Exercise

Installation D-Level
Installation Simulator

Document no.: 0032-3197 V00 Issued by: Global Solutions & Services Date: See DMS Restricted 1
 Table of contents
Inst. Simulator

Introduction
Exercise 1A
Exercise 1B
Exercise 1C
Exercise 1D
Exercise 1E
Exercise 1F
Exercise 1G
Exercise 1H
Exercise 1I
Exercise 1J
Exercise 1K
Exercise 1L
Exercise 1M
Exercise 1N
Exercise 1O
Exercise 1P

Document no.: 0032-3197 V00 Issued by: Global Solutions & Services Date: See DMS Restricted 2
 Introduction
Inst. Simulator

Introduction

The installation simulator has been developed to provide the installation technician with first hand
experience in specific areas where difficulties are usually encountered during real turbine
installations. The exercises on the simulator have been designed to be as similar and realistic as
possible to some of the tasks insuring that the participant realises and knows the level of work
quality that is/will be expected from him/her while installing Vestas wind turbines.

Through the practical exercises, the participant will learn how to prepare and mount wires and
cables onto the various plugs, terminals and contactors. At the same time the participants will
learn how to carry out cable work (fixating cables in tidy bunches), learn how to establish and
complete proper cable loops, and learn how to determine and apply proper torques and settings for
different bolt sizes and connections.

Required material:
Various tools for cable work

Required documentation:
V80 2MW MK5:
Cable/core list
Cable list
Doc. 948719 and 927856

Notes:

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 Mounting fibre optic cables
Inst. Simulator

Fig.1

Exercise 1A

In this exercise the participant will become

familiar with the fibre optic cable by having to
handle and mount the cable onto the VCP board.

 The smallest bending diameter of the fibre

optic cable is 100mm, preferably though
not less than 200mm

• Find the fibre optic cable numbered W980 from

the supplied cable assortment box.
See Fig. 1
Fig.2
• Install the fibre optic cable W980 onto the port
of the VCP board, according to Doc. 948719.

• Install the fibre optic cable W985 between the

VCP board and the top controller, See Fig.2

• Place the fibre optic cable W980 into the cable

tray below the VCP board and the top controller
in direction of the HV (High Voltage) cable.
See Fig.3

Fig.3

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 Becoming familiar with the cables
that connect the top and the ground
Inst. Simulator controllers to each other

Fig.4

Exercise 1B

In this exercise the participant must find and

mount the four cables W55A, W55B, W81B and
W983B from the cable assortment box that will
connect the top to the ground controller according
to the cable list.

• Pull the four cables through the PGs into the

right cabinet (A1 and A4).

• Mount these four cables to the proper terminals

in the correct cabinets .(Cable core list)
See Fig.4
Fig.5
• Tighten the PGs around the cables

• Lay the four cables into the cable tray together

with the fibre optic cable from exercise 1A, so
that they run towards the HV cable.
•
• Tidily bunch all the cables that are now lying in
the cable tray together and strip them to the
cable tray with the supplied 30cm long cable
ties.

See that the distance between the cable ties are

equal and that the mounted cables leave an
orderly impression.
See Fig.5

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 Creating a good upper cable loop
between the Nacelle and the HV
Inst. Simulator cable

Fig.6

Exercise 1C

In this exercise the participant will learn that a

properly dimensioned loop is required to allow the
cables in the tower to travel during yaw activity.

• Take the bundle of cables from the cable tray

positioned under the top controller and create a
loop that is 200 mm in diameter.
See Fig. 6

• Holding the loop you have created, strip it

firmly to the HV cable using 10 big cable ties.
See Fig. 7
Fig.7

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 Fastening the cables to the HV cable
Inst. Simulator

Fig.8

Exercise 1D

This exercise is in continuation to exercise 4.3.

In exercise 1C a cable loop was created and

fastened to the HV cable with 10 large cable ties.
In this exercise the participant will learn how to
fasten the cables to the HV cable using the proper
distance between the cable ties.
See Fig.8

• From the upper cable loop and down to the

lower cable loop (Leave space near the
bottom of the HV cable to create a lower
Fig.9
cable loop that is similar to the upper
cable loop. The lower cable loop must end
in the cable tray below the ground
controller), tie the small cables to the HV
cable at intervals that equal one ladder rung.
• Take a cable tie a cut it to be approx. 15 cm
long (this only apply to the simulator. In the
actual setup the measurement is 30 cm), and
use it as a measuring stick.
See Fig.9

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 Creating a good lower cable loop
between the HV cable and the
Inst. Simulator ground controller

Fig.10

Exercise 1E

In this exercise the participant will again have the

opportunity to create a cable loop whose main
intention is to allow the cables in the tower to
move during yaw activity.

• Take the bundle of cables leaving the HV cable

and create a loop that is 200 mm in diameter
that ends in the cable tray below the ground
controller.
See Fig.10

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 Mounting fibre optic cables
Inst. Simulator

Fig.11

Exercise 1F

In this exercise the participant will once again

have the opportunity to handle and mount the W980
fibre optic cable W980. This time to the ground
controller.

 The smallest bending diameter of the fibre

optic cable is 100mm, preferably though
not less than 200mm

• Take the fibre optic cable W980 from the cable

tray located below the ground controller
cabinet and insert it through the PG and into
Fig.12
the ground controller cabinet. See Fig. 11

• Do not tie the fibre optic cable to the cable tray

yet. This will be carried out in exercise 1G
together with the rest of the ground controller
cables.

