachment points only.
y Remove packaging immediately prior to commencing the assembly only.
6.1.2 Personnel requirements

Transports within the company without the help of hoisting means that require
monitoring or conveyance equipment as well as the assembly at the site may
only be realized by instructed personnel.
Transports with hoisting means that require monitoring or conveyance
equipment may only be realized by trained experts.
6.1.3 Personal protective equipment

Generally wear the following during transports:
y Protective work clothing
y Protective work gloves
y Anti-slip safety boots
Also wear a hard hat during transport work utilizing hoisting means or ground
conveyors, e.g. hoist, chain hoist, fork lift.
Wear the entire personal protective equipment against fall and be secured at a
suitable attachment point when working at the loading hatch in the nacelle.
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6.2 Transport inspection

Immediately inspect the incoming delivery for completeness and transport
damage upon arrival.
If transport damage is visible from the outside, react in the following manner:
• Do not accept the delivery or accept the delivery with reservation only.
• Document the extent of the damage in the transport documents, the
checklists for the incoming goods, or the delivery note of the transport
company.
• Inform the construction site management.
• File a complaint.
Complain about defects in time!

Complain about any defect as soon as it has been detected. Claims for
damages may only be submitted within the applicable complaint periods.
6.3 Hoisting, lowering, transporting, and storing

The wind turbine is equipped with a chain hoist and a deck crane for the
purpose of hoisting and lowering loads. The chain hoist is located directly above
the loading hatch in the rear part of the nacelle. Looking at the hub, the deck
crane is located to the right of the drive train. In addition to hoisting and lowering
loads, the deck crane is also used for supporting assembly work. The nacelle
roof may be hydraulically opened above the deck crane (ref. section
4.3.7 "Nacelle") in order to hoist loads from the service platform (only in case of
offshore systems) into the nacelle and vice versa.
6.3.1 Operating the chain hoist

The chain hoist may only be operated by authorized personnel.
Perform the following steps in order to hoist loads by means of the chain hoist:
1. Position the nacelle with the loading hatch (2) in a beneficial position above
the load to be hoisted from the tower base.
2. Stop the wind turbine and secure it against automatic movements.
3. Ascend to the nacelle while observing the special safety notices (ref. section
2.9 "Ascending and descending in the tower").
4. Check the correct fitting of the entire personal protective equipment against
fall and secure yourself at a suitable attachment point in close proximity of
the loading hatch.
5. Close the guard door (1) in front of the loading hatch (2) and position
yourself in a secure spot. After that, open the loading hatch (2).
6. Operate the chain hoist in accordance with the operating instructions
provided by the manufacturer in order to hoist the load. In that context, the
load-bearing hook of the chain hoist must be controlled by means of a rope
by the guide from the ground in order to prevent damage to the tower.
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7. Close the loading hatch (2) again immediately after hauling up the load. The
guard door (1) may only be opened after that!
Open the loading hatch (2) for the purpose of lowering a load after properly
attaching the load and closing the guard door (1) only.
Fig. 6.3.1-1: Loading hatch with guard door
6.3.2 Operating the deck crane

The deck crane may only be operated by authorized personnel.
An extensive description is available in the deck crane documentation
(ref. section 1.6 "Associated documents"). The permissible loads as a function
of the projection specified therin must be observed under all circumstances.
Fig. 6.3.2-1: Operating touch panel deck crane

The deck crane is controlled by means of the remote control included in the
delivery (fig. 6.3.2–2) or at the operating touch panel (fig. 6.3.2–1). The switch
(1) at the operating touch panel may be used to select one of these operating
means. The operating touch panel exhibits an emergency stop pushbutton (2)
which only affects the deck crane.
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Fig. 6.3.2-2: Remote control deck crane
6.3.3 Transporting loads

Packaging protects its contents!
The packaging protects the components against transport damage,
corrosion, and other damage prior to the assembly. For that reason, do not
destroy the packaging and only remove it immediately prior to the installation of
the component.
Subject to the following conditions, loads with attachment eyes may be

transported with the chain hoist / the deck crane:
y The chain hoist / the deck crane must have been designed for the weight of
the load.
y The operator must have been authorized to operate the chain hoist / the
deck crane.
Attaching:
1. Attach ropes, belts, or multi-point suspensions (ref. figure on the left).
2. Ensure that the load is hanging straight, pay attention to an offset center of
gravity if necessary.
3. Commence the transport.
Subject to the following conditions, loads mounted on pallets may be

transported with the chain hoist / the deck crane:
y The chain hoist / the deck crane must have been designed for the weight of
the load.
y The operator must have been authorized to operate the chain hoist / the
deck crane.
y In case of transports with the chain hoist, the pallet fits in its shape and size
through the loading hatch in the nacelle.
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Attaching:
1. Attach ropes, belts, or multi-point suspensions in accordance with the figure
on the side to the pallet.
2. Ensure that the load does not get damaged by the attachment means. Use
other attachment means if required.
3. Ensure that the load hangs straight. Pay attention to the center of gravity!
4. Commence the transport.
6.3.4 Storing accessories, modules, and spare parts

Observe the following conditions when storing accessories, modules, and spare
parts:
y Do not store them without protection outside.
y Store them in a dry and dust-free environment.
y Protect them from aggressive materials.
y Protect them from direct exposure to sunlight.
y Avoid mechanical vibrations.
y If equipment is stored for more than 3 months, inspect the general condition
of all components and the packaging at regular intervals. Refresh or renew
the conservation if required.
Observe additional storage notes on the packaging!

If the accessories, modules, and spare parts exhibit additional storage
notes that exceed the requirements detailed in this manual, these must be
observed accordingly.
6.3.5 Handling packaging materials

Dispose of packaging material in accordance with the valid legal provisions and
regulations applicable at the site.
Damage to the environment due to incorrect disposal!

Packaging materials are valuable raw materials and may be used further or
processed and recycled in a reasonable manner in many cases.
y Dispose of packaging materials in an environmentally friendly manner.
y Observe the disposal regulations applicable at the respective site.
Commission a specialized company with the disposal if necessary.
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Operating manual
7 Installation and initial commissioning

Installation and initial commissioning of the wind turbine
by REpower Systems AG only!
The installation and the initial commissioning of the wind turbine may
only be performed by employees commissioned or individuals authorized by
REpower Systems AG.
Danger due to incorrect installation and initial commissioning!

Installation work and the initial commissioning require trained personnel with
extensive experience. Errors during the installation may lead to life-threatening
situations or cause substantial property damage.
y The entire work for the installation and the initial commissioning must be
exclusively performed by employees of or individuals authorized by
REpower Systems AG.
y On principle, also commission REpower Systems AG with the required work
arising from movements, reinstallations, and recommissioning activities in
the future.
y Refrain from all unsanctioned movements, installations, and / or
recommissioning activities.
The wind turbine is handed over to the operator after the assembly, the
complete installation, the initial commissioning, and the realization of
documented test runs by REpower Systems AG.
It is permissible for the operator to operate the wind turbine in the intended
manner while observing the details contained in this operating manual as well
as the associated documents detailed in section 1.6 following the handover.
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Operating manual
8 Operation
8.1 Safety notices for the operation
Risk of life due to movable components!
Individual components or parts in the wind turbine may make sudden
movements and cause life-threatening situations during operation. Reaching
into movable components or running parts may cause fatal injuries!
y Do not ascend the tower and do not access the nacelle during automatic
operation.
y Never ascend the tower in order to stop the wind turbine at the top box.
y Prior to ascending, always request active status in order to prevent the wind
turbine from being remotely activated.
y Prior to commencing any work:
• Deactivate the wind turbine and secure it against reactivation.
• Components or parts that are designated to be worked on must also be
secured against activation, e.g. by activating the
emergency stop, disconnecting circuit breakers, or deactivating and
securing the main switch, prior to commencing the work.
Risk of life due to deactivated safety mechanisms!

Manually activating the wind turbine and its components may deactivate
automatic safety mechanisms and result in life-threatening situations or cause
severe property damage.
y The operation is permitted to qualified and authorized individuals only.
y Always take the current weather conditions and the operating state of the
wind turbine into consideration.
y Set all switches back to their original or normal positions upon exiting the
wind turbine.
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Risk of injury due to improper operation!

The improper operation may cause severe injuries or property damage.
y All operations must be exclusively performed by sufficiently qualified
personnel that have been authorized and instructed by the operator.
y Perform all operating steps in accordance with the details in this operating
manual.
y Ensure that all covers, protective measures, and safety mechanisms have
been correctly installed and function properly prior to commencing the work.
y Never deactivate protective measures or safety mechanisms during the
operation.
y Ensure order and cleanliness in the working area! Loosely scattered
objects, e.g. components, parts, tools, and cleaning accessories, may
cause accidents.

