General documentation

Technical description
Wind turbine class Nordex Delta4000 - N163/5.X

2000627EN
Revision 00/2019-06-03

- Translation of the original operating instructions (E0004923356, rev. 00) -

This is a translation from German. In case of doubt, the German text shall prevail.
Document is published in electronic form.
Original document at Nordex Energy GmbH, Engineering.

2019 by Nordex Energy GmbH

The present document has been created by Nordex Energy GmbH and/or affiliated
companies as defined in section 15ff. of the German Stock Corporation Act (AktG).
This document, including any presentation of its contents in whole or in parts, is the
intellectual property of Nordex Energy GmbH and/or affiliated companies within the meaning
of section 15 et seq. of the German Stock Corporation Act (AktG). The information contained
in this document are confidential and must never (not even in extracts) be disclosed to third
parties without the prior written approval of Nordex Energy GmbH.
All rights reserved.
Any disclosure, duplication, translation or other use of this document or parts thereof,
regardless if in printed, handwritten, electronic or other form, without the explicit approval of
Nordex Energy GmbH is prohibited.
Copyright 2019 by Nordex Energy GmbH.

Contact details
For questions relating to this documentation please contact:
Nordex Energy GmbH
Langenhorner Chaussee 600
22419 Hamburg
Germany
Phone: +49 (0)40 300 30 -1000
Fax: +49 (0)40 300 30 -1101
http://www.nordex-online.com
info@nordex-online.com

2019 by Nordex Energy GmbH

General documentation Revision 00/2019-06-03

1. Structure
The Nordex N163/5.X wind turbine (WT) is a speed-variable wind turbine with a
rotor diameter of 163 m and a nominal power between up to 5700 kW which can
be adapted dependent on location. The wind turbine is designed for class S in
accordance with IEC 61400-1 or wind zone S in accordance with DIBt 2012 and
is available in 50 Hz and 60 Hz variants.
A Nordex N163/5.X wind turbine consists of the following main components:
● Rotor with rotor hub, three rotor blades and pitch system
● Nacelle with drive train, generator, yaw system, medium voltage transformer
and converter
● Tubular tower or hybrid tower with MV switchgear

1.1 Tower
A N163/5.X class wind turbine can be erected on a tubular steel tower or on a
hybrid tower. The steel tower is cylindrical and consists of several sections. This
tower is bolted to the anchor cage embedded in the foundation. The bottom part
of the hybrid tower consists of a concrete tower and the top part of a tubular steel
tower with two sections.
Corrosion protection is guaranteed by a coating system of the surface according
to ISO 12944. A service lift, the vertical ladder with fall protection system as well
as resting and working platforms inside the tower allow for a weather-protected
ascent to the nacelle.

2
3

4
1

Fig. 1 Overview of the bottom section in a tubular steel tower, tower plates not
shown

1 Tower access 2 MV switchgear 3 Control cabinet

4 Tower service lift 5 Ladder path 6 Flange platform

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The foundation structure of all towers depends on the soil conditions at the
intended location.

1.2 Rotor
The rotor consists of the rotor hub with three slewing bearings, the pitch system
for blade adjustment and three rotor blades.
The rotor hub consists of a base element with support system and spinner. The
base element consists of a stiff cast structure, on which the pitch bearings and
the rotor blades are assembled. The rotor hub is covered with the spinner which
enables the direct access from the nacelle into the rotor hub.
The rotor blades are made from high quality fiber glass and carbon fiber
reinforced plastic. The rotor blade is tested statically and dynamically in
accordance with the guidelines IEC 61400-23 and DNVGL-ST-0376 (2015).
Optionally the blades can be equipped with serrations to optimize the noise level.
The serrations consist of multiple serrated light gray plastic components with
lengths between approx. 0.3 to 0.5 m which have been fastened to the rear edge
of the blades.

Fig. 2 Serrations on a rotor blade's trailing edge

The pitch system serves to adjust the pitch angle of the rotor blades set by the
control system. For each individual rotor blade the pitch system comprises an
electromechanical drive with 3-phase motor, planetary gear and drive pinion, as
well as a control unit with frequency converter and emergency power supply.
Power supply and signal transfer are realized through a slip ring in the nacelle.

