I401_639_EN
Revision 1
2006-01-23
Maintenance Instructions
Wind Turbine N80/90
Function Test of the Safety Devices
Document Number: Created:
I401_639_EN
Revision:
1 R. Simon L. Ladwig
Date: Checked:
2006-01-23
Department responsible:
Central Engineering/ENS I. Schmidt
Confidentiality: Released:
SC – Supplier confidential
Status:
FI – Final G. Steininger
AST: Document will be distributed electronically.
1685 Original with signatures at Central Engineering/ENS.
Nordex Energy GmbH, Bornbarch 2, D-22848 Norderstedt
All rights reserved. Observe protection notice ISO 16016.
I401_639_EN_R01_Test_Safety_devices_N80_N90.doc Page 1 / 12
Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
Revision Index
Rev. Date Author Modification (Section) AST
2 2006 Jan 23 Simon Technically revised, new layout 1685
Table of contents
20 Function test of the safety devices ................................................................................ 3
20.1 Aligning the turbine............................................................................................................. 3
20.2 System reaction after triggering the safety chain ............................................................... 4
20.3 System values after triggering an emergency stop ............................................................ 6
20.4 Resetting the safety chain .................................................................................................. 9
20.5 Triggering the failure mode of the pitch drives ................................................................. 10
20.6 Activating the brake programs.......................................................................................... 11
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
20 Function test of the safety devices
The following tests should be carried out by two persons.
Maintenance for type: 1 2 3 4
20.1 Aligning the turbine to true north XXXX
This test checks whether the WT is correctly aligned.
Prerequisites:
- The WT has stopped.
- The service personnel are logged into visualisation with access
rights to level 300 at least.
Align the WT as follows:
9 Completely untwist the cable loop below the nacelle.
9 Change parameter P15.02 "KabVerdrillung Null" ("CableTwist
Zero") ("Tech." menu, "Parameters" submenu) to any value and
confirm with "Enter".
The software now sets the display for cable twist to "0".
9 Afterwards, set parameter P15.02 to "0".
9 Use a compass to determine the north direction and turn the hub
of the WT towards the north in the shortest way possible.
NOTE
When working with a compass, make sure that the person taking the
measurement is at a distance of at least 30 m from the tower.
9 Determine the current cable twist ("Monitor" menu, "Azimut"
("Yaw") submenu, value "Verdrillung" ("Cable twist")).
9 Enter the determined cable twist with a preceding sign in the
parameter P15.00 "Offset Kabelverdrillung Null - Nord" ("Offset
cable twist zero - north").
The value can range between –180° and +180°.
9 Check whether the north direction is marked in the nacelle or in the
tower. If not, mark it accordingly.
9 Turn the nacelle in the direction of the reference point "Mühle-
Nord-Schalter" ("turbine north switch") in the shortest way
possible.
9 Stop the yaw system shortly before the switch is triggered.
In this process, the "Mühle-Nord-Schalter" (mill north switch) must
not be triggered. Otherwise, an error message will be generated
and a turbine reset required.
9 Determine the current position of the nacelle ("Monitor" menu,
"Azimut" ("Yaw") submenu, value "Gondel Pos." ("Nacelle pos.").
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
9 Enter the determined position in the parameter P15.01 "Offset
Referenzpunkt - Nord" ("Offset reference point - north").
The value ranges between 0° and 360°, the preceding sign is not
important.
Maintenance for type: 1 2 3 4
20.2 System reaction after triggering the safety chain X XX
Prerequisites:
- The wind speed must at least reach the value of the start wind
speed.
- The service personnel are logged into visualisation with access
rights to level 300 at least.
