Generator brushes and electrical systems

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This page covers generator brush maintenance, slip-ring work, generator temperatures, and electrical alarms for the wind farm turbines.

Overview

WI-GEN-014 applies to WTG-01 through WTG-12 with a 690 V double-fed asynchronous generator and describes checking and replacing generator brushes on Litware LT-32 turbines at Quellmoor Ridge wind farm.¹²³ Generator brush work requires a permit to work, at least two technicians, generator lockout including stator and rotor, and protective equipment because carbon dust is conductive.⁴⁵⁶ The brush-maintenance rule is to replace the complete brush set when any brush has less than 18 mm remaining; alarm A3210 appears when remaining brush length reaches approximately 20 mm.⁷⁸ The maintenance plan schedules generator brush inspection every 6 months and slip-ring cleaning every 12 months, both referencing WI-GEN-014.⁹¹⁰

Brush replacement materials and tools

• The required brush set is LWS-P-51207 and contains 18 brushes.¹¹
• The required slip-ring cleaning kit is LWS-P-55031.¹²
• Required tools include a 5 to 25 N·m torque wrench, a caliper, and an industrial vacuum cleaner.¹³

Replacement procedure

• The operating procedure begins by obtaining the permit to work, stopping the turbine, and locking out the generator.¹⁴
• Each brush length must be measured with a caliper and recorded.¹⁵
• The slip ring must be cleaned with kit LWS-P-55031, then new brushes must be installed and checked for free sliding.¹⁶¹⁷
• Brush-holder screws must be tightened to 12 N·m.¹⁸
• After replacement, turbine power must be limited to 50 % for 8 hours before returning to rated power.¹⁹
• Measured brush lengths and the work order number must be recorded.²⁰
• The estimated work duration is 3 hours for two technicians, excluding run-in.²¹

Recent brush alarm and corrective work

• WTG-09 had alarm A3210 Generator brush wear limit reached raised on 2026-07-16 and cleared on 2026-07-18, and WTG-09 was in maintenance mode on 2026-07-18 from 07:58:12 to 11:52:40.^22232425
• Work order WO-26-0436 for WTG-09 replaced generator brushes for A3210 under WI-GEN-014, used part LWS-P-51207 quantity 1, and recorded the shortest brush as 16 mm.²⁶
• The shift handover note also records that WTG-09 had its generator brushes replaced under WO-26-0436 following alarm A3210 from 16/07, with the shortest measured brush below the WI-GEN-014 threshold.²⁷
• For WTG-09, a complete LWS-P-51207 set was replaced, the brush-holder screws were tightened to 12 N·m, and run-in was performed at 50 % power for 8 hours.²⁷

Generator temperature and electrical alarms

• WTG-12 had alarm A3201 Generator winding temperature high raised at 147.3 °C and cleared at 139.5 °C on 2026-08-26.²⁸²⁹
• A6101 Grid voltage out of range alarms affected WTG-01 through WTG-12 on 2026-06-06, with value 87.2 %, followed by clear entries at 99.6 %.^303132333435
• A6101 Grid voltage out of range alarms affected WTG-01 through WTG-12 on 2026-06-18 at 89.2 %, and the alarms cleared at 99.6 %.^{36373839404142434445464748495051}
• A6101 Grid voltage out of range was raised for WTG-01 through WTG-12 on 2026-08-02 with value 89.3 %, then cleared at 99.6 %.^525354555657
• On 2026-08-21, WTG-01 through WTG-12 raised A6101 Grid voltage out of range at 87.8 %, entered stopped-fault status, then cleared A6101 at 99.6 % and ended the stopped-fault status.^{5859606162636465}

Contradictions

No contradictions were found between current sources.

Superseded information

No superseded information.

Sources consulted

• LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt: current, authority 8, dated 2024-03-15
• WI-GEN-014 Rev. A - Generator Brush Replacement: current, authority 7, dated 2025-09-15
• 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10): current, authority 6, dated 2026-07-10
• Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm: current, authority 6, dated 2026-07-01
• SCADA alarm and status log, 2026-04-01 to 2026-08-31: current, authority 5, date unknown
• Work Orders Export through 2026-08-31: current, authority 5, date unknown
• Gearbox Fundamentals for Wind Technicians: current, authority 4, dated 2025-10-20
• Shift Handover Note - Day Shift - 18/07/2026: current, authority 2, date unknown