1.3 Nacelle
The nacelle contains essential mechanical and electric components of the wind
turbine. The nacelle can be pivoted on the tower.
The transformer converts the generator/converter system's low voltage to the
medium voltage defined by the point of supply. The cooling water is re-cooled in
a passive cooler on the roof of the nacelle.
In the switch cabinet, all electrical components required for the control and
supply of the turbine are located.
With the mechanical rotor brake the rotor is locked during maintenance work.
For this, a sufficient oil pressure is generated by the hydraulic pump.

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The converter connects the electrical grid to the generator which means the
generator can be operated with variable rotational speeds. The cooling water is
re-cooled in a passive cooler on the roof of the nacelle.
The gearbox increases the rotor speed until it reaches the speed required for
the generator.
The bearings and gearings are continuously lubricated with oil. A 2-stage pump
enables the oil circulation. A combination filter element with coarse, fine and
ultrafine filter retains solid particles. The control system monitors the
contamination of the filter element. 
The gear oil used for lubrication also cools the gearbox. The temperatures of the
gearbox bearings and the oil are continuously monitored. If the optimum
operating temperature is not yet reached, a thermal bypass directs the gear oil
directly back to the gearbox. If the operating temperature of the gear oil is
exceeded it is cooled down.
The gearbox cooling is realized with an oil/water cooler that is installed directly
at the gearbox. The cooling water is re-cooled together with the cooling water
from the generator, converter and transformer in a passive cooler on the roof of
the nacelle.
The rotor shaft is supported in the rotor bearing inside the nacelle. A rotor lock
is integrated in the rotor bearing, with which the rotor can be reliably locked in
place mechanically.
All nacelle assemblies are protected against wind and weather conditions by
means of a nacelle housing.
The coupling acts as force-transmitting connection between the gearbox and
the generator.
The generator is a 6-pole doubly-fed induction machine. An air/water heat
exchanger is mounted on the generator. The cooling water is re-cooled in a
passive cooler on the roof of the nacelle.
The yaw drives optimally rotate the nacelle into the wind. The yaw drives are
located on the machine frame in the nacelle. A yaw drive consists of an electric
motor, multi-stage planetary gear, and a drive pinion. The drive pinions mesh
with the external teeth of the yaw bearing. In the aligned position the nacelle is
locked with the yaw drives.

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2
4
3
5
8
6
7

1
10
9
11

Fig. 3 Schematic diagram of the nacelle, example

1 Transformer 2 Cabinet 3 Rotor brake
4 Converter 5 Gearbox 6 Rotor shaft
7 Rotor bearing 8 Nacelle housing 9 Coupling
10 Generator 11 Yaw drives

1.4 Auxiliary systems

Generator bearing, gearing of the pitch bearings, rotor shaft and gearing of the
yaw bearing are each equipped with an automatic lubrication system. An
automatic lubrication of the raceways of the pitch bearing can be offered as an
option.
Gearbox, generator, cooling circuit and all relevant switch cabinets are equipped
with heaters.
An electric chain hoist is installed in the nacelle which is used for lifting tools,
components and other work materials from the ground into the nacelle.
A second, movable overhead crane is used for carrying the materials within the
nacelle.
Various options of additional equipment are available for the wind turbine.

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2. Medium-voltage switchgear
The medium voltage components are used to connect a WT to the medium-
voltage grid in the wind farm or the grid of the local grid operator. The tower base
contains the MV switchgear. It consists of a transformer field with circuit
breakers and at least one ring cable field as default and up to three ring cable
fields as an option (dependent on the wind farm configuration). The transformer
panel consists of a vacuum circuit breaker and the disconnector with ground
switch. The ring cable panel consist of a switch disconnector with a ground
switch. The entire MV switchgear is assembled on a support/adapter frame.
Further characteristics of the MV switchgear:
● Routine tests of each switchgear in compliance with IEC 62271-200
● Type tested, SF6 insulation
● Internal switchgear for self-contained electrical systems (min. IP2X)
● SF6 tank: metal-clad, metal-enclosed (min. IP65), independent of
environmental influences
● Switch positions shown "On - Off - Grounded"
● Test terminal strip for secondary test
● Low-maintenance in accordance with class E2 (IEC 62271-100)

The system protection of the MV switchgear is achieved by the following items:

