Replacement Parts List No. 055236500 Rev. H 09/03
Fan Coil Large Capacity Direct Drive
SCD/SHD Sizes: 061- 201 Vintage: B FSCD/FSHD Sizes 06- 20 Design: A

Contents

About the Model Number Changes... 2 Parts List Revision History.... 3, 4 Nomenclature- Serial Number, Model Number... 5 Nomenclature- Complete (original)... 6 Nomenclature- Complete (current)... 7 Field Installed Accessories- SHD/SCD Secondary Drain Pan for SHD.... 8 Return Air Plenum Filters for SHD.... 8 Vibration Isolators.... 8 Heating Coil Kit.... 8 Field Installed Accessories- FSHD/FSCD Secondary Drain Pans.... 9 Heating Coil Kit.... 9 Vibration Isolators.... 9 Filters- FSCD.... 9 Filters- FSHD.... 9 Hanging Rails- FSHD Only.... 9 Double Deflection Grille- FSCD Only... 10 Stamped Grille- FSCD Only.... 10 " Duct Collar - FSCD Only.... 10 Perimeter Gasketing.... 10 Transformer.... 10 Wall Thermostats.... 11 Cooling Coils..... 12 Reheat Coils..... 13, 14 Unit Assembly- SCD 061B, 081B, 121B/ FSCD S06, S08, S12.. 15- 17 Unit Assembly- SCD 161B, 201B/ FSCD S16, S20.. 18- 20 Unit Assembly- SHD 061B, 081B, 121B/FSHD S06, S08, S12. 21, 22 Unit Assembly- SHD 161B, 201B/FSHD S16, S20.. 23, 24
About the Model Number Changes
In 1999 the model numbering nomenclature for the Large Capacity Direct-Driven Fan Coil changed: The SCD "B" Vintage unit is now the FSCD Design "A" unit. The SHD "B" Vintage unit is now the FSHD Design "A" unit. The unit's components did not change when the nomenclature did (a few engineering changes have taken place since this RPL was last issued, and the part number changes are noted). The complete model number nomenclature currently used has been added to this revision. Unless otherwise noted, all components listed in this revision apply to both the current and the original model numbered units.
13600 Industrial Park Blvd., P.O. Box 1551, Minneapolis, MN 55440 (763) 553-5330
Fan Coil,Lg. Cap. Direct-Driven: SCD/SHD 61-201 Vint. "B"; FSCD/FSHD 6-20

Rev. H 9/03

RPL 055236500 /Page 2
Parts List Revision History
Revision Date 9/88 3/99 7/99 Description New Reformatted, added stock accessories, and field installed items. Add new panel colors. All pages - Corrected footer to show correct RPL number. Page 14 - Corrected part numbers for size 201B Blower Housing Assembly (Ref. #66). Corrected part numbers for size 201B Motors (Ref. #86). Page 11 - Ref #86 (115V, SCD 061& 081) changed p/n's to 049266000. Page 14 - Ref #86 (115V, SCD 161) changed p/n to 049266000. Page 15 - Added 3-way Rotary Switch (SCB 161 & 201) p/n 038255700. Page 11 - Ref. #66 (Blower Housing) under SCD 121B was #030830604 and is now #030839604. Page 17 - Ref. #66 (Blower Housing) under SHD 121B was #030830604 and is now #030839604. Page 19 - Ref. #66 (Blower Housing) under SHD 201B was #030830604 and is now #030839604. All pages- Added new model nomenclature to footer. Page 4 - Added post 2/99 serial number nomenclature. Page 4 - Added current model nomenclature. Page 5 - Changed Sub-heading to "Complete Model Number- (Original)" Page 6 - New (added complete current model nomenclature). Page 7 - Changed heading to define specific application. Added coil and gasket part numbers to coil kit. Pages 8 thru 10- Added Field Installed Accessories for FSCD/FSHD. Page 11- Added 'RH' to Evaporator Coil listings. Added FSCD/FSHD codes to charts. Page 12 - Corrected part numbers for size 6 coil components. Corrected part number for size 8 post 5/97 2-row coil. Page 13 - Corrected part numbers for 2 row coils. Page 14 - Changed heading to include new nomenclature. Page 15 - Changed heading to include new nomenclature. Ref # 86 Corrected part numbers for size 12 115V motor; Corrected part numbers for 230V and 277V motors. Ref # 120 changed p/n for sizes 8 & 12 LH Drain Pan to 106346501 & 107262401 and size 6 RH Drain Pan to 106510301. Ref #125 added RH Drain Pan for sizes 6 & 8 built after 4/02. Ref# 141 changed p/n for size 12 Bottom Cabinet Assy to 106510901. Ref #144 changed p/n for sizes 8, 12 Side Panel to 106180001. Ref #147 moved to page 16. Page 16 - Changed heading to include new nomenclature. Added item #147. Ref # 172 added Filter Door on unit sizes 6 & 8 built after 4/01. Rotary Switch p/n changed to 107112101. Page 17 - Changed heading to include new nomenclature. Page 18- Changed heading to include new nomenclature. Ref #125 added RH Drain pan for unit size 16 built after 4/02. Ref #141 changed p/n for size 16 to 106180201. Ref #144 changed p/n for size 16 to 106180001; changed p/n for size 20 to 106262801. Page 19 - Changed heading to include new nomenclature.
E (Continued on next page)

Continued on next page.