Related

• Assets: Quellmoor Ridge Wind Farm, WTG-01, WTG-02, WTG-03, WTG-04, WTG-05, WTG-06, WTG-07, WTG-08, WTG-09, WTG-10, WTG-11, WTG-12
• Components: gearbox, gearbox oil heater, generator, generator brushes, HSS bearing, hydraulic system, IMS bearing, oil cooler, oil cooler fan motor, oil filter element, pitch bearing, pitch bearing bolts, planetary stage, rescue kit, rotor blade, slip ring, yaw system
• Spare parts: AWI-10442, AWI-31007, FGT-P-11872, FGT-P-11880, FGT-P-13010, FGT-P-14002, FGT-P-21904, FGT-P-22328, FGT-P-22331, LWS-P-30418, LWS-P-30422, LWS-P-51207, LWS-P-55031, PWS-220-D208, PWS-320-D208
• Products: Fabrikam FGT-3200, Litware LT-32, Proseware PWG 220, Proseware PWG 320
• Alarm codes: A1001 Emergency stop activated, A2101 Gearbox oil sump temperature high, A2102 Gearbox oil sump temperature trip, A2110 Gearbox HSS bearing temperature high, A2120 Gearbox oil pressure low, A2130 Gearbox oil level low, A2140 Gearbox oil filter differential pressure high, A3201 Generator winding temperature high, A3210 Generator brush wear limit reached, A4105 Pitch system fault, A5001 Yaw misalignment, A6101 Grid voltage out of range, A7001 Ice detected on rotor blades
• Status codes: S200 Ready - low wind, S310 Maintenance mode, S420 Curtailed - environmental condition, S430 Curtailed - grid operator setpoint, S510 Stopped - fault, S600 Stopped - icing
• Procedures: SOP-GBX-010 Gearbox oil change, SOP-LOTO-001 Lockout/tagout of wind turbines, SOP-WAH-003 Working at height and rescue, WI-GEN-014 Generator brush replacement
• Service bulletins: SB-LWS-2025-07 Gearbox oil viscosity grade change for LT-32 CCV turbines, SB-LWS-2025-11 Pitch bearing bolt re-torque
• Organisations: Contoso Renewables, Fabrikam Getriebetechnik GmbH, Litware Wind Systems, Proseware Lubricants, Trey Research Laboratories, Wingtip Blade Services

Sources

Footnotes

1. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 2 · ✓ quote verified ↩

2. WI-GEN-014 Rev. A - Generator Brush Replacement — table 1, row 7 · table ↩

3. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 4 · ✓ quote verified ↩

4. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 6 · ✓ quote verified ↩

5. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 7 · ✓ quote verified ↩

6. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 8 · ✓ quote verified ↩

7. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 14 · ✓ quote verified ↩

8. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 15 · ✓ quote verified ↩

9. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 9 · table ↩

10. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 10 · table ↩

11. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 10 · ✓ quote verified ↩

12. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 11 · ✓ quote verified ↩

13. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 12 · ✓ quote verified ↩

14. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 17 · ✓ quote verified ↩

15. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 20 · ✓ quote verified ↩

16. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 22 · ✓ quote verified ↩

17. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 23 · ✓ quote verified ↩

18. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 24 · ✓ quote verified ↩

19. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 27 · ✓ quote verified ↩

20. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 28 · ✓ quote verified ↩

21. WI-GEN-014 Rev. A - Generator Brush Replacement — ¶ 30 · ✓ quote verified ↩

22. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1281 · table ↩

23. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1317 · table ↩

24. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1313 · table ↩

25. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1318 · table ↩

26. Work Orders Export through 2026-08-31 — row 78 · table ↩

27. Shift Handover Note - Day Shift - 18/07/2026 — lines 6–12 · ✓ quote verified ↩ ↩²

28. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1878 · table ↩

29. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1879 · table ↩

30. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 690 · table ↩

31. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 691 · table ↩

32. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 712 · table ↩

33. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 713 · table ↩

34. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 714 · table ↩

35. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 737 · table ↩

36. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 864 · table ↩

37. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 866 · table ↩

38. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 868 · table ↩

39. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 870 · table ↩

40. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 872 · table ↩

41. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 874 · table ↩

42. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 876 · table ↩

43. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 878 · table ↩

44. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 880 · table ↩

45. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 882 · table ↩

46. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 884 · table ↩

47. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 886 · table ↩

48. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 888 · table ↩

49. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 889 · table ↩

50. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 909 · table ↩

51. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 911 · table ↩

52. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1437 · table ↩

53. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1459 · table ↩

54. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1461 · table ↩

55. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1482 · table ↩

56. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1466 · table ↩

57. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1484 · table ↩

58. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1714 · table ↩

59. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1736 · table ↩

60. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1715 · table ↩

61. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1737 · table ↩

62. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1738 · table ↩

63. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1758 · table ↩

64. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1740 · table ↩

65. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1761 · table ↩

Provenance badges✓ quote verified the quoted words were found verbatim in the source texttable values parsed deterministically from the cited table rows