All operating activities must generally be realized by sufficiently qualified
personnel that have been authorized and instructed by the operator only.

The following must be worn on principle while working at or in the wind turbine:
y Hard hat
In addition, wear the following while ascending and descending in the tower,
performing any work at or in the nacelle, and on the nacelle roof:
y Complete personal protective equipment against fall
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8.2 Activating
8.2.1 Preparations
Check the following prior to starting the wind turbine:
y No unauthorized persons in the nacelle
y No locks have been set
y No manual switching states
y No opened switching cabinets
y No tools or other items in the wind turbine
y All covers have been installed
y All hatches of the nacelle have been closed
8.2.2 Starting the wind turbine

The wind turbine may be started in the following manner after checking
(ref. section 8.2.1 "Preparations"):
1. Request access rights and active status (ref. section 10.6.1 "Requesting
active status").
2. Push the RESET key at the touch panel.
The wind turbine is now switched to the automatic operating mode
(ref. section 5.1 "Automatic operation").
y If the conditions for the start-up have been fulfilled (system test successful),
the wind turbine will start up after approx. 2 minutes.
y Request the customer service of REpower Systems AG or the operator in
case of error messages or failures.
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8.3 Stopping the wind turbine

The normal state of a wind turbine is the automatic operating mode. The
automatic operating mode is characterized by the fact that the wind turbine is
connected to the power grid and generates power.
The wind turbine must always be stopped in a first step for the purpose of
evaluating possible damage, prior to ascending the wind turbine, or ahead of
manual activities in or at components!
Risk of life due to unsecured components during standstill!

The rotor holding brake remains opened, even after stopping the wind turbine.
Components or parts may unexpectedly become mobile and cause life-
threatening situations.
y Do not open protective covers or covers.

The wind turbine is not automatically switched to the voltage-free state while
stopping or upon standstill. Touching live components poses an immediate risk
of life!
y Do not open switching cabinets.
y Do not touch live components.
Perform the following steps in order to stop the wind turbine:

1. Notify the service control room (PMS) or the remote monitoring system of the
wind turbine of the stop.
2. Push the STOP key at the touch panel in the tower base.
3. Request access rights and active status (ref. section 10.6.1 "Requesting
active status").
4. Attach the warning sign (ATTENTION! No switching or operating the keypad!
Work is being performed in this system!) at the bottom box
(ref. section 2.6 "Securing against reactivation").
8.4 Manual wind adjustment

8.4.1 Wind adjustment via touch panels
The manual wind adjustment may be made both at the touch panel of the
bottom box in the tower base as well as at the touch panel of the top box in the
nacelle.
Operating the wind adjustment via the touch panels ref. section 9.5.5 "Wind
adjustment at the touch panel".
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8.4.2 Wind adjustment via switch settings

The wind adjustment may be manually activated by means of the switch at the
bottom box in the tower base for special service and maintenance work
(ref. fig. 8.4.2-1 "Switch for the manual wind adjustment in the tower base").
After the activation, the switch remains in the set position. The switch must be
returned to the "0" position in order to stop the nacelle again.
Risk of life due to rotating drives of the wind adjustment!

Individuals may receive life-threatening injuries from manually activated drives
of the wind adjustment while working in the nacelle.
y Observe the warning sign (ATTENTION! No switching or operating the
keypad! Work is being performed in this system!) at the bottom box.
y Activate the wind adjustment only if it is certain that no individuals are
present in the range of the wind adjustment in the nacelle.
Risk of damage due to excessive cable twisting!

Manual switching bridges all automatic safety mechanisms and the safety
chain!
y Check the condition of the cables prior to activating the wind adjustment.
y Check the direction of rotation.
y Ensure that the switch is set to the "0" position after completing the
activation.
The switch for the manual activation of the wind adjustment is located at the
bottom box in the tower base.
Fig. 8.4.2-1: Switch for the manual wind

adjustment in the tower base
The switch supports three positions:
y (1) CCW: Manual wind adjustment in CCW direction
(counter-clockwise)
y (2) CW: Manual wind adjustment in CW direction (clockwise)
y (0) 0 position: The automatic wind adjustment is active.
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Switch back to the automatic wind adjustment after switching!

If the wind turbine is in standstill and the situation permits it, set the
switch back to the 0 position. This reactivates the automatic wind adjustment.
The switch must always be manually reset to the 0 position.
8.5 Closing the rotor holding brake

The rotor holding brake may be activated for maintenance work by means of the
"Close brake" switch (1) at the top box in the nacelle.
Fig. 8.5-1: Switch at the top box

1. Stop the wind turbine.
2. If the wind turbine is in standstill, close the rotor holding brake by activating
the "Close brake" switch (1) at the top box.
3. If needed, position the boreholes in the locking disk for the locking cylinders
(ref. section 3.2.2"Locking and releasing the rotor").
Wait for the closing process to complete!

The rotor holding brake only closes upon reaching a very slow generator
speed. Activating the "Close brake" switch in production mode triggers brake
program 60.
8.6 Resetting the safety chain

Authorization required!
A reset of the safety chain requires the access authorization "Service".
The safety chain may only be reset by authorized specialists.
The reset may be performed only if the cause of the triggering safety chain has
been resolved.
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Perform the following steps in order to reset the safety chain:

1. Briefly turn the rotary switch (1) at the bottom box in the tower base to the
"1" position or press the pushbutton (2) at the top box in the nacelle.
2. Also reset the safety chain at the touch panel.
Fig. 8.6-1: Switch in the tower base Fig. 8.6-2: Switch at the top box
Activating the service switch

Activate the service switch (1) at the top box prior to working in the rotor hub.
An emergency stop pushbutton may be used as an alternative. Activating the
service switch triggers the safety chain and locks up the electrical auxiliary
drives. Moving the rotor blades via the synchronous controller of the pitch
system remains possible.
Activating the service switch prior to maintenance work:

1. Switch the key switch (1) to the "1" position.
2. Remove the key and keep it safe until the work has been completed.
Activating the service switch after the maintenance work:

1. Switch the key switch (1) to the "0" position.
2. Remove the key and keep it safe.
3. Reset the safety chain
(ref. section 8.6 "Resetting the safety chain").
Fig. 8.6-3: Switch at the top box
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8.7 Using the elevator system, ascent support

Operate the elevator system or the ascent support in accordance with the
accompanying operating instructions provided by the respective manufacturer.
Risk of life due to the wind turbine in the active operating state!
There is a danger of life-threatening injuries due to component movements in
the tower and the nacelle during the operation of the wind turbine.
y Stop the wind turbine prior to ascending. (ref. section 2.9.2 "Securing the
wind turbine")
y Prior to using the elevator system, read the operating instructions available
in the cabin in order to be familiar with the operation of the elevator system
in case of a failure as well.
y Prior to activating the elevator system, ensure that no individuals or objects
are present in the range of the elevator path.
y Always wear the entire personal protective equipment against fall when
ascending and descending. This also applies when using the elevator
system available in the tower (ref. section 2.9.3 "Elevator system").
y Never ascend while the ladder exhibits ice formations.
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9 Control
9.1 Safety notices for the control
Risk of life due to moving components!
into moving components or running parts may cause fatal injuries!
operation.
Risk of injury due to faulty operations of the control system!

Operating errors may cause severe personal injuries or property damage.
y The control system may only be operated by sufficiently qualified personnel
that have been authorized and instructed by the operator.
y Perform all steps in accordance with the details in this operating manual and
the operating instructions for the control system.
y Never modify parameters or perform operating steps at the control system if
the effects are not clearly and exactly known.
operation of the wind turbine.

All control activities at the touch panels may generally only be performed by
sufficiently qualified personnel that have been authorized and instructed by the
operator.

The following must be worn on principle while being present at or in the wind
turbine:
In addition, wear the following while ascending and descending in the tower and
performing any work at or in the nacelle:
y The entire personal protective equipment against fall
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9.2 Concept and technical principles

Touch panels are available for accessing the control system. Access from the
outside to the wind turbines is possible by means of an external PC and is
registered as Remote in REguard Monitoring.
REguard Monitoring is a web-based application that accesses the control
system data via a web server.
9.3 General
The wind turbine may be operated via touch panels at the bottom box in the
tower base or at the top box in the nacelle. The touch panels may be used to
monitor and control all functions of the wind turbine.
Fig. 9.3-1: Position of the touch panel in the tower base
Fig. 9.3-2: Position of the touch panel in the nacelle
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Access authorization required!