RPL 055236500 /Page 3
Parts List Revision History Continued
Revision E (continued) Date 9/02 Description Page 19 - Changed heading to include new nomenclature. Ref #171 change size 16 p/n to 107260201. Ref #172 changed size 16 p/n to 011128690. Ref #179 Antique Ivory Stamped Grille p/n for size 19 changed to 107250801. Single Deflection Grille p/n for size 19 changed to 107107800. Single Deflection Grille p/n for size 19 changed to 020157507. Double Deflection Grille p/n for size 20 changed to 020157407. N/S Rotary Switch p/n changed to 107112101. Page 20 - Changed heading to include new nomenclature. Page 21 - Changed heading to include new nomenclature. Ref #86 corrected p/n's for all motors. Ref #120 changed size 8 LH Drain Pan p/n to 106346501; changed size 12 LH Drain Pan p/n to 107262401. Changed size 6 RH Drain Pan p/n to 106510301. Page 22 - Changed heading to include new nomenclature. Page 23 - Changed heading to include new nomenclature. Ref #86 corrected p/n's for all motors. Ref #120 changed size 16 LH Drain Pan p/n to 106511501; changed size 16 RH Drain Pan p/n to 106346401. Changed size 20 RH Drain Pan p/n to 107174154. N/S changed size 20 Return Air Plenum Assy p/n to 107261201. Added note to pages with italicized numbers indicating these numbers are not set up in WDSII. Page 2- The note about the 1999 Model numbering nomenclature for the Large Capacity Belt driven Fan Coil changed to read Direct-Driven not Belt Driven. Pages 10,16,17,19 - Added this note to applicable pages; 'All part numbers listed in italics are NOT set-up in WDSII (not orderable). Please contact SMG Parts Tech'. Page 12 - 061B or S06 Coils, 03=R,N, Evap DX 4 & 6 row was corrected to RH.

9/02 10/02

RPL 055236500 /Page 4

Nomenclature

Serial Number (until 2/1999)

7 6A 12345 01

Engineering Revision Serial Number Factory 7= Auburn, NY 5= Staunton, VA Year and Month of Manufacture: Year Month Q= 1985 A= Jan. R= 1986 B= Feb. S= 1987 C= Mar. T= 1988 D= Apr. U= 1989 E= May V= 1990 F= Jun W= 1991 G= Jul X= 1992 H= Aug Y= 1993 J= Sep. Z= 1994 K= Oct. 5= 1995 L= Nov. 6= 1996 M= Dec. 7= 1997 8= 1998 9= 1999
Serial Number (2/1999 to present)

AUB U 048

Serial Number Month of Manufacture 01= January 02= February 03= March 04= April 05= May 06= June 07= July 08= August 09= September 10= October 11= November 12= December
Year 99= 1999 00= 2000 01= 2001 02= 2002 U= Unit Factory AUB= Auburn, NY
Unit Model Number- Original
Vintage Application Series
Stock Unit Model Number- Original

SCD B R

Unit Hand Vintage Application Series
Nominal cfm in 100's ex. 08= 800 Unit Type: SCD- Seasonmaker Ceiling Direct-Drive Large Capacity Fan Coil SHD- Seasonmaker Hideaway Direct-Drive Large Capacity Fan Coil

Unit Model Number- Current

FSCD 1 S06 A

Voltage A= 115/60/1 J= 265/277/60/1 Nominal cfm in 100's ex. S08= 600 Design Series 1= Design A Unit Type: FSCD- Seasonmaker Ceiling Direct-Drive Large Capacity Fan Coil FSHD- Seasonmaker Hideaway Direct-Drive Large Capacity Fan Coil

RPL 055236500 /Page 5

Continued Complete Unit Model Number- Original
Code 01 & 02 Unit Size and Vintage 061B= Nominal 600 Cfm 081B= Nominal 800 Cfm 121B= Nominal 1200 Cfm 161B= Nominal 1600 Cfm 201B= Nominal 2000 Cfm 03 Unit Hand R= Right Hand L= Left Hand Cooling Coil A= Standard Water Coil with Manual Air Vent (3 Row) B= Hi-Capacity Water Coil with Manual Air Vent (4 Row) C= 6 Row Water Coil (no longer offered) J= Standard DX Coil (4 Row) K= Hi-Capacity DX Coil (6 Row) Optional Factory Installed Separate Reheat Coils Y= None A= Separate 1- Row Reheat Coil w/ Manual Air Vent B= Separate 2- Row Reheat Coil w/ Manual Air Vent Secondary Drain Pan (SCD Only) 1= Secondary Drain Pan (carries field valve piping into primary drain pan) (standard) 3= Full length Drain Pan (extends from primary pan to the entering air side) Discharge Air Grilles (SCD) or Return Air Plenums (SHD) A= Stamped Discharge Grille (SCD) D= Double Deflection Grille (SCD) E= Single Deflection Grille (SCD) B= Duct Collar (SCD) Y= Hanging Rails Only (SHD) P= Factory Installed Plenum (SHD) Motor Voltage K= 115/60/1 L= 230/50/1 M= 277/60/1

01 & 02

RPL 055236500 /Page 6
Continued Complete Unit Model Number- Current
Code Unit Design Series (Vint.) 1= Design A 02 Unit Size (Capacity) S06= 600 cfm S08= 800 cfm S12= 1200 cfm S16= 1600 cfm S20= 2000 cfm 03 Voltage A= 115/60/1 J= 265/277/60/Cooling Coil Type D= 3-Row/2-Pipe, HW/CW J= 6-Row, HW/CW 05 Heating Options 00= None 70= 1-Row Heating Coil 71= 2-Row Heating Coil 06 Unit Hand J= Right Hand (Coil & Motor) L= Left Hand (Coil & Motor) 07 Controls 34= 3-Speed Wall Switch 08 Discharge AG= Stamped Grille (FSCD only) AY= Front (FSCD only) AX= Front w/Duct (FSHD only) 09 Return Air/Outdoor Air 20= Rear Return (FSCD only) 17= Rear Ducted w/Filter (FSHD only) 10 Power Connection A= Junction Box 11 Color I= Antique Ivory (FSCD only) Z= None (FSHD only) 12 SKU Type C= Extended Lead Time 13 Product Style 1= 1st Style Change

RPL 055236500 /Page 7

Field Installed Accessories SHD/SCD
Secondary Drain Pan for SHD
Description Secondary Drain Pan Unit Sizes All Part Number 020475400
Return Air Plenum Filters for SHD
Description 2" Throwaway Filter 2" Throwaway Filter 2" Throwaway Filter 2" Throwaway Filter 2" Throwaway Filter 2" Cleanable Filter 2" Cleanable Filter 2" Cleanable Filter 2" Cleanable Filter 2" Cleanable Filter Unit Sizes 061B 081B 121B 161B 201B 061B 081B 121B 161B 201B Part Number 065816304 065816305

