Why repairing Enercon components makes sense
Repairs are typically cheaper than new components. Repair costs are between 50-70% cost of new and lead times typically are 2-3 weeks for UK customers and 3-4 weeks if repairs are coming in from abroad.
The parts that are provided by Enercon, particularly for legacy machines such as the E48 and E70 are being discontinued and support withdrawn from these platforms as the OEM shifts its focus towards larger, more modern machines. By repairing components, you ensure parts continuity. The Enercon E70 and E82 fit a niche in markets like the UK where grid capacity and tip height are limited. We do not have tall forests or mountains to hide current production Enercon machines like the 6MW platforms. The 2MW platforms are very reliable and have been very successful in single stick and utility scale wind farms. For this reason the second hand value and life extension options for these machines are positive.
If you have a compatible board that you know works, repairing it without changing the software ensures compatibility is maintained between the component and the wind turbine.
What can we repair?
Enercon PCBs such as rectifier drives, IGBT drivers, Inverter control boards, motor control, pitch control and optoveilers. We have a range of experience with a large number of PCBs.
We can also repair minor components such as slip rings, pitch cabinets (with calibration), capacitor banks and motors.
PCBs
Enercon PCBs are numerous in function and version but the approach to repairing them is always the same. We map a working board for components and their function, and once this is recorded, we develop test rigs to test switching, communications and component function. Wearing components such as optocouplers, electrolytic capacitors and relays are changed as standard. Failed components are identified in our test reports for technician knowledge transfer. After the repair is completed, we perform a final check using a thermal imaging camera to test whether there are any hot spots that may contribute to early failure.
Enercon Slip Ring Repair
The cost of new Enercon slip rings are high, often more than 8-10K EUR per unit. This creates a strong business case for repair even with transportation costs. Common failure modes such as ring wear, gold wire brush failure and damaged connectors can be replaced with equivalent parts. Expensive parts with large amounts of embedded energy such as the power rings and housing are often recoverable and yield rates are high.
Pitch Cabinets
Pitch cabinets which contain control and power equipment are often good candidates for repair. It is easy to troubleshoot PCBs, battery banks and capacitors then identify faults and repair them. The challenge with these systems is calibration. Thankfully we have access to a test rig which allows us to test and calibrate the pitch cabinet function before it goes back into service.
Pitch Motors
Pitch motors can be a challenge when repairing due to the high cost of rewinds and the weight of yaw and pitch motors reducing economics viability through transport costs. The challenge with motor repair is that the cost of new motors is so cheap (as they are made in large factories in the thousands), any small batch repairs carry significant labour costs and having to rewind a motor can result in a negative business case. For those with legacy part availability challenges or who are environmentally conscious the quality of repair is assured with 12 month warranties as standard.
What about customs?
Don’t get me started on Brexit, but here we are. Post-Brexit problems with customs declarations have largely been addressed through experience and processes. Here at Windy Productions we are set up for temporary import and export, ensuring there are no customs issues. We collect, provide the necessary paperwork and manage queries when they arise. For an easy life, all you need are the weight and dimensions of the package or pallet, a count up of the components and an address and we can do the rest.
Other benefits of repairs
Warehouse space is precious and broken parts take up much needed room. Having a clear out saves space, improves organization and ensures buffer stock for failures. As component scarcity increases, legacy stock such as PCBs and other IP or supply chain protected parts become invaluable.
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