With the exception of the stop function, all functions that may be
executed are protected by means of password levels in order to prevent
unauthorized operations.
Stopping the wind turbine may be triggered at any time, even without entering a
password.
Interruption of the power supply

If a power interruption has occurred, the touch panels automatically start
and display the start page upon the return of the power supply.
Illumination, displays, and status

The backlight and the display automatically deactivate after an
adjustable time if no operation has been performed during that period.
9.4 Active status and priority rules

If the intention is to execute functions, active status must be requested in
REguard Monitoring beforehand.
The touch panels for controlling the wind turbine have been assigned different
priorities. A touch panel that is located closer to the technical power-generating
equipment is generally assigned a higher priority.
y Priority 1: Touch panel at the top box in the nacelle
y Priority 2: Touch panel at the in the tower base
y Priority 3: Remote access from the remote monitoring system (Remote)
If 2 operators simultaneously access the wind turbine via different touch panels,
the operator using the touch panel with the lower priority will be unable to obtain
active status.
This priority rule ensures that it is impossible to switch the wind turbine to
automatic mode from the outside without knowing about the progress of the
work while work is being performed at the wind turbine.
The password may be used in combination with the entries in the access list
that is stored in the computer to determine which individual executed which
functions at what time.
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9.5 Touch panels

Interventions in the control system of the wind turbine by means of the touch
panels may only be realized by sufficiently qualified personnel that have been
authorized and instructed by the operator.

into moving components or running parts may cause fatal injuries!
operation.
Risk of injury due to faulty operations of the control system!

Operating errors may cause severe personal injuries or property damage.
y Never modify parameters or perform operating steps at the control system if
the effects are not clearly and exactly known.
operation of the wind turbine.
9.5.1 Design of the touch panels
Fig. 9.5.1-1: Touch panel with display
9.5.2 Activating the touch panel

y CTRL key for the activation of the touch panel illumination
y Push an arbitrary key twice in order to activate the touch panel
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9.5.3 Function keys

The following section introduces the individual keys and the triggered function.
The access to the functions depends on the user status (operator, maintenance,
service etc.). Some keys have been assigned multiple functions. These
functions will become active if CTRL or SHIFT is pushed together with the
desired key. If the Key(s) column in the following table specifies multiple keys,
the indicated keys must be pushed at the same time in order to access the
associated function.
Assignment of the function keys
Key(s) Display Function
The wind turbine stops, brake program 60 is

being triggered (ref. section 5.1.6 "Deactivating"
The status of the wind turbine is being reset

The automatic mode is being initiated (start-up
procedure)
The wind turbine starts
Displays the placement in the selected menu
Displays the placement with regard to other

menus
Switches between the number and the letter

assignment of the keys 0 through 9.
After activating the F3 key, the letter A will
appear in the display upon pushing the 1 key.
Pushing the key twice displays B, and pushing it
three times shows C.
If the value to be edited does not contain
letters, letters will not be displayed either.
The cursor moves up one line
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The previous menu is displayed
The image is scrolled upwards
The image is scrolled downwards
The graphic menu is shown
The cursor moves down one line
The next menu is displayed
The cursor jumps to the end of the line
The cursor jumps to the beginning of the line
SHIFT
Exiting the submenu

One menu level upwards
Exiting the submenu

Switching to the main menu level
A submenu is activated by pushing ENTER. (If

the cursor is displayed in a square format, a
submenu is hidden in the respective line).
ENTER
9.5.4 Line editor

If a line of a menu contains a value that may be edited, a line editor will be
activated upon pushing the ENTER key. Similar to the keypad of a cell phone,
the keys 0 – 9 may be used to enter digits and letters. The "F3" key must be
pushed in order to switch between the digit and letter entry, ref. table above.
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Example: Entering the letter "e"

y Use the "F3" key to switch to letter input
y Push the "2" key twice
If the value to be edited does not contain letters, letters will not be
displayed either and/or cannot be entered.
Some function keys exhibit different assignments in the line editor.
Assignment of the function keys in the line editor
The cursor moves to the left
The cursor moves to the right
Switches between the number and the letter

assignment of the keys 0 through 9.
After activating the F3 key, the letter A will
appear in the display upon pushing the 1 key.
Pushing the key twice displays B, and pushing it
three times shows C.
The cursor jumps to the end of the line
The cursor jumps to the beginning of the line
SHIFT
The character to the right of the cursor is deleted

The following characters move to the left
Switching between Insert mode and Delete

mode
SHIFT Insert mode: If a character is entered, it will be
inserted at the cursor position. The following
characters will be moved to the right
Delete mode: If a character is entered, it will
replace the character that is present at the
cursor position
Entering digits or letters
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Annulling and interrupting the input
The entered value is confirmed and replaces the

previous value
ENTER The line editing is terminated
(If the entered value is outside of any
predefined thresholds, the editing will be
continued and the maximum or minimum value
will be shown in the display)
9.5.5 Wind adjustment at the touch panel

The touch panel may also be used to activate/deactivate the wind adjustment of
the wind turbine and manually turn the nacelle (ref. section 8.4 "Manual wind
adjustment").
Assignment of the function keys for the wind adjustment

Push and hold for a longer period of time
Switching to the wind adjustment mode
The automatic wind adjustment (yaw) is
deactivated
The automatic wind adjustment (yaw) is

activated
Manual wind adjustment (yaw)

Counter-clockwise; (CCW)
Manual wind adjustment (yaw)

Clockwise; (CW)
9.5.6 Adjusting the touch panel brightness

Key(s) Function
The brightness of the touch panel is reduced
The brightness of the touch panel is increased
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Operating manual
10 Menus
The menus are shown in the display area of the touch panel. The following
menus may be accessed:
• Start menu • Event lists menu
• Status menu • Access list* menu
• Grid menu • Serial number menu
• Parameters* menu • Data log control* menu
• Status code list menu • Maintenance* menu
• Status counter menu
* Special access rights are required for these menus
10.1 Structure of the menus

The menus exhibit a tree structure. A number of menu entries (= lines) "hide"
additional submenus which in return may contain other submenus.
If a menu entry contains a submenu, the cursor will be displayed in the form of a
square. A submenu is accessed by selecting the respective menu entry by
means of the cursor and pushing the ENTER key. The selected submenu is
opened. Additional submenus are opened in the same manner.
The ESC key is used to switch from a submenu to the level above.
10.2 Handling the menus

The menus on the touch panel may be scrolled to the right and left by means of
the F5 and F10 keys, respectively.
The text lines on the touch panel may be scrolled up and down by means of the
F4 and F9 function keys, respectively.
Start Status Grid Parameter*
Status Status Maintenance* Serial No.

code list counter
Data log Access list* Event list

control*
* Special access rights are required for these menus
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10.3 Display area of the touch panel

During the normal operation of the wind turbine, the display area of the touch
panel of the wind turbine exhibits the following contents upon activation:
Fig. 10.3-1: Display during normal operation
10.4 Error messages

An error message is referred to as status code.
Depending on the access rights, a status code may be reset by means of data
communication or in a manual manner (directly at the display). However, this
requires that the cause of the occurrence has been resolved.
All possible status codes are listed in the operating instructions for the control
system.
The most recent 100 activated status codes are displayed in the Status code
list menu.
The number of times a status code has occurred is indicated in the Status
counter menu.
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10.5 Start menu

The Start menu displays the current operating state of the system.
Fig. 10.5-1: Start menu
Display Meaning
08–08–25 Date in the format YY–MM–DD

(year–month–day)
10:00:37 Time in hours:minutes:seconds, 24 hour format
0 Access rights level
G Grid operation
5169.9 kW Current power
13.8m/s Current wind speed
12RPM Rotor speed in rpm
1178RPM Generator speed in rpm
7°, 105% Current blade/pitch angle
7° , 105% The current moment with regard to the nominal
moment
System OK Status of the system
NORMAL OPERATION The system produces current and supplies it
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10.6 Login at the system