Vibration Isolators

Description Rubber-in-Shear Isolator Unit Sizes All Part Number 017888004 (4)
Heating Coil Kit (includes Duct Collar, Angles, Gasketing)
Description 1- Row Heating Coil Kit 1- Row Heating Coil Kit 1- Row Heating Coil Kit 1- Row Heating Coil Kit 1- Row Heating Coil Kit 2- Row Heating Coil Kit 2- Row Heating Coil Kit 2- Row Heating Coil Kit 2- Row Heating Coil Kit 2- Row Heating Coil Kit Unit Sizes 061B 081B 121B 161B 201B 061B 081B 121B 161B 201B Kit Coil Only Gasket 021539902 (2) 021539902 (2) 021539902 (2) 021539902 (2) 021539902 (2) 021539902 (2) 021539902 (2) 021539902 (2) 021539902 (2) 021539902 (2)

RPL 055236500 /Page 8

Field Installed Accessories FSHD/FSCD

Secondary Drain Pans

Description Secondary Drain Pan- FSCD/FSHD Full Length Secondary Drain Pan- FSCD Only Left Hand Unit (C06=L) Left Hand Unit (C06=L) Left Hand Unit (C06=L) Left Hand Unit (C06=L) Right Hand Unit (C06= J) Right Hand Unit (C06= J) Right Hand Unit (C06= J) Right Hand Unit (C06= J) Unit Sizes All S06 S08/S12 S16 S20 S06 S08/S12 S16 S20 Part Number 048937301
Heating Coil Kit (includes duct collar, angles, gasketing)
Description 1- Row Heating 1- Row Heating 1- Row Heating 1- Row Heating 1- Row Heating 2- Row Heating 2- Row Heating 2- Row Heating 2- Row Heating 2- Row Heating Coil Coil Coil Coil Coil Coil Coil Coil Coil Coil Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Unit Sizes S06 S08 S12 S16 S20 S06 S08 S12 S16 S20 Kit Coil Only Gasket (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)
Description Kit (contains 4 R-I-S Isolators) Rubber-in-Shear Isolator only

Unit Sizes All All

Part Number 106319704 0178880041
Quantity required: FSCD (4); FSHD (6).

Filters- FSCD

Description Filter- FSCD Filter- FSCD Unit Sizes S06 - S16 SPack Individual 060687107 000011800

Filters- FSHD

Description Filter- FSHD Filter- FSHD Filter- FSHD Filter- FSHD Filter- FSHD Unit Sizes S06 S08 S12 S16 SPack 107109912 Individual 065810408

Hanging Rails- FSHD Only

Description Hanging Rails Kit (rails + screws) Unit Sizes All Part Number 107111302

RPL 055236500 /Page 9

Double Deflection Grille- FSCD Only
Description Double Deflection Grille Kit (includes grille and screws) Unit Sizes S06 S08 S12 S16 S20 Part Number 020157407 (2)
NOTE: All part numbers listed in italics are NOT set-up in WDSII (not orderable). Please contact McQuay Parts.
Stamped Grille- FSCD Only
Description Stamped Grille Kit (includes painted grille and screws) Unit Sizes S06 S08 S12 S16 S20 Part Number 107108100
" Duct Collar - FSCD Only
Description Duct Collar Kit Duct Collar Kit Duct Collar Kit Duct Collar Kit Duct Collar Kit (includes (includes (includes (includes (includes duct duct duct duct duct collar collar collar collar collar and and and and and screws) screws) screws) screws) screws) Unit Sizes S06 S08 S12 S16 S20 Part Number 107108200

Perimeter Gasketing

Description Gasket- 60 Foot Roll Unit Sizes All Part Number 001318260

Transformer

Description 120V- 24V, 75 VA 265V- 120V, 300 VA Unit Sizes All All Part Number 062986901 047662501

RPL 055236500 /Page 10

Field Installed Accessories Wall Thermostats
Application 2 or 4 Pipe, 24 Volt, with On/Off or 3 Wire Floating, Auto Changeover Thermister Probe for or 4 Pipe, Fan/Valve Cycle, 3 Speed Switch, Auto Changeover 2 or 4 Pipe, Fan/Valve Cycle, 3 Speed Switch, Manual Changeover 2 or 4 Pipe, Fan/Valve Cycle, No Speed Switch, Auto Changeover 2 or 4 Pipe, Fan/Valve Cycle, No Speed Switch, Manual Changeover 4 Pipe, DPDT, Valve Cycle Deadband, 3 Speed No Manual Changeover 4 Pipe, F , Fan/Valve Cycle 3 Speed Switch No Manual Changeover 4 Pipe, DPDT, Valve Cycle No Changeover 2 Pipe, SPST, 2" X 4" 4" X 4" Subbase w/Manual Changeover used with 001181900 4" X 4" Adapter Plate Unit Sizes All Part Number 107345301

107345501

107345304

107345302

107345305

107345303

048445901

056799301

All All All All

039398400 106510201

RPL 055236500 /Page 11

Cooling Coils

061B or S06 Coils
SCD/SHD "B" FSCD/FSHD Description C03= C05= Code 04= 1 Evaporator DX- 4 Row, LH L, M J 1 Evaporator DX- 6 Row, LH L, M K 1 Evaporator DX- 4 Row, RH R, N J 1 Evaporator DX- 6 Row, RH R, N K Water- 3 Row All A D Water- 6 Row All C J 1 DX Coils are no longer offered, and were never offered on the FSCD/FSHD units. Part Number 048946100 048948500

081B or S08 Coils

SCD/SHD "B" FSCD/FSHD Description C03= C05= Code 04= 1 Evaporator DX- 4 Row, LH L, M J 1 Evaporator DX- 6 Row, LH L, M K 1 Evaporator DX- 4 Row, LH R, N J 1 Evaporator DX- 6 Row, LH R, N K Water- 3 Row All A D Water- 6 Row All C J 1 DX Coils are no longer offered, and were never offered on the FSCD/FSHD units. Part Number 048946300 048948700

121B or S12 Coils

Description Evaporator DX- 4 Row, Evaporator DX- 6 Row, Evaporator DX- 4 Row, Evaporator DX- 6 Row, Water- 3 Row Water- 6 Row

LH LH LH LH

SCD/SHD "B" C03= C05= L, M J L, M K R, N J R, N K All A All C

FSCD/FSHD Code 04=

Part Number 048946500 048948900
DX Coils are no longer offered, and were never offered on the FSCD/FSHD units.