● Pressure relief by pressure absorber duct in case of arcing
● Improved personal safety and system protection in case of arcing by type
testing in compliance with IEC 62271-200
● Protection device supplied with converter current and stabilized for activation
current as overcurrent-time protection relay (independent maximum current
protection)
● Actuating openings for switchgear are interlocked to preclude operation of
more than one simultaneously, and can be locked as an option
● Corrosion protection of the switchgear cells through hot-dip galvanization and
painted surfaces
Transformer and converter are located in the nacelle. The transformer has
been specified in accordance with IEC 60076-16 and meets the eco-design
requirements of 548/2014/EC.
The steel components at the transformer are dimensioned for corrosion
protection class C3 (H).
Additional protection measures:
● Grounded housing (dry-type transformer) or grounded tank (ester
transformer)
● Overtemperature protection with temperature sensor and relay
● Hermetic protection (leakage) and overpressure protection for ester
transformer

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3. Control and electrical system

The turbine operates automatically. A programmable logic controller (PLC)
continuously monitors the operating parameters using various sensors,
compares the actual values with the corresponding setpoints and issues the
required control signals to the WT components. The operating parameters are
specified by Nordex and are adapted to the individual location.
When there is no wind the WT remains in idle mode. Only various auxiliary
systems are operational or activated as required: e.g., heaters, gear lubrication
or PLC, which monitors the data from the wind measuring system. All other
systems are switched off and do not use any energy. The rotor idles. If the
optional STATCOM function is activated, the converter remains in operation and
facilitates the supply of reactive power to the grid. When the cut-in wind speed
is reached, the wind turbine will change to the mode 'Ready for operation'. Now
all systems are tested, the nacelle turns into the wind and the rotor blades turn
into the wind. When a certain speed is reached, the generator is connected to
the grid and the WT produces energy.
At low wind speeds the WT operates at part load. The rotor blade remain turned
into wind to the maximum extent. The power produced by the WT depends on
the wind speed.
When the nominal wind speed is reached, the WT switches over to the nominal
load range. If the wind speed continues to increase, the speed control changes
the rotor blade angle so that the rotor speed and thus the power output of the
WT remain constant.
The yaw system ensures that the nacelle is always optimally aligned to the wind.
To this end two separate wind measuring systems on the nacelle measure the
wind direction. Only one wind measuring system is used for the control system,
while the second system monitors the first and takes over in case the first system
fails. If the measured wind direction deviates too greatly from the alignment of
the nacelle, the nacelle is yawed into the wind.
The wind energy absorbed from the rotor is converted into electrical energy
using a doubly-fed induction machine with slip ring rotor. Its stator is connected
directly, and the rotor via a specially controlled frequency converter, to the MV
transformer which connects the turbine to the grid. Only part of the power needs
to be routed via the converter, permitting low electrical system losses.

3.1 Safety systems

Nordex wind turbines are equipped with extensive equipment and accessories
to provide for personal and turbine safety and ensure continuous operation. The
entire turbine is designed in accordance with the Machinery Directive 2006/42/
EC and certified as per IEC 61400.
If certain parameters relating to the safety of the system are exceeded, moni-
toring is carried out in the safety-oriented control system, i.e. secure sensors
transmit the sensor data to the safety-oriented control system via a secure bus
system for evaluation. From there, the system is stopped via secure actuators

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and placed in a safe state. Different brake programs are triggered depending on
the cause of the shutdown. In case of external causes, such as too high wind
speed or if the operating temperature has fallen below the minimum value, the
system is gently slowed down by means of rotor blade adjustment.
Other safety features are used to safely decommission drives for maintenance
work.

3.2 Lightning/overvoltage protection, electromagnetic

compatibility (EMC)
The lightning/surge protection of the wind turbine is based on the EMC-
compliant lightning protection zone concept, which comprises the
implementation of internal and external lightning/surge protection measures
under consideration of the standard IEC 61400-24.
The wind turbine falls into lightning protection level I. All components of the
internal and external lightning/surge protection are designed in accordance with
lightning protection level I.
The wind turbine with the electrical equipment, consumers, the measurement,
control, protection, information and telecommunication technology meets the
EMC requirements according to IEC 61400-1, item 10.11.

