ESI 54S Rebuilding Process
Disassemble: Remove the teetering hub, brake assembly, 85 KW generator and gearbox from the bedplate and prepare to rebuild each item individually.
Generator: Disassemble, clean parts, inspect bearing journals, replace
ball bearings (6314, 6312), dip and bake stator, reassemble test and paint. Original generator nameplate information: Manufactured by Marathon Electric, 85 KW, 480 VAC, 1835 RPM, frame 365TCZ, amps 126, type TDS.
Mechanical brake assembly: Manufactured by Industrial Clutch. Disassemble, machine wear plates, replace
brake pads, replace “O” ring in piston, replace springs, reassemble. Note:
the pads are installed by rivets
Gearbox: Manufactured by Flender
Corporation, type PZ90S, ratio 19.612:1, driven rpm @ 90, catalog rating 150HP, service rating 94HP, 5 gallon synthetic oil capacity.
Rebuild as necessary. Minimum repairs would include replacing the outboard seals and new synthetic oil. More extensive
repairs would entail replacing bearings and seals and gears as necessary.
Bedplate: Disassemble, sand and paint. Service the yaw bearing.
Teetering hub: Disassemble,
clean parts, inspect bearing journals, replace bearings, reassemble, and paint
Blades: constructed of fiberglass
over wood. Sand and repair exterior of blades, repair fiberglass dings as necessary,
paint with epoxy paint, and balance. Work
to be subcontracted to Knight & Carver
Air compressor: Fractional HP unit
produced by various manufactures, Repair with rebuild kits or replace complete unit
Switches: Pressure switch, vibration sensing (wobble) switch and brake pad wear indicator switch- service and test or replace
Hoses-and control wires: replace
Droop cables: Main power cable size 2/4 SO and control cable 16/16 SO. Replace
both at 90’ length each per unit
Control Panel: Strip control panel components except for the disconnect lever and
meter socket. and update relays and Second Wind control system with PLC
or printed circuit board. Recondition or replace circuit breaker and magnetic
contactor as required. .
Towers: 80’ lattice type triangular tower, galvanized, constructed in 20’ sections. Tower weight is
approximately 4000 pounds. Clean, inspect welds on upright sections, touch
up as necessary with galvanized paint.
Bolts: tower bolts, blade nut bolts, wing tip bolts all to be replaced..
Electrical connection box: Located
at tower base to be repaired or replaced. And an internal power block rated at
150 amp installed.
Nacelle covers: constructed of fiberglass To be repaired , sanded and painted.
Reassemble: Install generator and
gearbox on bedplate, and align, install compressor, air tank, hoses, gauges and switches, install teetering hub, install brake assembly, and paint complete unit as
per customer instructions.
Additional Items- not included
in the remanufacturing process:, but can be quoted and supplied by seller:
New high tensile strength “J” bolts need to be made for the foundations- 12
ea per unit
Remote operating and monitoring capabilities
On-site evaluation and array set-up
On-site assistance in construction,
startup and maintenance