The Start menu contains the lines Access rights and Request active status.
Fig. 10.6-1: Start menu

y Select the line Access rights by means of the cursor
y Push the ENTER key. The password editor is active.
y Enter the password (the cursor moves, the password will not be shown).
y Push the ENTER key.
If the password is valid, the access rights will be modified in accordance with
the password level. The access rights determine which menus will be displayed
and which variables may be edited.
10.6.1 Requesting active status

y Select the line Request active status by means of the cursor.
y Push the ENTER key.
y Enter the operator number.
The line Release active status appears on the touch panel, the √ symbol
appears in the top right corner, the touch panel is active. The current access
level is displayed.
If a touch panel with a higher priority has been activated, active status
may not be obtained (ref. section: 9.4 "Active status and priority rules").
10.6.2 Deactivating active status

y Select the line Release active status by means of the cursor.
y Push the ENTER key twice.
The active status is deactivated.
If no entries have been made at the touch panel in the tower base for a
period of 30 min, the access rights and the active status will automatically be
reset.
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The active status must be manually deactivated at the touch panel in the
nacelle upon exiting the nacelle. The active status of the touch panel in the
nacelle is not automatically reset and cannot be deactivated via the touch panel
in the tower base or via remote access either.
10.7 Status menu

The Status menu displays operating times, the number of start-ups, production
figures, the pressure, the temperature, and the status of the digital inputs and
outputs.
Fig. 10.7-1: Status menu in overview

A submenu is opened by positioning the cursor in the respective line and
pushing the ENTER key. The example in figure 10.7–1 shows opening the
Temperatures submenu.
Display Meaning
System System submenu with information about the

production/consumption, operating hour counters,
counters of var. auxiliary drives etc.
Oil The Oil control submenu with information about the
oil system, e.g. the system pressure, the pressure
in the gearbox pump, the operating hour counter of
the hydraulic pump etc.
Yawing The Yaw submenu with information about the yaw
program and yaw data, e.g. the position of the
nacelle, the angle of twist etc.
Temperatures The Temperatures submenu with a list of the
monitored modules.
RPMs The Speeds submenu with a list of the monitored
modules.
Controller No further information available
Lennord+Bauer No further information available
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Display Meaning
Pitch motor Display of the pitch direction (+/-) and the current.
Wind The Wind submenu with details about the wind
direction and the wind speed.
Oper. timers The Operating counters submenu with details
about the set time prior to the wind turbine
switching to the state "Waiting for wind" due to the
power having dropped below the MIN value.
WP4084 No further information available
10.7.1 System submenu

Display Meaning
System prod./cons. Produced kWh

Consumed kWh
Produced kvarh
Consumed kvarh
Time of the most recent reset, prior values
Operation timer/counter The current number of start-ups and operating
hours
Prior values for start-ups and operating hours
(brake program below 50)
Stop timer/counter The number of executions of brake programs 50 or
higher.
Brake1 timer/counter The number of activations of rotor holding brake 1
Brake2 timer/counter The number of activations of rotor holding brake 2
(B)free timer/counter The number of hours the rotor holding brake was
not activated
Parallel timer/counter The number of grid parallel hours; operating hours
of the generator
Gear oil pump t/c Operating hours of the gearbox oil pump
Gear fan t/c Operating hours of the gearbox fan
Generator fan t/c Operating hours of the standard generator fan
Generator fan 2 t/c Operating hours of the additional generator fan
Pitch active t/c Operating hours of the pitch drives
Batt driven pitch Battery-powered operating hours of the pitch drive.
Total rotor turns The number of rotor turns, arranged by various
past time periods
Particles counter The number of particles in the gearbox oil
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10.7.2 Oil submenu

Display Meaning
(H) timer/counter The current number of activations and operating

hours
Prior values for start-ups and operating hours
(H) pressure xx.x bar Pressure in the oil system
Gear oil pump xx.x bar Pressure in the gearbox pump
Gear oil in. xx.x bar Pressure at the gearbox oil inlet
10.7.3 Yaw submenu

Display Meaning
Yaw programm active: x Display of the active yaw program

Yaw delay CCW** xxx s Yaw delay of the CCW direction
Yaw delay CW* xxx s Yaw delay of the CW direction
Yaw > timer/counter The current number of activations and operating
hours (CW)
Prior values for activations and operating hours
Yaw < timer/counter The current number of activations and operating
hours (CCW)
Yaw <> timer/counter The current number of activations and operating
hours (CW and CCW)
Rela. wind dir xxx° The number of degrees the nacelle is offset from
the wind
Cable twist Xxxx° Angle of twist of the cables in the tower
Nacelle pos. Xxx° Position of the nacelle with regard to N=0°
Wind direction 1 xxx° Wind direction of vane 1 with regard to N=0°
Wind vane 1 xxx° Direction of vane 1 with regard to the nacelle.
0° -adjustment Is used for the adjustment of the vane.
Active wind vane: x Indicates which vane is active.
Wind direction 2 xxx° Wind direction of vane 2 with regard to N=0°
Wind vane 2 xxx° Direction of vane 2 with regard to the nacelle.
*CW = clockwise; **CCW = counter-clockwise
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10.7.4 Temperatures submenu
Fig. 10.7.4-1: Temperatures submenu

Additional submenus may be opened from the Temperatures submenu.
Display Meaning
Gear oil xxx°C Current temperature

Gear bearing 1 xxx°C Current temperature
Gear inlet xxx°C Current temperature
(G) bearing 1 xxx°C Current temperature
(G) bearing 2 xxx°C Current temperature
(G) stator wind. xxx°C Current temperature
Inlet Conv. hot xxx°C Current temperature
Gear bearing 2 xxx°C Current temperature
Out door xxx°C Current temperature
Nacelle xxx°C Current temperature
Rotor bearing xxx°C Current temperature
Internal xxx°C Current temperature
Pitch motor 1 xxx°C Current temperature
Hub box xxx°C Current temperature
10.7.5 RPM submenu

Display Meaning
Rotor xxxx RPM Rotor speed

Generator xxxx RPM Generator speed
Gear xxxx RPM Gearbox speed
Gear 2 xxxx RPM Gearbox speed
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10.7.6 Controller submenu

Display Meaning
No information available
10.7.7 Lennord+Bauer submenu

Display Meaning
10.7.8 Pitch motor submenu

Display Meaning
Pitch direction 1 x Displays the active direction of pitch axis No. 1.

Pitch motor 1 x.x A Displays the current for pitch motor No. 1.
10.7.9 Wind submenu

Display Meaning
Wind 1: xx.x m/s Wind speed from the anemometer (input M428)
Wind 2: xx.x m/s Wind speed from the anemometer (input M431)
Wind 3: xx.x m/s Wind speed from the ultrasonic anemometer
(input M734)
Wind direction 1 xxx° Wind direction (input M236)
Wind direction 2 xxx° Wind direction (input M735 if system 2 or 3 has
been selected).
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10.7.10 Oper. timers submenu

Display Meaning
Power G1>0 xxxx s Time before the operating state switches to "Wait
for wind" due to the power being lower than *Power
G1>0 xxxkw.
Power G1>>0 xxxx s Time before the operating state switches to "Wait
for wind" due to the power being lower than *Power
G1>0 xxxkw.
10.7.10.1 WP4084 submenu
Display Meaning
10.7.10.2 WP4084#1 submenu
Display Meaning
10.7.10.3 WP4084#2 submenu
Display Meaning
10.7.10.4 Reset maximum values submenu
Display Meaning
No access
10.7.11 Communication submenu

Display Meaning
Parkport: Com3 If the wind turbine has been configured as wind

farm slave, this line is the only visible line in that
submenu. If the wind turbine has been configured
as wind farm master, this line is not displayed.
Modem connected This menu line indicates whether a modem has
been connected to Com 4. If this is not the case,
"Modem NOT conn." will be displayed. If the wind
turbine has been configured as wind farm master,
this line will be visible.
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Display Meaning
Modem ready to dial This menu line indicates whether the modem is
ready. If this is not the case, "Modem not ready"
will be displayed. If the wind turbine has been
configured as wind farm master, this line will be
visible.
Modem port Comx Modem communication gate. If the wind turbine
has been configured as wind farm master, this line
will be visible.
Modem in time xxxx s Countdown to the next modem initialization. If the
wind turbine has been configured as wind farm
master, this line will be visible.
Alarmlog Selecting >Enter< for this line displays a protocol of
the alarm calls. If the wind turbine has been
configured as wind farm master, this line will be
visible.
10.7.12 Inputs submenu

Display Meaning
10.7.13 Outputs submenu

Display Meaning
10.7.14 I/O abbreviation submenu

Display Meaning
10.7.15 Analog signal status submenu

Display Meaning
Terminal 239 xx Status of analog input M239 (OK or DEF.).