3.3 Low-voltage grid types

The 750 V low-voltage grid as an IT grid configuration and three phase rotary
current grid is insulated against ground and is the primary low voltage energy
system of the wind turbine. The elements of the electrical operating and
measuring devices of this grid are grounded directly or via separate protective
equipotential bonding cables. As a further protection measure for personal and
turbine protection in the 750 V IT grid a central insulation monitor has been
installed.
The 400 V/230 V low-voltage grid has its neutral point grounded directly at the
supplying grid transformers as TN system and three-phase system. The
equipment grounding conductor PE and the neutral conductor are available
separately. The bodies of the electrical equipment and consumers are
connected directly and straight to the neutral points of the supplying grid
transformers via equipment grounding conductors, including the protective
equipotential bonding. The 400 V/230 V low voltage grid is the auxiliary low
voltage system of the wind turbine.

3.4 Auxiliary power of the wind turbine

The auxiliary low voltage required by the wind turbine in stand-by mode and
feed-in mode is requested by the following consumers:
● System control including main converter control
● 400 V/230 V auxiliary power of the main converter

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● 230 V AC UPS supply including 24 V DC supply

● Yaw system
● Pitch system
● Auxiliary drives such as pumps, fans and lubrication units
● Heating and lighting
● Auxiliary systems such as service lift, obstacle lights
Long-term measurements show that the average base load (average active
power) of the auxiliary low voltage system during WT feed-in operation mode is
approx. 15 kW, based on one year. These values are already included in the
power curves.
For locations with an average annual speed of 6.5 m/s approx. 10 MWh auxiliary
consumption arise, however, this value is greatly dependent on location.
Auxiliary consumption is defines as the energy consumption of the WT from the
grid for a period during which the WT does not supply current to the grid.

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4. Technical data

Design
Standard -20 °C to +45 °C
Design temperature
CCV -40 °C to +45 °C
Operating temperature range -20 °C to +40 °C1)
Operating temperature range CCV -30 °C to +40 °C1)
Default: -20 °C, restart at.-18 °C
Stop
CCV: -30 °C, restart at -28 °C
Max. height above MSL 2000 m1)
In accordance with IEC 61400-1 and DIBt
Certificate
2012
3-blade rotor with horizontal axis
Type
Up-wind turbine
Output control Active single blade adjustment
Nominal power up to 5700 kW1)
Nominal power starting at wind speeds of 
Approx. 11.0 m/s
(at air density of 1.225 kg/m3)
Operating speed range of the rotor 6.0 rpm to 11.8 rpm
Nominal speed Approx. 10.4 min
Cut-in wind speed 3 m/s
Cut-out wind speed 20 m/s2)
Cut-back-in wind speed 19,5 m/s2)
Calculated service life  20 years
1)
Nominal power is achieved up to defined temperature ranges depending on the power factor.
2) Depending on the project, the cut-out wind speed can be decreased to safeguard the structural stability.

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Power adjustment depending on reactive power and temperature (up to

height 1000 m above MSL)

Fig. 4 Power adjustment for wind turbine Nordex N163 in Standard Mode

Towers TS118 TS148 TCS164

Hub height 118 m 148 m 164 m
DIBt S/ DIBt S/
Wind class IEC S
IEC S IEC S
2 steel sections
Number of tower sections 6 6
1 concrete part

Rotor
Rotor diameter 163.0 m
Swept area 20867 m2
Nominal power/area 273 W/m2
Rotor shaft inclination angle 5°
Blade cone angle 3.5 °

Rotor blade
Material Fiber glass and carbon fiber reinforced plastic
Total length 79,7 m

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Rotor shaft/rotor bearing

Type Forged hollow shaft
Material 42CrMo4 or 34CrNiMo6
Bearing type Spherical roller bearing
Lubrication Regularly using lubricating grease

Mechanical brake
Type Actively actuated disk brake
Location On the high-speed shaft
Number of brake calipers 1
Brake pad material Organic pad material

Gearbox
Type Multi-stage planetary gear + spur gear stage
50 Hz: i = 121.5
Gear ratio
60 Hz: i = 145.8
Lubrication Forced-feed lubrication
Oil quantity including cooling
Max. 650 l
circuit
Oil type VG 320
Max. oil temperature Approx. 77 °C
Oil change Change, if required

Electrical installation
Nominal power PnG Up to 5700* kW
Nominal voltage 3 x AC 750 V ± 10 % (specific to grid code)
Nominal current during full
4876 A
reactive current feed-in InG at SnG
Nominal apparent power SnG at
6334 kVA
PnG
1.00 as default setting
Power factor at PnG 0.90 underexcited (inductive) up to
0.90 overexcited (capacitive) possible
Frequency 50 and 60 Hz
*)All
values are maximum values. The values may deviate depending on the rated voltage, rated apparent power
and WT active power.