• Install the fibre optic cable W980 onto the

CT291, according to Doc. 948719.
See Fig.12

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 Inserting and mounting the cables
coming from the top controller to the
Inst. Simulator ground controller

Fig.13

Exercise 1G

In this exercise the participant must take the

cables from the lower cable loop, lay them in the
cable tray under the ground controller, and insert
the cables through the PGs into the ground
controller.

 Note the cables must enter the ground

controller in such a manor that each cable
enters nearest its corresponding terminal.

• Pull the four cables through the PGs into the

ground controller.

• Mount these four cables to the proper terminals

in the ground controller. See Cable core list
See Fig.13

• Tighten the PGs around the cables

• Lay the four cables into the cable tray together

with the fibre optic cable from exercise 1A. Fig.14

• Tidily bunch all the cables that are now lying in

the cable tray together and strip them to the
cable tray with the supplied 30cm long cable
ties.

See that the distance between the cable ties are

equal and that the mounted cables leave an
orderly impression. See
Fig.14

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 Mounting the red protective pipe to
the HV cable
Inst. Simulator

Fig.15

Exercise 1H

With this exercise the participant will get the

opportunity to learn how to mount the red
protective pipe to the HV properly.

• Find the two halves of red protection pipe and

the cable ties from the cable assortment box.

• Mount the red protective pipe according to the

Doc. 950997 below the upper cable loop on the
left side of the HV cable.
See Fig.15

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 Fastening the hub controller cables
Inst. Simulator

Fig.16

Exercise 1I

With this exercise the participant will have to tidily

run and fasten the hub controller cables to the
cable trays and the cable tie holders along the
simulated nose cone holder towards the pitch
block.
See Fig.16

• Take the pre-installed cables W880A, W296A,

W283A, W297A, W284A, and W277A and unroll
them so that they can be laid into the cable
tray directly under the hub controller.
Fig.17
• Mount the cables using the pre-mounted plugs
on to the different components on the pitch
block according to Doc. 964089

• Once all the plugs have been mounted, create a

cable loop between the pitch block and the last
cable tie holder that will tolerate and permit the
pitch block to move without putting any tension
or stress on the cables. See
Fig.17

• Run the cables tidy bunched together, inside

the protection pipe downwards to the cable tray
located under the hub controller
See Fig. 18.
Fig.18
• Tie the protection pipe to the cable tie holders.

• Once the cables have been fastened in an

orderly manor to the cable trays, wind up the
remaining cable and fixate it behind the cabinet
using the cable tie holders located on the
board.

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 Connecting the FT-sensor
Inst. Simulator

Fig.19

Exercise 1J

With this exercise the participant will learn how to

route and mount the cable for the FT-sensor.

• Find the cable labeled W391A in the cable

assortment box.

• Connect the multi-socket to the FT-sensor.

• Route the cable in the cable tray towards the

junction box A6A See
Fig.19

• Connect the cable to the right terminals in A6A

according to the cable core list

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 Connecting the yaw-sensor
Inst. Simulator

Exercise 1K
Fig.20
With this exercise the participant will learn how to
route and mount the cable for the yaw-sensor.

• The cable W397 is already mounted in the yaw-

sensor. Fig. 20

• Route the cable W397 to A4 through small hole

right to the YAW sensor. Fig. 20A

• Connect the cable to the right terminals in A4 ,

according to the cable core list.

Fig.20A

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 Connecting the generator cables
(Cable lug connection)
Inst. Simulator

Fig.21

Exercise 1L

With this exercise the participant will learn how to

mount the generator cables in the generator
junction box 4.19

• Find the 4 x 35▫ cables

• Insert the 3 cables through the Pg´s in the

generator junction box labeled 4.19.

• Make sure to insert approx. 500 mm of cable.

• Connect the cables to the copper busbars.

 Note! In reality the Wki1000999-03 is

used. See this doc. For relevant
information to complete the exercise
different task.

 Note! In this exercise there are 2 different

terminations.
See Fig. 21.
The 2 options depend on the
type of generator used in the turbine.

• After connecting the cables to the busbars, run

the cables in the cabletray towards the junction
box AT6, otherwise labeled 4.20, in a tidy
manner.

• Evenly distribute the zip ties. Approx. 300 mm

• Insert the cables into the Pg´s in the bottom of
the junction box AT6/4.20.

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 Connecting the generator cables
(Through terminal connection)
Inst. Simulator

Fig.22

Exercise 1M

With this exercise the participant will learn how to

mount the generator cables in the junction box
AT6/4.20. Using a through terminal connection.

• Find the 4 x 35▫ cables.

• Insert the cables into the Pg´s. in the top of the

junction box AT6/4.20.
See Fig 22

• Connect all 6 generator cables in AT6 according

to Doc.1001802.

• Insert the other end of the cables through the

Pg´s in main cabinet AT1/4.21.

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 Connecting the generator cables
(End terminal connection)
Inst. Simulator

Fig.23

Exercise 1N

With this exercise the participant will learn how to

mount the generator cables in the main cabinet
AT1/4.21. (Located in the bottom of a V82 turbine).

• .Be sure to route the cables in a nice curve

See Fig.23

• Connect the cables to the copper busbars

according to Wki. 1001145-01EN
(see the NM1659 installation manual
named “Terminating generator cable Fig.24
termination block connection” not the V82
manual)

 Note! In this exercise the terminal block

connecter will be a single phase connecter.
See Fig.24.

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