Testing the emergency stop switches:
9 Start the WT and wait for run-up.
9 Actuate the emergency stop switch at the bottom control cabinet.
9 Check the system reaction according to the table below.
9 Document the result in the K401_639 report.
9 Release the emergency stop switch.
9 Reset the safety chain.
9 Switch on the main switch again.
9 Reset the turbine.
9 Restart the WT.
9 Repeat this test for each emergency stop switch.
Testing the vibration switch:
9 Start the WT and wait for run-up.
9 Trigger the vibration switch manually.
9 Check the system reaction according to the table below.
9 Document the result in the report K401_639.
9 Reset the safety chain.
9 Reset the turbine.
NOTE
Newer turbines are equipped with a second vibration switch. This switch
must be checked in the same way.
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
Testing the overspeed protection system by means of the limit relay
for the rotor speed:
9 While the turbine is stopped, determine and record the set trigger
value (default value) at the limit relay for the rotor speed (in the top
box).
9 Set this limit value to 5.0 Hz.
9 Start the WT and wait for run-up.
9 Check at which rotor speed the safety chain is triggered.
Document the value in the report K401_639.
9 Check the system reaction according to the table below.
9 Document the result in the K401_639 report.
9 Reset the safety chain.
9 Reset the turbine.
9 Reset the trigger value at the limit relay to the default value.
Depending on the trigger, the following system reactions must occur:
Trigger System reaction
Main switch switched
Failure mode of pitch
contactors dropped
(-102K2 to -102K5)
Mechanical brake
Emergency stop
immediately
triggered
engaged
out
off
Emergency stop switch:
Bottom control cabinet X X X X
Converter cabinet (if available) X X X X
Top box X X X X
Mobile operation terminal of the top box X X X X
Gearbox X X X X
Hydraulic unit X X X X
Limit relay rotor speed X X X
Vibration switch 1 X X X
Vibration switch 2 (if available) X X X
If the system does not react as described in the above table:
9 Inform Nordex service.
9 Stop the WT.
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
WARNING
Faulty safety devices may cause danger to persons and property.
If the prescribed test results are not achieved, the WT must be stopped
until the error has been eliminated.
Maintenance for type: 1 2 3 4
20.3 System values after triggering an emergency stop X XX
In the following, some system values after an emergency stop has been
triggered (brake program 4) are to be checked. During the first test, the
emergency stop is to be triggered by the safety chain and in a second
test by the operating control.
These checks can be carried out from the bottom control cabinet.
These system values must be read out via the visualisation at the turbine
PC from the fastlog file (see below).
Prerequisites:
- The WT has stopped.
- The service personnel are logged into visualisation with access
rights for level 300 at least.
Adapting the fastlog file
To make it possible to read out the above-mentioned system values, the
trigger time for the fastlog file must be adapted before starting the tests.
9 Change parameter P26.09 "Triggerzeitpunkt für Fastlog" ("Trigger
time for fastlog") from 10 to 1 ("Tech." menu, "Parameters"
submenu).
NOTE
By default, the data in the fastlog file is recorded for 20 s, 10 s before
until 10 s after the occurrence of the error.
By changing the parameter as described above, the data-recording
period is set to 1 s before the error until 19 s after the error.
Triggering by means of the safety chain:
9 On the bottom control cabinet, open the door with the emergency
stop switch.
DANGEROUS VOLTAGE
Bare live parts in the control cabinet.
Any contact with live parts may cause death or serious injury.
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
9 Pry off and remove the normally open contact (green contact
block) on the emergency stop switch.
Figure 1 Normally open contact on the emergency stop switch
9 Bridge the normally open contact on auxiliary contactor 105K5 (11;
14).
NOTE
The steps described above make sure that the following reactions are
not triggered by the operating control, but exclusively by the safety chain.
9 Actuate the emergency stop switch on the bottom control cabinet.
9 Display the system values to be checked in the fastlog file for this
provoked error (see below).
9 Document the service values in the K401_639 report.
9 Reset the emergency stop switch.
9 Reattach the normally open contact on the emergency stop switch.
9 Remove the bridge on the normally open contact (11; 14) of the
auxiliary contactor 105K5.