161B or S16 Coils

Description Evaporator DX- 4 Row, Evaporator DX- 6 Row, Evaporator DX- 4 Row, Evaporator DX- 6 Row, Water- 3 Row Water- 4 Row Water- 6 Row
SCD/SHD "B" C03= C05= L, M J L, M K R, N J R, N K All A All B All C

D N/A J

Part Number 048949100

201B or S20 Coils

Part Number 048949300
Manual Air Valve for All Coil Sizes
Description Air Valve Unit Sizes All Part Number 000577800

RPL 055236500 /Page 12

Reheat Coils

1 & 2 Rows

End Views

(LH Coil Shown)

112 114

Front View

Ref. No. 1 Part Description 1 Row Reheat Coil (SCD/SHD C06= A; FSCD/FSHD C05=70) Until 5/97 After 5/Row Reheat Coil (SCD/SHD C06= B; FSCD/FSHD C05=71) Until 5/97 After 5/97 Screw (F/SHD) Plate (F/SCD) Blowoff (F/SHD) Top Duct Angle (F/SHD) Side Duct Angle (F/SHD) Rear Duct Angle (F/SHD & F/SCD) Bottom Duct Angle (F/SHD) Qty. Part Number 048940600
Ref. No. 1 Part Description 1 Row Reheat Coil (SCD/SHD C06= A; FSCD/FSHD C05=70) Until 5/97 After 5/Row Reheat Coil (SCD/SHD C06= B; FSCD/FSHD C05=71) Until 5/97 After 5/97 Screw (F/SHD) Plate (F/SCD) Blowoff (F/SHD) Top Duct Angle (F/SHD) Side Duct Angle (F/SHD) Rear Duct Angle (F/SHD & F/SCD) Bottom Duct Angle (F/SHD) Qty. Part Number 048940700

RPL 055236500 /Page 13

1 & 2 Rows, Continued 121B or S12 Coils
Ref. No. 1 Part Description 1 Row Reheat Coil (SCD/SHD C06= A; FSCD/FSHD C05=70) Until 5/97 After 5/Row Reheat Coil (SCD/SHD C06= B; FSCD/FSHD C05=71) Until 5/97 After 5/97 Screw (F/SHD) Plate (F/SCD) Blowoff (F/SHD) Top Duct Angle (F/SHD) Side Duct Angle (F/SHD) Rear Duct Angle (F/SHD & F/SCD) Bottom Duct Angle (F/SHD) Qty. Part Number 048940800

161B or S16Coils

Ref. No. 1 Part Description 1 Row Reheat Coil (SCD/SHD C06= A; FSCD/FSHD C05=70) Until 5/97 After 5/Row Reheat Coil (SCD/SHD C06= B; FSCD/FSHD C05=71) Until 5/97 After 5/97 Screw (F/SHD) Plate (F/SCD) Blowoff (F/SHD) Top Duct Angle (F/SHD) Side Duct Angle (F/SHD) Rear Duct Angle (F/SHD & F/SCD) Bottom Duct Angle (F/SHD) Qty. Part Number 048940900
Ref. No. 1 Part Description 1 Row Reheat Coil (SCD/SHD C06= A; FSCD/FSHD C05=70) Until 5/97 After 5/Row Reheat Coil (SCD/SHD C06= B; FSCD/FSHD C05=71) Until 5/97 After 5/97 Screw (F/SHD) Plate (F/SCD) Blowoff (F/SHD) Top Duct Angle (F/SHD) Side Duct Angle (F/SHD) Rear Duct Angle (F/SHD & F/SCD) Bottom Duct Angle (F/SHD)

Part Number 048941000

RPL 055236500 /Page 14
Unit Assembly SCD 061B, 081B, 121B/ FSCD S06, S08, S12

Diagrams

Component Assembly

(RH Unit Shown)

220 66

Fan Deck Detail

179 139

Cabinet Assembly

RPL 055236500 /Page 15

Components

Ref. No. Part Description Blower Housing Assembly Fan Wheel until 3/94 after 3/94 Cutoff Plate Capacitor 115/60/1 Units 230/50/1 Units 277/60/1 Units Capacitor Cap Capacitor Bracket Motor 115/60/1 Units 230/50/1 Units 277/60/1 Units Drain Pan Assembly- LH Units Drain Pan Assembly- RH Units Fan Panel Assembly Bottom Plate Top Plate Hanger Drain Pan- Secondary Drain Pan- Full Length- LH Drain Pan- Full Length- RH (until 4/02) Drain Pan- Full Length- RH (after 4/02) Drain Pan (C07=1 only) LH Units RH Units Baffle LH Units RH Units Corner Assembly LH Unit RH Unit Angle- Mist Gray (until 2/98) LH Unit RH Unit Angle- Antique Ivory (after 2/98) Angle- Putty Beige (after 2/96) Hanger Channel- Mist Gray (until 2/98) Hanger Channel- Antique Ivory (after 2/98) Hanger Channel- Putty Beige (after 2/96) Bottom Cabinet Assembly End Cabinet Panel Baffle Side Cabinet Panel Top Cabinet Panel Baffle SCD 061B FSCD S010939103 not used not used 065853201 SCD 081B FSCD Snot used not used 043915301 not used SCD 121B Qty. FSCD S071560990 not used not used 043914901 not used 1 1

124 125

145 146
Fan Coil,Lg. Cap. Direct-Driven: SCD/SHD 61-201 Vint. "B"; FSCD/FSHD 6-20 Rev. H 9/03 RPL 055236500 /Page 16