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10.7.16 Wind farm power control submenu

Display Meaning
Power management x Indicates whether the power control has been

activated in the wind farm power controller (ARC-
net Master IC500).
Inty. pulse avail. X Indicates whether the interval impulse has been
activated in the wind farm power controller. For
further information, please refer to the instructions
for P01509.
Power average time xxs Displays the time of the average power during
which the wind turbine must return the power
output to the wind farm power controller. For further
information, please refer to the instructions for
P01509.
Prod. Sp.PPM xxxx kw Displays the nominal output value from the wind
farm power controller to this wind turbine. This
value is initialized as *Red. power xxxx kw upon
starting the controller in order to prevent the
activation of status code 99, e.g. in case of a
malfunction of the wind farm communication
following a grid failure.
Prod.sp.WEA xxxx kw Displays the nominal output value used by the wind
turbine. This is normally "Prod. vo.PPM xxxkW";
however, *Red. power xxxx kW is used in case of a
communication error (status code 1007). If the
noise reduction is active, *[P] Nom 1 xxxxkW will be
used.
Actual Power xxx kW Displays the current power output which is
transmitted from this wind turbine to the wind farm
power controller.
Mean Power xxx kW Displays the average power that has been supplied
during an interval time.
Intervall time xx S Displays the time since the most recent impulse
from the wind farm power controller.
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10.7.17 Availability submenu

Display Meaning
Total Pushing <ENTER> at this line displays the

Availability submenu. The submenu exhibits almost
the same structure as the Operation timer/counter
submenu.
Group 1-32 Pushing <ENTER> at this line displays the
Individual availability groups timer/counter
submenu. The submenu displays the same
information as the Operation timer/counter
submenu.
10.7.17.1 Weather data submenu
Display Meaning
Total Pushing <ENTER> at this line displays the total

weather data.
Subtotal 1 Pushing <ENTER> at this line displays the subtotal
1 weather data.
Subtotal 2 Pushing <ENTER> at this line displays the subtotal
2 weather data.
One month back Pushing <ENTER> at this line displays the One
month back list with the weather data.
12 months back Pushing <ENTER> at this line displays the
12 months back list with the weather data.
20 years back Pushing <ENTER> at this line displays the
20 years back list with the weather data.
10.7.17.2 Wind rose calculations submenu
Display Meaning
Wind speed1 xx.x m/s This value indicates averaged wind speed 1
(averaged for x number of counts).
Wind speed2 xx.x m/s This value indicates averaged wind speed 2
Wind direct. xxx° This value indicates the averaged wind direction
Temperature xxx°C This value indicates the averaged outdoor
temperature (averaged for x number of counts).
Air pressure xxx.xhPa This value indicates the averaged outdoor
temperature (averaged for x number of counts).
Energy x.xx W/m2 This value displays the calculated energy in the
sector.
Precipitation x.x mm This value indicates the amount of precipitation.
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Display Meaning
Wind rose sector 1-12 The next 12 menu lines are arranged by wind
direction (viewed from north 0°):
1: 345-015°
2: 015-045°
3: 045-075°
4: 075-105°
5: 105-135°
6: 135-165°
7: 165-195°
8: 195-225°
9: 225-255°
10: 255-285°
11: 285-315°
12: 315-345°
Count xxxxx Number of counts since the most recent reset.
yy-mm-dd hh:mm:ss Displays the time and date of the most recent reset.
Simultaneously pushing <ENTER> and "1" resets
the counts and consequently the weather data as
well.
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10.8 Grid menu
Fig. 10.8-1: Grid menu
Display Meaning
Grid, common Pushing <ENTER> in this line opens the common

Grid menu.
Grid, separate Pushing <ENTER> in this line opens the individual
Grid menu.
10.8.1 Grid, common submenu
Fig. 10.8.1-1: Grid, common submenu
Display Meaning
xxxxV xxxx.xkW Grid voltage and grid power

xxxxxA xxxx.xkVAr Grid current and reactive grid power
xx.xxHz Grid frequency
Cos phi x.xx/xx° Grid power factor and phase angle
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10.8.2 Grid, separate submenu

Display Meaning
L1: xxxV xxxxA xxx° This line is repeated three times, once for each
phase. Strand voltages and currents in the grid and
angles between the voltages are displayed.
Peak values Pushing <ENTER> displays the maximum values
(voltage, current, and angle) for the three phases.
E-ON : Phase status Pushing <ENTER> indicates which of the three
phases caused the activation of status code 128.
The following is displayed here:
L1: xx-xx-xx,xx:xx:xx
The time and date may be used to determine in
which of the three phases an error occurred.
10.9 Parameters menu
Fig. 10.9-1: Parameters menu
Display Meaning
System control Pushing <ENTER> in this line opens the System

control submenu.
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10.9.1 System control submenu
Fig. 10.9.1-1: System control submenu
Display Meaning
Date xx-xx-xx Enter the WP3100 date, yy-mm-dd.

Time xx:xx:xx Enter the WP3100 time, hh:mm:ss.
Language CUSTOM Select the language, Default (English) or Custom
(German).
Custom lang. ENABLED This parameter is provided for
activating/deactivating the custom language.
English is the default language.
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10.10 Status list menu
Fig. 10.10-1: Status list menu
Display Meaning
Toggle header Pushing <ENTER> switches between the following

lines of text: "Status list", "Date and time", "Status
number", and "Status code name".
Statuslist xx The figure displays the "Status list" line. The list
displays the most recent 100 status codes that
have been activated. After selecting a status code
between 00 and 99 and pushing <ENTER>,
additional information will be displayed for this
status code.
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10.10.1 Status list point submenu
Fig. 10.10.1-1: Status list point submenu
Display Meaning
Statuslist xxx This submenu is displayed if the "Status list" line

has been selected as title modification. The Status
code information submenu is displayed by pushing
<ENTER>.
yy-mm-dd hh:mm:ss Date and time of the most recent activation of the
status code. The Status code information submenu
is displayed upon pushing <ENTER>.
S : Set time -> Activate status code
C : Reset time -> Reset status code
Statusnumber xx Status code number. Pushing <ENTER> opens the
Status code information submenu.
Statuscode name Status code description
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10.11 Status count menu
Fig. 10.11-1: Status count menu
Display Meaning
Toggle header Pushing <ENTER> toggles between the lines

"Status code number", "Status code name", and
"Number xx times".
Status xxxx The figure displays the "Status number" line. After
selecting a status number and pushing <ENTER>,
information about this point will be displayed in the
Status counter menu, ref. figure below.
Fig. 10.11-2: Status counter menu following the selection
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10.12 Event list menu
Fig. 10.12-1: Event list menu
Display Meaning
Toggle header Pushing <ENTER> switches between the lines

"Event-list", "Date & time", "Status code display",
and "Status code & event name".
Event-list xxx The figure displays the "Event list". The list displays
the most recent 100 events. Selecting an event
between 00 and 99 and pushing <ENTER>
displays information about this point, ref. figure
below.
Fig. 10.12-2: Event list menu following the selection
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10.13 Access list menu
Fig. 10.13-1: Access list menu
Display Meaning
Toggle header Pushing <ENTER> switches between the lines

"Access-list", "Date & time". "Access text", and
"Access right & dongle information".
Access-list xxx The line "Access-list" has been selected in the
figure. The list displays the most recent 100 entries.
Selecting a number between 00 and 99 and
pushing <ENTER> displays information about this
point.
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10.13.1 Access-list point submenu
Fig. 10.13.1-1: Access-list point menu
Display Meaning
Access-list xxx Access-list point