9 Reset the safety chain.
9 Switch on the main switch again.
9 Reset the turbine.
Triggering by means of the operating control:
9 Temporarily bridge the normally open contact on the emergency
stop switch of the bottom control cabinet.
This way, the emergency stop is only triggered by the operating
control.
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
9 Display the system values to be checked in the fastlog file for this
provoked error (see below).
9 Document the service values in the K401_639 report.
9 Reset the turbine.
After the tests:
9 Close the control cabinet door.
9 Set parameter P26.09 "Triggerzeitpunkt für Fastlog" ("Trigger time
for fastlog") from 1 to 10 ("Tech." menu, "Parameters" submenu).
Displaying the fastlog file:
9 In the visualisation, open the "Fastlog" submenu in the "Logs"
menu.
9 Select the fastlog file that was generated last.
9 Under "Auswahl" ("Select"), select the following files for the
display:
- error message FM51 "Not-Aus Schaltschrank" ("Emergency
stop control cabinet"),
- rotor brake pressure and
- the three pitch angles
9 Under "Darstellung" ("Display"), display the data.
Evaluate data:
9 Compare the determined ACTUAL values with the TARGET
values.
System value TARGET value
Brake pressure during the first 14 s after the error was N80: 75 ± 5 bar
triggered
N90: 85 ± 5 bar
Brake pressure 14 s after the error was triggered ≤ 5 bar
Time between triggering the error and applying the rotor
brake, e.g. until the brake pressure has fallen below 90 ≤ 0.1 s
bar
Time between triggering the error and pitch start, i.e. until
≤ 0.1 s
the pitch angle starts to change
9 In the case of deviations, call the Nordex service and wait for
further instructions.
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
Maintenance for type: 1 2 3 4
20.4 Resetting the safety chain X XX
This test serves to check whether the safety chain is properly reset.
It must only be possible to reset the triggered safety chain if the trigger
no longer exists.
For this purpose, carry out the following test for each component of the
safety chain:
9 Trigger the component of the safety chain as described below.
9 While the component is triggered, actuate the "Safety chain reset"
button (does not work if triggered by overspeed).
9 Check that the safety chain has not been reset.
Indicator lamp "Safety chain activated" lights.
9 Reset the triggered component.
9 Check that the safety chain has not been reset.
Indicator lamp "Safety chain activated" lights.
9 Reset the safety chain.
9 Make sure that reset was successful.
Indicator lamp "Safety chain activated" is off.
9 Document the results in the K401_639 report.
9 If required, switch on the main switch again.
9 Reset the turbine.
The individual components of the safety chain are triggered as follows:
• Emergency stop switch:
Actuate the emergency stop switch.
• Vibration switch:
Move the vibration switch below the generator manually to such
extent that it responds.
• Limit relay for the rotor speed:
- Record the setting of the limit relay for the rotor speed (in the
top box) and change it to 5 Hz.
- Start the WT and wait for the safety chain to trigger.
- After the test, reset the limit relay to the original setting.
If the expected result is not achieved in one of these tests:
9 Inform Nordex service.
9 Wait for further instructions.
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
Maintenance for type: 1 2 3 4
20.5 Triggering the failure mode of the pitch drives X XX
This test checks whether the failure mode of the pitch drives is triggered
correctly by certain events. This check must be carried out from the
nacelle.
Before each test, the rotor blades are set to a pitch angle < 90°. While
this check is being carried out, the rotor must be locked.
Prerequisites:
- The WT has been stopped manually.
- The rotor is locked.
- The service personnel are logged into visualisation with access
rights to level 400 at least.
Determining the blade angle manually:
To carry out the following test, a rotor blade angle must be determined
manually:
9 In the visualisation, open the "Parameters" submenu in the "Tech."
menu.
9 Set parameters P34.05 and P34.06 to the value "0".
9 Select the "Hand" ("Manual") button in the top right of the button
bar to switch to manual pitch operation and confirm with "Enter".