Components, Continued

Ref. No. Part Description Diffusion Plate Filter Frame Mist Gray (until 2/98) Antique Ivory (after 2/98) Filter Door Mist Gray (until 2/98) Antique Ivory ( 2/98 - 4/01) Antique Ivory (after 4/16/01) Filter- Throwaway Until 5/98 After 5/98 Stamped Grille Mist Grey (until 2/98) Antique Ivory (after 2/98) Duct Angle Collar Mist Grey (until 2/98) Antique Ivory (after 2/98) Single Deflection Grille Double Deflection Grille Steel Spacer 3-Way Rotary Speed Switch SCD 061B FSCD S107112101 SCD 081B FSCD S107112101 SCD 121B Qty. FSCD S1

220 N/S

N/S= Not Shown on Diagram. NOTE: All part numbers listed in italics are NOT set-up in WDSII (not orderable). Please contact McQuay Parts.

RPL 055236500 /Page 17

Unit Assembly SCD 161B, 201B/ FSCD S16, S20

68 120

139 139

144 145

RPL 055236500 /Page 18
Ref. No. Part Description Blower Housing Assembly Fan Wheel until 3/94 after 3/94 Cutoff Plate Capacitor 115/60/1 Units 230/50/1 Units 277/60/1 Units Capacitor Cap Capacitor Bracket Motor 115/60/1 Units 230/50/1 Units 277/60/1 Units Drain Pan Assembly- LH Units Drain Pan Assembly- RH Units Fan Panel Assembly Bottom Plate Top Plate Hanger Drain Pan- Secondary Drain Pan- Full- LH Drain Pan- Full- RH (until 4/02) Drain Pan- Full - RH (4/02 and later) Drain Pan (C07=1 only) LH Units RH Units Corner Assembly- Left LH Unit RH Unit Corner Assembly LH Unit RH Unit Angle- Mist Gray (until 2/98) LH Unit RH Unit Angle- Antique Ivory (after 2/98) Hanger Channel- Mist Gray (until 2/98) Hanger Channel- Antique Ivory (after 2/98) Bottom Cabinet Assembly End Cabinet Panel Baffle Side Cabinet Panel Top Cabinet Panel Support Diffusion Plate SCD161B FSCD S010846700 SCD201B FSCD S010876200 Qty. 1 1

146 147

Fan Coil,Lg. Cap. Direct-Driven: SCD/SHD 61-201 Vint. "B"; FSCD/FSHD 6-20 Rev. G 10/02 RPL 055236500 /Page 19
Ref. No. 171 Part Description Filter Frame Mist Gray (until 2/98) Antique Ivory (after 2/98) Filter Door Mist Gray (until 2/98) Antique Ivory (2/98 - 4/01) Antique Ivory (4/01 and later) Filter- Throwaway Until 5/98 After 5/98 Stamped Grille (C08= A) Mist Grey (until 2/98) Antique Ivory (after 2/98) Duct Angle Collar (C08= B) Mist Grey (until 2/98) Antique Ivory (after 2/98) Single Deflection Grille (C08= C) Double Deflection Grille (C08= D) 3-Way Rotary Switch SCD161B FSCD S011129001 (1) 107250801 (1) 011129301 (2) 011129390 (2) 107107800 (1) 020157410 (1) 038255700 SCD201B FSCD S038255700 Qty.

RPL 055236500 /Page 20

Unit Assembly SHD 061B, 081B, 121B/FSHD S06, S08, S12

131 131

RPL 055236500 /Page 21
Ref. No. Part Description Blower Housing Assembly Fan Wheel until 3/94 after 3/94 Cutoff Plate Capacitor 115/60/1 Units 230/50/1 Units 277/60/1 Units Capacitor Cap Capacitor Bracket Motor 115/60/1 Units 230/50/1 Units 277/60/1 Units Drain Pan Assembly- LH Units Drain Pan Assembly- RH Units Fan Panel Assembly Bottom Plate Top Plate Hanger Drain Pan Pan Gasket Angle- LH Angle- RH Diffusion Panel Return Plenum Assembly Top Panel Bottom Panel Access Panel Filter Access Door Filter Frame Plenum Wrap Assembly Filter SHD061B FSHD S065535701 not used not used 065810404 SHD081D FSHD S065536402 not used not used 065810405 SHD121B Qty. FSHD Snot used not used 1

131 147

N/S= Not Shown on Diagram.

RPL 055236500 /Page 22

Unit Assembly SHD 161B, 201B/FSHD S16, S20

RPL 055236500 /Page 23

Ref. No. Part Description SHD161B FSHD S16 SHD201B FSHD S20 Qty.
Blower Housing Assembly Fan Wheel until 3/94 after 3/94 Cutoff Plate Capacitor 115/60/1 Units 230/50/1 Units 277/60/1 Units Capacitor Cap Capacitor Bracket Motor 115/60/1 Units 230/50/1 Units 277/60/1 Units
Drain Pan Assembly- LH Units Drain Pan Assembly- RH Units Fan Panel Assembly Bottom Plate Top Plate Hanger units with no plenum (C08= Y) units with plenum (C08= P) Angle Left Side Right Side Diffuser Panel Return Air Plenum Assembly Filter Frame Filter Access Plenum Wrap Assembly Access Panel Filter- Throwaway

049269400 049545900

065535801 065810407

049269500 049546000

065535901 065810408

147 N/S

RPL 055236500 /Page 24

Project funded by the European Commission under the 6th (EC) RTD Framework Programme (2002- 2006) within the framework of the specific research and technological development programme Integrating and strengthening the European Research Area

Project UpWind

Contract No.: 019945 (SES6)
Integrated Wind Turbine Design
RESEARCH REPORT on Rough Design of 10 and 20 MW Direct-drive Generators
(Deliverable No.: D 1B2.b.hp1)
AUTHOR: AFFILIATION: ADDRESS: TEL.: EMAIL: FURTHER AUTHORS: REVIEWER: APPROVER:
Deok-je Bang , Henk Polinder
Delft University of Technology1, 2 Mekelweg4, 2628CD Delft, the Netherlands1, 2 +27 857911, +d.j.bang@tudelft.nl , h.polinder@tudelft.nl