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Electrical installation
Total weight ca. 9 t
Isolating medium Ester
Rated voltage OV, Ur 750 V
Maximum rated voltage OV,
20 kV / 30 kV / 34 kV
dependent on MV grid, Ur
20 kV and 30 kV: + 4 x 2,5 %
Taps, overvoltage side
34 kV: + 4 x 0,5 kV
20; 20,5; 21; 21,5; 22 kV
Grid voltage OV 30; 30,75; 31,5; 32,25; 33 kV
34; 34,5; 35; 35,5; 36 kV
Rated frequency, fr 50/60 Hz
Vector group Dy5
Installation altitude (above MSL) Up to 2000 m
Rated apparent power, Sr 6350 kVA
Impedance voltage, uz 8 bis 9 % ± 10 % tolerance
Minimum peak efficiency index, η 99,571 %
Activation current  5,5 x IN (peak value)
Power loss1)
Idle losses 3000 W
Short circuit losses 70000 W
*)
The values are, If not specified otherwise, maximum values. The values may deviate depending on the rated
voltage, rated apparent power and WT active power.

MV switchgear
Rated voltage
24, 36 or 40.5 kV
(dependent on MV grid)
Rated current 630 A (>630 A optional)
Rated short-circuit duration 1s
24 kV: 16 kA (20 kA optional)
Rated short circuit current
36/40.5 kV: 20 kA (25 kA optional)
Minimum/maximum ambient NCV: -25 °C to +40 °C
temperature during operation CCV: -30 °C to +40 °C
Connection type External cone type C according to EN 50181
Circuit breaker
Number of switching cycles with
E2
rated current

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MV switchgear
Number of switching cycles with
E2
short-circuit breaking current
Number of mechanical switching
M1
cycles
Switching of capacitive currents Min. C1 - low
Disconnector
Number of switching cycles with
E3
rated current
Number of switching cycles with
E3
short-circuit breaking current
Number of mechanical switching
M1
cycles
Disconnector
Number of mechanical switching
M0
cycles
Ground switch
Number of switching cycles with
rated short-circuit breaking E2
current
Number of mechanical switching
≥ 1000
cycles

Generator
Degree of protection IP 54 (slip ring box IP 23)
Nominal voltage 750 V
Frequency 50 and 60 Hz
50 Hz: 650 to 1500 rpm
Speed range
60 Hz: 780 to 1800 rpm
Poles 6
Weight Approx. 10.6 t

Cooling
Gear box
1st cooling circuit: Oil circuit with oil/water heat
Type
exchanger and thermal bypass
Coarse filter 50 µm / fine filter 10 µm / ultrafine filter
Filter
<5 µm

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Cooling
Generator and Converterar box
Water circuit with water/air heat exchanger and thermal
Type
bypass
Flow rate Approx. 160 l/min
Coolant Water/glycol-based coolant
Transformer
Coolant Water/glycol-based coolant
1st cooling circuit Ester circuit with ester/water heat exchanger

2nd cooling circuit Water/air

Pitch system
Pitch bearing Double-row four-point contact bearing
Gearing/raceway lubrication Regular lubrication with grease
Electric motors incl. spring-loaded brake and multi-
Drive
stage planetary gear
Emergency power supply Batteries

Yaw system
Yaw bearing Double-row four-point contact bearing
Gearing/raceway lubrication Regular lubrication with grease
Electric motors incl. spring-loaded brake and four-stage
Drive
planetary gear
Number of drives 6
Yaw speed Approx. 0.5 °/s

Automation
Field bus system Profinet
Secure field bus system Profisafe via Profinet
Plant control Profinet plant control
Security control Integrated security control

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2019 by Nordex Energy GmbH
Nordex Energy GmbH
Langenhorner Chaussee 600
22419 Hamburg
Germany
http://www.nordex-online.com
info@nordex-online.com
2019 by Nordex Energy GmbH