Carrying out the test:
9 Trigger one of the events mentioned below.
9 Check that all three rotor blades are moved into feathered position
at the maximum adjustment speed.
9 Document the result in the K401_639 report.
9 Restore the original state with regard to the triggering event.
9 Reset the turbine.
Events to be triggered:
• Switch off the supply voltage of the pitch drives. For this purpose,
switch off circuit breaker 100F1.
• Deactivate the digital output "Abschaltung Pitch" ("Pitch switch-
off").
For this purpose, invert status ST445 "Pitch Notfahrt Befehl Aus"
("Pitch failure mode command off") ("Tech." menu "Status
Eigenschaften" ("Status properties") submenu).
• Disconnect the interbus line from the hub. For this purpose,
remove the Sub-D-9 plugs with the following designation in the top
box:
- N80 with loop modules: 105A12 OUT
- N80/90 with ST modules: 105A7 OUT
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
Final step:
As a final step, reset the system to automatic pitch operation:
9 In the visualisation, open the "Parameters" submenu in the "Tech."
menu.
9 Select the "Auto" button in the top right of the button bar to switch
to automatic pitch operation and confirm with "Enter".
If during one of the tests the failure mode of the pitch drives is not
triggered correctly:
9 Inform Nordex service.
9 Wait for further instructions.
Maintenance for type: 1 2 3 4
20.6 Activating the brake programs X XX
This test is used for checking whether certain events activate the correct
brake program. This check must be carried out for brake programs 1, 2
and 4 for the run-up as well as the grid operation.
Prerequisites:
- The WT has been stopped manually.
- The service personnel are logged into visualisation with access
rights to level 400 at least.
Activating brake programs 1, 2, 4:
Brake programs 1, 2 and 4 can be activated from the bottom control
cabinet.
For each of these brake programs, proceed as follows:
9 Start the WT.
9 Activate the brake program before the generator speed exceeds
700 rpm.
Thus, for:
- brake program 1:
actuate the "Stop" button.
- brake program 2:
invert status ST263 ("Tech." menu / "Status Eigenschaften"
("Status properties"). As a final step, status ST263 must be
reset.
- brake program 4:
actuate the emergency stop switch at the bottom control
cabinet.
9 Make sure that the correct brake program has been triggered.
For this purpose, select and display the "ANA085 OS-
Betriebszustand" ("ANA085 OS operational status") value in the
visualisation under "Logs" / "Trends".
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Maintenance Instructions I401_639_EN
Wind Turbine N80/90 Revision 1
Function Test of the Safety Devices 2006-01-23
The following brake program / operational status assignment
applies:
- brake program 1: operational status 21
- brake program 2: operational status 22
- brake program 4: operational status 24
9 Document the result in the K401_639 report.
9 Reset the turbine and repeat the test for the next brake program.
9 Repeat the entire procedure for the grid operation of the WT.
If the expected results are not achieved:
9 Inform Nordex service.
9 Wait for further instructions.
Activating brake program 3:
Brake program 3 can only be activated from the nacelle.
9 Start the WT.
9 Activate brake program 3 by actuating the service hatch switch in
the nacelle by means of opening the hatch.
9 Make sure that brake program 3 has been triggered.
For this purpose, select and display the "ANA085 OS-
Betriebszustand" ("ANA085 OS operational status") value in the
visualisation under "Logs" / "Trends". Brake program 3
corresponds to operational status 23.
9 Document the result in the K401_639 report.
9 Reset the turbine.
9 Repeat these steps in the case that brake program 3 is triggered
by:
- switching the service switch on the mobile operation terminal of
the top box to "Service".
- the system pressure falling below 160 bar.
For this purpose, open valve 240 while the hydraulic unit is
switched off until the system pressure falls below 160 bar.
If the expected results are not achieved:
9 Inform Nordex Service.
9 Wait for further instructions.
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