YY-MM-DD HH:MM:SS Date and time for this access in the access list.
Xxxxxxxxxxxxxxxxxxx Access text. The texts may exhibit the following
values: "Access right", "User activated", "User
deactivated", "Remote logon", or "Remote logoff". If
the line displays "Access right" or "User activated",
the following line will display the access right or the
username.
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10.14 Serial number menu
Fig. 10.14-1: Serial number menu
Display Meaning
MM :P01544/020808 The project number/the revision date of the

software of the main master processor.
MS1 :P01544/020808 The project number/the revision date of the
software of the main slave 1 processor.
MS2 :P01544/020808 The project number/the revision date of the
software of the main slave 2 processor.
Main WP3101 The WP3101 circuit board in the main WP3100.
Pushing <ENTER> opens the Product code and
serial number submenu.
Main WP3002 The WP3002 circuit board in the main WP3100.
IC1000 The IC1000 connected to the main WP3100.
WP3050 #1 The WP3050 #1 connected to the main WP3100.
WP3050 #2 The WP3050 #2 connected to the main WP3100.
WP4084: 1 The WP4084 No. 1 connected to the main
WP3100. Pushing <ENTER> opens the Product
code and serial number submenu.
WP4084: 2 The WP4084 No. 2 connected to the main
WP3100. Pushing <ENTER> opens the Product
code and serial number submenu.
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Display Meaning
WKG Components The reference number of the wind turbine

components connected to the wind turbine.
(Makes it possible to maintain the serial numbers of
different components. This menu is not maintained
by REpower)
10.14.1 Product-code and serial number submenu
Fig. 10.14.1-1: Product-code and serial number submenu
Display Meaning
Product-code: xxxxx The Mita-Teknik A/S product code for this particular
PCB.
Serial #: xxxxxxxxxx The Mita-Teknik A/S serial number for this
particular PCB.
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10.15 Service menu
Fig. 10.15-1: Service menu
Display Meaning
Alarmcall test: x Pushing <ENTER> sets the function to 'ON'. Status

code 38 is activated and an alarm call is
transmitted to the WPMS. If the status code is
reset, this line will be automatically set to OFF.
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Wind turbine 5M Maintenance
Operating manual
11 Maintenance
Maintenance of the wind turbine at regular intervals is mandatory in order to
permanently ensure the operating safety and the conservation of value.
The schedule of required maintenance included in the wind turbine delivery
details all required maintenance activities. Performed tasks must be logged and
signed in that schedule.
The schedule of required maintenance must always be kept in the wind turbine.
11.1 Safety notices for the maintenance

The following generally applies prior to each ascent:
y Stop the wind turbine.
y Switch on the tower light.
y Arrange the warning sign (ATTENTION! No switching or operating the
keypad! Work is being performed in this system!) at the bottom box.
y Request active status.
Risk of life due to high direct voltage

The sets of rechargeable batteries of the blade pitch drives are not protected
against touch. For that reason, they may only be handled by skilled electricians
and with special care.
Risk of injury due to improper maintenance!

Improperly performed maintenance work may cause severe injuries or property
damage.
y Maintenance work may only be performed by authorized personnel.
y Never deactivate, bypass, or make otherwise inoperable protective
measures or safety mechanisms.
y Deactivate and shut down the wind turbine and secure it against reactivation
prior to commencing the work.
y Set the rotor lock prior to removing enclosures.
y Ensure that all covers, protective measures, and safety mechanisms have
been correctly installed and function properly prior to reactivating.
y Always ensure order and cleanliness in the working area prior to, during, and
after the work in the wind turbine! Loosely scattered objects, e.g.
components, parts, tools, and cleaning accessories, may cause accidents.
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y Maintenance work may only be performed by authorized personnel.
y Never perform work alone. At least 2 individuals must ascend the wind tur-
bine. Each individual must always be able to inform about the respective
location and an imminent change of the location. The individual must wait for
the confirmation from the other person(s) prior to leaving the location.
11.1.3 Complete personal protective equipment

The following must generally be worn and/or carried while working at or in the
wind turbine:
y Hard hat
y Safety glasses
y Hearing protection
11.1.4 Working in the rotor hub

• Stop the wind turbine.
• Generally turn as many rotor blades as technically possible into the vane
position (90° blade pitch).
• Activate the rotor holding brake by means of the service switch.
• Set the rotor lock (ref. section 3.2.2 "Locking and releasing the rotor
• ").
• Deactivate the battery maintenance switch and the grid maintenance switch
of the pitch system in the rotor hub.
• Prior to recommissioning: Reset all switches again.
11.1.5 Working at the drive train

• Set the rotor lock (ref. section 3.3.2 "Locking and releasing the rotor
• ").
• Set the "Service brake" switch at the top box to the
"Close" or "1" position.
• Do not reach into rotating machine components.
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11.1.6 Working at the yaw brakes and the yaw drives

• Activate the service switch.
• The wind turbine is held by the motor brakes of the yaw drives while work is
being performed at the yaw brakes.
• Always work at a single yaw brake only. The brakes must remain engaged at
the other drives.
11.1.7 Log entries

All activities at and in the wind turbine (assembly, maintenance etc.) must be
documented on principle (e.g. in the assembly report). These documents are
filed in the log of the wind turbine. This is the only way to facilitate
comprehensive monitoring of the wind turbine. The log is kept together with the
operating manual in the entrance area in the tower base of the wind turbine.
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11.2 Reporting damage

Danger of severe property damage!
If minor irregularities are not resolved quickly, they may cause substantial
damage.
y Deactivate the wind turbine upon detecting irregularities.
y Immediately commission the repair at the customer service.
Immediately inform the customer service in case of the following particularities:

y Insect or bird nests in the wind turbine
y Oil leaks, in particular at the rotor hub, the gearboxes, the wind adjustment
(yaw), the hydraulic equipment, brakes etc.
y Abnormal noise, in particular at the generator, at the rotor hub, at the rotor
bearings, at the gearboxes, in case of a high pitch sound of the blades etc.
y Cracks and / or brittleness in elastomer bearings or hoses
y Rust or cracks, in particular at load-bearing components (tower, machine
base, rotor hub)
y Cracks in the concrete foundation
y Water, high levels of dust, or sand in the wind turbine
y Traces of smoke residue in the electrical system or at the lightning protection
spark gaps
y Cracks, traces of smoke residue, high levels of dirt at the rotor blades
y Released or loose screw connections
y Fluid loss of the cooling aggregates
Additional checks at regular intervals

y Commission a specialized company with the inspection of the fire
extinguisher and the first aid kit at regular intervals. Observe the mandated
inspection intervals and expiration dates.
y Commission suitably certified entities with the inspection of the entire
personal protective equipment against fall at regular intervals. Observe the
mandated inspection intervals and expiration dates.
y Soilings with lubricants or other substances must always be cleaned up
immediately.
y Check the ladder steps, the platforms, and the nacelle floor for grease, oil, or
other substances during each ascent. Soiled spots must always be cleaned
immediately in order to resolve the slipping risk.
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11.3 Measures in case of an unscheduled standstill

of the wind turbine
Longer periods of standstill of the wind turbine may cause substantial technical
problems, e.g. pressure marks in the gearing of the gearbox, dry anti-friction
bearings, markings in the bearing rings.
In case of an unscheduled standstill, the wind turbine must be switched to a
safe state in order to minimize possible damage:
1. Coordinate the reason for the deactivation and the necessary deco-
mmissioning procedure with the customer service.
2. Turn the nacelle with the rotor hub into the main wind direction.
3. Turn all 3 rotor blades to the 91° limit switches.
4. Activate the rotor holding brake by activating the emergency stop.
5. Set the rotor lock (ref. section 3.2 "Rotor lock").
6. Deactivate the battery maintenance switch and the grid maintenance switch
of the pitch system in the rotor hub. Do not disconnect plugs.
7. Visually check whether all 3 rotor blades are correctly positioned at the limit
switches (91° blade pitch) within the rotor hub. Reaching the 91° blade pitch
must also be determined via a message by the control system.
8. Remove all loose objects from the rotor hub and the nacelle.
9. If the wind turbine has already been in operation, also relubricate the rotor
bearing with approx. 20 kg of grease (grease type in accordance with the
specifications provided by the manufacturer) in order to counter corrosion of
the rotor bearing.
10.Release the rotor lock and open the rotor holding brake to ensure that the
wind turbine may idle (= slowly turn). The wind turbine may withstand wind
speeds up to 50 m/s (approx. 180 km/h) without damage in that state.
11. If a relubrication system has been installed at the rotor bearings and at the
generator bearings, it must remain activated as long as the grid voltage is
available and the control system of the wind turbine is ready for operation.
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11.4 Measures in case of a longer standstill of the

wind turbine
In case of a longer standstill (more than 2 weeks), the following measures must
be performed in addition to the steps detailed in section 11.3 at regular intervals
unless the authorized customer service provided other instructions regarding
the measures for the protection of individuals and the wind turbine:
1. While the lubrication pump is running, turn each individual rotor blade at
least 45° and back to the end position (91° blade pitch) every 4 weeks.
2. While the lubrication pump is running, turn the nacelle at least 45° and back
into the main wind direction every 4 weeks.
Recommissioning with rechargeable batteries that have not been charged

may cause dangerous situations!
The recommissioning of the wind turbine with rechargeable batteries of the pitch
system that have not or just insufficiently been charged may cause dangerous
situations for individuals and property.
y Ensure that the rechargeable batteries of the pitch system have been
charged for at least 24 hours prior to recommissioning the wind turbine after
a longer standstill.
y Check the voltage of the rechargeable batteries. A total discharge of the
rechargeable batteries may result in permanent damage.
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Wind turbine 5M Disassembly and disposal
Operating manual
12 Disassembly and disposal

The technical components of the wind turbine must be immediately
disassembled and the structural facilities must be dismantled after the final
termination of the operation.
y Continue using accumulated residual materials to the extent possible,
recycle individual components or dispose of them in an environmentally
friendly manner.
y Seal, develop, or renaturalize the footprint in accordance with the
requirements applicable at the location.
12.1 Safety notices for the disassembly and disposal

Chapter 2 "Safety" comprehensively details the special dangers to be taken into
consideration in the wind turbine. In addition, the accident prevention
regulations and environmental protection rules applicable at the location must
be observed during the disassembly, the dismantling, and the disposal.
Observe the additional notes in chapter 6 "Transport, packaging, storage"!