Project members

Document Information
DOCUMENT TYPE DOCUMENT NAME: REVISION: REV.DATE: CLASSIFICATION: STATUS:

Help desk document

1.0 12/18/2008 R1: Restricted to project members Released
Abstract: The objective of this report is to design 10 and 20 MW permanent magnet (PM) generators for directdrive wind turbines. Different large direct-drive generator concepts are reviewed to address the total mass and size of the generators as a function of the torque rating. A rough design of 10 MW and 20 MW direct-drive generators is given to estimate the mass, size and cost of the generators. Total mass of direct-drive and geared generators for large wind turbines up to 20 MW is estimated and compared as a function of the torque rating. This report concludes with the summary of design and comparison results of the different generator concepts.

UPWIND

Contents
1. 2. 3. 4. Introduction.... 4 Large direct-drive generators for wind turbines.. 5 Design of 10 and 20 MW direct-drive PM generators.. 9 Mass comparison of different generator systems.. 12 4.1 Mass estimation of geared generator systems.. 12 4.2 Mass estimation of direct-drive generator systems... 13 5. Conclusions.... 14 References.... 14
STATUS, CONFIDENTIALITY AND ACCESSIBILITY

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S0 S1 S2 S3 S4 Approved/Released Reviewed Pending for review Draft for commends Under preparation PL: Project leader R0 R1 R2 R3 R4

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Accessibility

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Type of Report [Deliverable]

Introduction

The objective of this report is to give a rough design of 10 and 20 MW direct-drive generators for wind turbines. The direct-drive generator systems for wind turbines have been discussed as a better choice than the geared generator system in terms of the energy harnessed, reliability and maintenance problem [1][2][3][4][5]. The permanent magnet (PM) machine is superior compared to the electrically-exited machine in terms of the mass, cost, efficiency and reliability. For further wind turbine technology, it is expected to develop larger wind turbines to reduce the cost of energy production, especially for offshore. One of the objectives of UpWind project is up-scaling wind turbines up to 20 MW. In this report, PM generators are thus chosen for a rough design of 10 and 20 MW direct-drive generators for wind turbines. When designing the electric machines including PM direct-drive generators, the electromagnetic design and the mechanical design are important points to consider. To minimize the active material and the inactive material is a goal of the designs. In the consideration of only electromagnetic design, direct-drive generators are usually designed with a large air gap diameter and small pole pitches to increase the efficiency, to reduce the active mass and to keep the end winding losses small. Therefore the direct-drive generators with a large air gap diameter seem attractive to minimize the active material. However considering the structural design of large direct-drive generators, the aspect is different with the electromagnetic design. Such direct-drive generators operate at low speed, so that high torque is demanded. High torque results in high tangential force and large air gap diameter of the generator. Large air gap diameter demands large mass of inactive material. When scaling up the wind turbine, the inactive mass is increased more and more. Therefore it is an important issue to minimize the generator mass in both the electromagnetic design and the mechanical design for large direct-drive wind turbines. Recently, McDodalds et al have discussed about the mass minimization of large direct-drive PM generators for 2, 3 and 5 MW wind turbines in [6]. Where, the optimum ratios of the axial length to air gap diameter Krad of the generators have been chosen to minimize the total mass of the generators. It seems to indicate that the ratio Krad is increased and the ratio of mass to torque m/T is kept or even decreased a little bit, when scaling up the turbines. These results have been obtained by the theoretical design, so that it is expected that the total mass including practical aspects will be larger than the mass by theoretical design. In order to estimate the total mass of direct-drive generators, the mass to torque ratio m/T is used as a criterion because the mass of rotating machine is mainly belong to the torque to have enough strength. This report starts with a short review of different direct-drive wind generators to address the mass, size, and torque rating. The power rating of the generators is from 1.5 MW up to 5 MW [6][7][8][9]. Secondly, a rough design of 10 and 20 MW direct-drive generators is given to estimate the mass, size and cost of the generators. In this design, it is assumed that the mass to torque ratio m/T of the generators is 25 kg/kNm, and the air gap speed of the generator rotors is 4 m/s by referring the values in [6]. Dimensions, material mass, cost and operation characteristics of 10 and 20 MW PM generators are drawn as the results of this design. Next, in order to grasp the interrelationship between the mass and torque rating of rotating machines, the mass of gearboxes is investigated. The constructions of gearboxes are different with the direct-drive generators, but the mass and size of large direct-drive low-speed electric machines have been rarely discussed in references. Thus the mass to torque ratio m/T of gearboxes is dealt prior to estimate the mass of different generators. Total mass of direct-drive and geared generators for large wind turbines up to 20 MW is estimated and compared as a

function of the torque rating. The values of m/T of different generators are given by referring references [6][7][8][9][11]. Finally, the report concludes with the summary of design and comparison results as discussed in previous sections, and with some suggestions to estimate the mass of large direct-drive generators in further researches.
Large direct-drive generators for wind turbines
In order to address the mass, size and torque rating of large direct-drive generators for wind turbines, different direct-drive generators on the market and in literature are reviewed in this section. The largest direct-drive wind turbine is currently E-126 (6 MW) of Enercon GmbH. The E-112 model (4.5 MW), which is the former version of E-126 model, is shown in Figure 1 [7]. The generator of E-112 is an electrically excited direct-drive machine, of which mass and diameter are about 220 ton and 12 m, respectively [6][8]. Figure 2 depicts a 1.5 MW PM direct-drive generator system manufactured Zephyros BV, currently Harakosan Europe [9]. The system uses single bearing and the generator is fully integrated in the structural design. The diameter of this generator is relatively small than the conventional electrically excited synchronous generator. In this configuration, the mechanical load path seems shorter than the traditional configuration with a main shaft. A cone shaped hollow structure with single bearing is used instead of a traditional main shaft with two bearings.
Figure 1: Structure of 4.5 MW EESG DD. Source: Enercon GmbH [7]
Figure 2: Structure of 1.5 MW PMSG DD. Source: Harakosan Europe [9]
A new direct-drive machine for wind turbines has been proposed in [8]. The fundamental idea of the machine - the NewGen (see Figure 3) is to reduce the stiffness demand by removing the load path from the rotor, the shaft and the stator by putting the bearings close to the air gap.
(a) Figure 3: New-Gen generator [8]
The reference [6] describes the mass minimization of conventional PMSG DD concept for different power levels: 2, 3 and 5 MW. In order to minimize the total mass of the generator, the ratio of axial length to air gap diameter Krad has been optimized. Figure 4 depicts the structure of the rotor and stator considered.

Figure 4: Structure of the rotor and stator for structural optimization [6] Table 1 gives the parameter and the generator mass of 1.5 MW Zephyros [9], 4 MW NewGen [8], and 4.5 MW Enercon [7] wind turbines, respectively. The ratios of m/T for the 1.5 MW (Zhphyros) and the 4.5 MW (Enercon) generators, which are 46.4 and 66.5 kg/kNm, are higher than the theoretically optimized 2, 3 and 5 MW generators [6]. It seems that the generator total mass in practical design will be larger than the theoretical design, because detailed parts for manufacturing are not considered in the theoretical design. The NewGen concept seems the lightest concept; it has the lowest m/T, which is about 18.4 kg/kNm. The total mass of NewGen concept (36.4 ton) seems to be competitive with DFIG 3G (about 35 ton) in mass [8]. The design parameters and results of the 2, 3 and 5 MW PMSG DD in [6] are summarized in Table 2. Figure 5 depicts the total mass as a function of Krad. The Krad of 2, 3 and 5 MW generators chosen as the optimum value are 0.2, 0.22, and 0.27 respectively. Considering the total mass and torque rating, the ratios of the total mass to torque rating m/T of 2, 3 and 5 MW generators are 25.5, 23.5 and 23.6 kg/kNm, respectively. The mass of generators discussed in [6][7][8][9] is shown as a function of the torque rating in Figure 6.
Table 1 Parameters and Mass of 1.5, 4 and 4.5 MW direct-drive generators Power Generator type Rotor speed [rpm] Torque rating [kNm] Diameter [m] Total mass [ton] Mass/torque [kg/kNm] Remarks 1.5 MW (Zephyros) 4 MW (NewGen) PMSG 46.4 Market available PMSG 9 36.9 18.kW prototype 4.5 MW (Enercon) EESG 66.5 Market available
Table 2 Parameter and Mass of 2, 3 and 5 MW PMSG DD [6] Rated power Rotor speed [rpm] Torque rating [kNm] Air gap diameter [m] Krad [-] Active mass [ton] Inactive mass [ton] Total mass [ton] Mass/torque [kg/kNm] Air gap [mm] 2 MW 19.4.3 0.2 14.6 10.25.MW 5.1 0.22 22.4 19.23.MW 12.6.1 0.27 39.9 50.23.56

Air gap diameter / 1000

Figure 5: Total mass of 2, 3 and 5 MW PMSG DD as a function of the ratio, Krad [6]
Figure 6: Mass comparison of different direct-drive generators
Design of 10 and 20 MW direct-drive PM generators
Table 3 gives the characteristics of 10 and 20 MW wind turbines, and the generator materials considered in this report. Figure 7 gives a cross section of the four pole pitches of the PM generator considered in this report. A full pitch winding with one slot per pole per phase is used. For the cost estimation of the generators, cost modelling in [12] is used in this design. Table 3 Wind turbine and generator material characteristics Wind turbine characteristics Rated grid power [MW] Rotor diameter [m] Rated wind speed [m/s] Rated rotational speed [rpm] Rotor blade tip speed [m/s] Maximum aerodynamic rotor efficiency [%] Mass density of air [kg/m3] Generator material characteristics Slot filling factor ksfil [-] Remanent flux density of permanent magnets Brm [T] Recoil permeability of permanent magnets rm [-] Resistivity of copper at 120 C Cu [ m] Loss modeling Eddy current losses in laminations at 1.5 T and 50 Hz PFe0e [W/kg] Hysteresis losses in laminations at 1.5 T and 50 Hz Pfe0h [W/kg] Maximum losses in the converter Pconvm [kW] Cost modeling [12] Power electronics cost [/kW] Laminations cost [/kg] Copper cost [/kg] Permanent magnet cost [/kg] Construction cost [/kg] 12 8.51.5 1.225 0.65 1.3 1.06 0.6.51.5 1.225 0.65 1.3 1.06 0.3

Figure 7: A linear cross-section of a PM synchronous generator [1] The PM generator dimensions are determined based on a force density of 40 kN/m2 [13][14]. In this design, the air gap speeds of generator rotors of 10 and 20 MW wind turbines are assumed as 4 m/s, which are similar with the speed for 2, 3, and 5 MW direct-drive generators in [6]. The ratios of total mass to torque m/T of the 2, 3, and 5 MW generators in [6] have been shown between 23.5 and 25.5 kg/kNm. These results seem to indicate that m/T can be assumed around 25 kg/kNm in the rough design, even though it does not include the practical aspects in design. The ratio m/T=25 kg/kNm is thus used in the design of 10 and 20 MW direct-drive PM
generators. Design results of these generators are given in Table 4 including dimensions, material mass and material cost. Figure 8 and Figure 9 depict the steady-state operation characteristics of 10 and 20 MW PMSG DD wind turbines, respectively. Table 4 Design results of 10 and 20 MW RFPM Generators Generator power P [MW] Generator torque T [MNm] Mass to torque ratio m/T [kg/kNm] (assumed) Number of phase m [-] Nominal current is [A] Peak flux density above a PM in the air gap Bg.max [T] No-load voltage ep [V] Number of pole pair per a phase p [-] Generator dimensions Air gap length lg [mm] Air gap diameter Dg [m] Axial stack length ls [m] Aspect ratio Krad [-] Pole pitch p [m] Magnet length lm [mm] Rotor yoke height hry [mm] Stator slot height hS [mm] Stator yoke height hsy [mm] Stator tooth width bt [mm] Stator slot width bs [mm] Generator material mass Laminations [ton] Copper [ton] PM [ton] Construction [ton] Total [ton] Cost Generator active material [M] Generator construction material [M] Converter [M] Total [M] 0.62 0.62 0.4 1.64 1.42 1.95 0.8 4.830 8.88 8.88 2.366 0.266 0.1 22.18 14.9 12.52 12.52 3.356 0.268 0.1 31.10.6 11.1.140 21.2 33.1.196
The active mass of 10 MW direct-drive PM generator with Krad=0.16 is about 65 ton [12][15], which is lighter than the active mass with Krad=0.266, about 86 ton. However, the total mass of 10 MW direct-drive PM generator with Krad=0.16, which is about 325 ton, is larger than the total mass with Krad=0.266, about 294 ton, because of the more heavy inactive part. For 20 MW direct-drive PM generator with Krad=0.268, the active mass and total mass are estimated to about 175 and 680 ton, respectively.