Contact with live components poses a risk of life.
Activated electrical drives may cause components to unexpectedly move and
result in the most severe injuries.
y Deactivate the electric power supply prior to the disassembly.
y Disconnect all connections from the power grid.
y Disconnect the rechargeable batteries from the blade pitch drives and
secure them.
Risk of life due to unsecured components!

Unsecured components may cause life-threatening situations for individuals in
the danger zone.
y Always wait for the complete standstill of movable components.
y Secure components against independent movements or activations.
Risk of life underneath hanging loads!

There is a risk of life due to falling or uncontrollably swinging components while
lifting, lowering, and moving loads.
y Never walk underneath hanging loads.
y Ensure the safe arrangement of the attachment means.
y Use approved hoisting means and attachment means with sufficient load-
bearing capacity only.
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Risk of injuries at hydraulic equipment!

Hydraulically operated components may unexpectedly move. In case of
damage, hydraulic fluid with high pressure may cause severe injuries.
y Deactivate the hydraulic system and release the pressure prior to the
disassembly.
Risk of injury in case of improper disassembly!

Stored residual energies, edged components, tips and corners at components
or required tools may cause severe injuries.
y Ensure sufficient space for the assembly prior to commencing the work.
y Be careful at open components with sharp edges.
y Ensure order and cleanliness at the assembly location! Loosely scattered
components and tools may cause accidents.
y Professionally disassemble the components while observing the applicable
regulations.
y Always secure components in such a manner that they may not fall down or
over.
y If something is unclear, contact REpower Systems AG.

y The disassembly may only be performed by comprehensively trained
specialists with experience.
y Work at the electrical systems and components may only be performed by
skilled electricians.
y Work at the hydraulic system may only be performed by hydraulics experts.
Expertise protects!
Work at electrically and hydraulically operated modules requires special
knowledge and experience. For that reason, these activities may generally be
performed by individuals that have obtained and proven the required
qualifications only.
y Never perform work alone. At least 2 individuals must generally ascend the
wind turbine. Each individual must always inform the other persons about
the respective location and an imminent change of the location. The
individual must wait for the confirmation from the other persons prior to
leaving the location.
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12.1.3 Complete personal protective equipment

The following must be worn on principle while working at or in the wind turbine:
y Hard hat
12.2 Disassembly
A crane and an auxiliary crane in accordance with the specification for the
assembly of the wind turbine are required for disassembly and dismantling.
12.2.1 Dismantling
Perform the following steps for the disassembly and dismantling:
1. Deactivate the wind turbine and secure it against reactivation.
2. Physically disconnect the entire power supply.
3. Discharge stored residual energies.
4. Remove operating and auxiliary materials and dispose of them in an
environmentally friendly manner.
5. Professionally clean modules and components
6. Take apart the components of the wind turbine while observing the
occupational health and safety as well as environmental protection
regulations applicable at the location. In that context, observe the following
notes for the modules and components.
12.2.2 Rotor blades

Remove the rotor blades consisting of glass-fiber reinforced plastic (GRP),
reduce them to small pieces, and recycle them as much as possible.
This accumulates approx. 57 t of small GRP pieces. The blade bolts generate
approx. 500 kg of scrap steel.
12.2.3 Nacelle and rotor hub

Successively disassemble and take apart the nacelle and the rotor hub.
Depending on the configuration, this generates approx. 100 t of scrap steel,
approx. 3.5 t of scrap copper, and approx. 3.5 t of GRP.
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12.2.4 Tower
Successively dismantle the tower plates, the climbing facility, and the platform
from top to bottom.
For a hub height of 80m, this generates approx. 200 t of scrap steel, 4.0 t of
scrap aluminum, and 3.0 t of scrap copper.
12.2.5 Switching equipment

Recycle or dispose of the switching equipment in accordance with the
regulations for handling electric devices and electronic scrap applicable at the
location.
The weight of the switching equipment to be disposed of equals approx. 5.0 t.
12.2.6 Foundation
Remove the foundation to 1 meter below the top soil. Brake the concrete and
recycle it as recycling gravel or chippings. Recycle the reinforcements as scrap
steel.
Depending on the foundation type, this accumulates 160 – 360 m³ of concrete
and 24 – 45 t of scrap steel.
12.2.7 Transfer station with transformer

One concrete transformer and/or transfer station is typically provided per wind
turbine. It is equipped with a transformer, measuring equipment, and medium
voltage switch gear.
Depending on the condition of the transformer, it is possible to reuse the
transformer at another location or provide it to third parties while observing the
applicable provisions after the disassembly of the wind turbine.
If the reuse or the handover is impossible, recycle or dispose of the transfer
station in accordance with the electronic scrap regulations.
This accumulates 6.0 – 12.0 t of concrete and 6.0 – 12.0 t of electronic scrap.
12.2.8 Crane setup area and access path

0.4 m of soil and gravel must be excavated in the entire range of the crane
setup area and the access path. Replace the top soil of the assembly area and
the access path.
This accumulates approx. 562 m³ of excavated gravel. Reuse the excavated
gravel if possible. Alternatively, place it in a controlled soil landfill.
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12.3 Disposal
If the operator has not concluded another return or disposal agreement with
REpower Systems AG, the disassembled components must be recycled:
y Scrap metallic residual components.
y Recycle plastic elements.
y Dispose of other components in accordance with their material composition.
y Abide by regulations (e.g. electronic scrap regulations).
Damage to the environment in case of incorrect disposal!

Electrical scrap, electronic scrap, lubricants, and other auxiliary materials are
harmful hazardous waste and must not enter the environment!
y Only commission duly authorized specialized companies with the disposal of
hazardous waste.
y Observe the regulations applicable at the location.
The authorities responsible for the location and specialized companies provide
information about disposals in an environmentally friendly manner.
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Wind turbine 5M Technical data
Operating manual
13 Technical data
13.1 Design data
Wind speed Value Unit
Activation wind speed (cut-in) Approx. 3.5 m/s
Nominal wind speed Approx. 13 m/s
Deactivation wind speed (cut-out) 25 – 30 m/s
13.2 Rotor
Rotor data Value Unit
Diameter 126 m
Coated rotor area 12,470 m²
Number of rotor blades 3
Material GRP
Nominal speed 6.9 – 12.1 rpm

(+15.0 %)
Circumferential velocity blade tip at 12.1 rpm 80 m/s
Axis slant of the rotor shaft 5 °
Cone angle of the rotor blades -4.0 °
Direction of rotation (looking with the wind at the Clockwise

rotor)
Arrangement to the tower Windward
13.3 Pitch system

Data of the pitch system
Functional principle Individual pitch adjustment by means of electric

motors
Power control Blade pitch and speed control
Maximum blade pitch 91° (limited by means of limit switches)
Blade drive Direct current motors, rechargeable battery-

buffered, controlled in a synchronous manner
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13.4 Gearbox
Gearbox data Value Unit
Design Planetary spur wheel
Nominal power Approx. 5,500 kW
Nominal moment Approx. 4,400 kNm
Ratio Approx. 1:97

power
13.5 Generator
Electrical system Value Unit
Design: Double-fed six-polar asynchronous

generator
Nominal power 5,400 kW
Protection class IP 54
Range of speeds 670 – 1,170 + 15% rpm

power
13.6 Tower
Tower data Value Unit
Design Steel pipe tower
Hub height offshore / onshore 84 – 120 m
Diameter 5.5 m
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13.7 Wind adjustment

Technical data of the wind adjustment
Functional principle Electric motor via cog wheel
Design 8 gearbox motors, 8 brake calipers
Pitch speed 0.28°/s
Storage Four point bearing with external gearing
Stabilization Mechanical brake
13.8 Weights
Detail Value Unit
Rotor blade (incl. flange)

LM 61.5P1 Approx. 19.0 t
LM 61.5P2 Approx. 19.6 t
Hub complete (incl. pitch system) 70.0 t
Nacelle (without rotor) 316.0 t
13.9 Safety systems

Safety system
Safety system Triple independent pitch system to 91°

Primary brake
Holding brake 2 brake calipers at a disk on the fast gearbox shaft
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13.10 Type label
Fig. 13.10-1: Type label of the wind turbine
The type label for the wind turbine is located on the outside of the entrance door
to the tower base. It includes the following details:
y Manufacturer
y Type identification
y Serial number
y Year of manufacture
y Nominal power
y Diameter of the rotor
y Hub height
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Operating manual
14 Annex
14.1 Escape and rescue plan
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Wind turbine 5M Index
Operating manual
15 Index
Access path ........................................171 Overspeed.........................................24
Activating ............................................119 rechargeable batteries ......................25
Ascending and descending...................41 system failure ....................................23
Ascending the tower .............................41 ventilator............................................26
Ascent support....................................125 Deactivating ..................................99, 130
Automatic operation ......................96, 119 Deck crane..............................74, 90, 111
Blade pitch ............................................66 Declaration of conformity ......................13
Brake systems ......................................80 Design ..................................................76
Brake wear signaling mechanism .........70 Design data.................................104, 175
Cable twist ............................................74 Disassembly
Clearance signaling switch ...................71 foundation .......................................171
Contact person .....................................10 switching equipment........................171
Control system......................................58 tower ...............................................171
Converter system..................................81 Disassembly ...............................166, 169
Copyright ..............................................10 nacelle.............................................169
Corrosion protection .............................92 rotor blades .....................................169
Crane setup area ................................171 Disassembly
Customer service..................................10 transfer station ................................171
Damage reports ..................................163 Disassembly
Dangers ................................................21 transformer......................................171
Work equipment ................................22 Disposal ......................................166, 173
direct current .....................................21 Drive train .............................................80
dirt and objects..................................27 working at........................................161
edges and corners ............................27 Elevator system ............................42, 125
electric current...................................21 Emergency measures...........................45
falling down .......................................22 Emergency stop pushbutton .................47
falling ice ...........................................23 Environmental conditions......................53
hot operating materials......................26 Environmental protection ......................46
hydraulic system ...............................24 Explosion protection .............................28
illegible symbols ................................27 Fire protection.................................28, 92
Lightning strike ..................................22 Foundation
moving components ..........................26 disassembly ....................................171
oil and grease....................................25 Function ................................................76
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Index Windenergieanlage 5M
Betriebshandbuch
Gearbox ........................................69, 176 instructed in electrical engineering ....17

Generator................................69, 81, 176 maintenance....................................161
Guarantee.............................................13 operation .........................................118
Hard hat ................................................18 qualification .......................................17
Hazard identification .............................30 requirements .....................................17
Hearing protection ................................19 transport ..........................................108
Hydraulic unit ........................................71 unauthorized individuals....................18
Hydraulics expert ..................................17 with switching authorization...............17
Instruction .......................................17, 23 Pitch system .....................59, 61, 79, 175
Labeling ................................................30 Production mode...................................97
Labels Protective equipment ............................18
in the nacelle .....................................34 against fall .................19, 118, 161, 169
in the tower........................................30 Against fall.......................................126
Liability..................................................12 disassembly ....................................169
Lifting/rappelling device ........................45 maintenance....................................161
Lightning protection ..............................92 operation .........................................118
Log................................................44, 162 transport ..........................................108
Lubricants .............................................46 Protective gloves ..................................18
Main menu ..........................................129 Protective work clothing........................18
Maintenance .......................................160 Reactivating ..........................................28
Manual operation ................................106 after an emergency stop ...................52
Module overview...................................77 Reactivation
Nacelle....................................73, 84, 110 securing against ..................28, 42, 120
dehumidifier.......................................86 Rechargeable batteries.........................46
disassembly ....................................169 Rescue device ......................................45
Nacelle cooler .......................................88 Rescue measures.................................45
Nominal load.........................................99 Rotor.............................................78, 175
Operating manual ...................................9 Rotor blades
Operating modes ..................................96 disassembly ....................................169
Operation ....................................106, 117 Rotor holding brake ..............................62
Operator................................................15 Rotor hub
Packaging ...................................107, 166 working in ........................................161
Partial load............................................97 Rotor lock .......................................52, 57
Personnel Safety ...........................................15, 166
disassembly ....................................168 disassembly ....................................166
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disposal ...........................................166 Skilled electrician ..................................17

maintenance....................................160 Spare parts ...........................................13
operation .........................................117 Standstill
personal ............................................18 measures ........................................165
safety system ..................................177 unscheduled....................................164
Safety boots..........................................18 Start-up.................................................97
Safety chain ..........................................60 Stopping the wind turbine ...................120
reset ..................................52, 123, 124 Storage .......................................107, 166
Safety glasses ......................................19 Switching equipment
Safety mechanisms ..............................47 disassembly ....................................171
Safety notices System management mechanisms.......58
transport ..........................................107 System states, permissible ...................53
Safety systems ...................................177 System test ...........................................97
Securing the wind turbine .....................42 Technical data ....................................175
Sensors.................................................64 Touch panel ........................................129
additional...........................................69 Tower............................................91, 176
blade pitch.........................................66 dehumidifier.......................................88
brake wear ........................................70 disassembly ....................................171
cable twist .........................................74 Trained personnel.................................17
clearance signaling switch.................71 Transport ....................................107, 166
direction of rotation............................64 Transport inspection ...........................110
Grid monitoring..................................74 Type label ...........................................178
hydraulic system ...............................71 Unauthorized individuals.......................18
oscillations.........................................68 Use
power ................................................66 intended ............................................16
speed ................................................64 Warranty ...............................................13
vibrations...........................................67 Weights...............................................177
wind direction ....................................67 Wind adjustment ...........................83, 177
wind speed ........................................67 manual ............................................120
Service switch.....................................124 Yaw...............................................83, 177
Service work in the rotor hub ................53 working at........................................162
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G 5.1 GP - bh.01 A A en Operating Manual

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G 5.1 GP - bh.01 A A en Operating Manual

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Operating manual

Doc.-ID: G-5.1-GP.BH.01-A-A-EN 2008-10-06

3 Safety mechanisms ......................................................................................................45

4 Design and function......................................................................................................73

4.3.9 Nacelle cooler..................................................................................................................... 83

5 Description of the operating modes ..............................................................................91

6 Transport, packaging, storage....................................................................................101

7 Installation and initial commissioning..........................................................................107

8.4 Manual wind adjustment................................................................................................................ 112

10.7.11 Communication submenu................................................................................................. 134

12 Disassembly and disposal ..........................................................................................157

13 Technical data ............................................................................................................163

This operating manual does not replace duly qualified technical

The assembly, commissioning, and removal stages may only be realized by

1.2 Address of the manufacturer

1.3 Customer service

1.5 Explanation of the symbols

… indicates an immediate hazard which, if not avoided, will result in death or

… indicates a potentially hazardous situation which, if not avoided, could result

… indicates a potentially hazardous situation which, if not avoided, may result in

… indicates a potentially hazardous situation which, if not avoided, may result in

… highlights useful hints and recommendations as well as information

1.6 Associated documents

1.7 Limitation of liability

1.9 Guarantee conditions

1.10 Declaration of conformity

1.11 Spare parts

Original spare parts may be acquired from REpower Systems AG.

2.1 Responsibility of the operator

In particular, the operator:

The operator is also responsible for

2.2 Intended use

Danger due to improper use!

2.3 Personnel requirements

2.3.2 Access to the wind turbine

2.4 Complete personal protective equipment

2.4.1 General personal protective equipment

Hard hat – EN 397

Protective gloves – EN 420

Safety boots – EN 345-347

Safety glasses – EN 166

Hearing protection – EN 352

2.4.2 Complete personal protective equipment against fall

Complete personal protective equipment against fall

Safety belts with fall protection eye EN 361

Shock absorbers EN 355

Fall protection slide EN 353-2

2 safety carabiners EN 362

Holding rope with rope shortener (rope, snap hook) EN 358

Hard hat with chin strap EN 397

2.4.3 Check the protective equipment!

2.5 Special dangers

Risk of life due to electric current!

Risk of life due to high direct voltage!

Risk of life due to damaged electrical work equipment!

Risk of life due to lightning strikes!

Risk of life due to falling down or falling objects!

Risk of life due to falling ice!

Risk of life due to failures at the wind turbine!

Risk of life due to components arbitrarily flying around!

Recognize failure indicators in due time!

Danger following special system states!

Risk of injuries at hydraulic equipment!