Figure 8: Operation characteristics of 10 MW direct-drive PM generator
Figure 9: Operation characteristics of 20 MW direct-drive PM generator
Mass comparison of different generator systems
In structural design of rotating machines including electric machines and gearboxes, the size of such machines depends on the torque rating rather than the power rating. The mass of the machines depend on the size. Therefore it seems that the total mass of the rotating machines mainly depends on the torque rating. If there are many references dealing with the size and mass of large low-speed direct-drive speed generators, then we can find some criteria with certain values to estimate the size and mass of the generators by using the data of the references. However, the mass and size of the generators have been rarely discussed in references, although the interest on large low-speed direct-drive has been increased. Therefore, firstly, the mass of gearboxes are investigated in this section. Secondly, the mass of different direct-drive generators up to 20 MW is estimated by using the m/T ratio as described in the previous section.
Mass estimation of geared generator systems
In order to investigate the interrelationship between the mass and torque rating of rotating machines, the mass of gearboxes is thus reviewed as a function of the torque rating in this section. The mass to torque ratio of different gearbox concepts in [10] is depicted in Figure 10, where the curve fitting mass m versus torque rating T is given as (1).

m = 0.0678 T 0.7782 (1)

Figure 10: Mass of gearbox as a function of the torque rating [10]

Mass [kg] 2000 2500

Torque [kNm]
Figure 11: Mass of gearbox for wind turbines as a function of the torque rating [11]
The mass of the gearboxes of Bosch Rexroth AG for wind turbines is also investigated as a function of the torque rating in Figure 11. The torque of these gearboxes is between 230 kNm and 2070 kNm, which are for 660 kW and 3300 kW wind turbines [11]. Figure 10 and Figure 11 show that the mass is increasing as a function of the torque, but the slop of mass to torque is decreasing a little bit when the torque is increasing. Regarding the data of Figure 11, the mass to torque ratio m/T seems decreased roughly from 14 kg/kNm to 12.5 kg/kNm when the torque is increasing. The mass of generator has not been included in Figure 11, so that total mass of geared generators must be larger than the mass of gearbox. In this report, the total mass of DFIG described in [8] is taken to define the ratio of mass to torque m/T of geared generators. The value of m/T for geared generators is assumed as the following for the mass estimation of geared generator system. A geared generator concept with m/T=17.4 kg/kNm The mass of a geared generator concept (DFIG) is estimated in Figure 12 as a function of the power.
Mass estimation of direct-drive generator systems

Different direct-drive generators discussed in the previous section are compared based on the mass as a function of torque rating together with the geared generators. In this comparison, the value of the ratio m/T of each generator concept is assumed to have the same value. The generator concepts to compare are described as follows. New-Gen direct-drive generator concept with m/T=18.4 kg/kNm A traditional direct-drive PM generator concept with m/T=25 kg/kNm Zephyros direct-drive PM generator concept with m/T=46.4 kg/kNm Enercon direct-drive EE generator concept with m/T=66.5 kg/kNm The mass of these four different direct-drive generator concepts are also estimated in Figure 12 as a function of the power.
Figure 12: Mass estimation of different generators concepts as a function of the power

Conclusions

The mass of large direct-drive generators on the market and in literature has been addressed. Comparing total mass, m of different direct-drive generators as a function of the torque rating, T, NewGen concept seems to be competitive with DFIG 3G in total mass of generator. Enercon concept and Zephyros concept seem heavier than both NewGen and DFIG 3G concepts. Rough design of 10 and 20 MW direct-drive PM generators have been drawn considering mass, cost and electromagnetic characteristics of the generators. In this design, the axial length to air gap diameter ratios, Krad have been chosen to 0.266 and 0.268, respectively. Total mass of these generators has been estimated by assuming m/T is 25 kg/kNm, which is similar with the value of m/T of traditional direct-drive PM generator concepts by theoretical design. The electromagnetic mass and total mass of 20 MW direct-drive PM generator have been estimated to 2.1 times and 2.8 times of 10 MW, respectively. Thus it is expected that the inactive material is becoming dominant when scaling up direct-drive wind generators. Total cost of 20 MW has been estimated to 4.17 M, which is 2.54 times of 10 MW (1.64 M). Different generators concepts such as direct-drive and geared generators have been compared based on the mass as a function of torque rating. In this comparison, the value of the ratio m/T of each generator concept is assumed to have the same value when the power is increased up to 20 MW. However, in order to make these mass estimations accurate, it is required to ascertain the interrelationship between the mass and the torque rating of large direct-drive generators in further researches.

References

[1] H. Polinder, F.F.A. van der Pijl, G.J. de Vilder, P. Tavner, Comparison of direct-drive and geared generator concepts for wind turbines, IEEE Trans. Energy Conversion, Vol. 21, pp. 725-733, September 2006. [2] G. Bywaters, V. John, J. Lynch, P. Mattila, G. Nortor, J. Stowell, M. Salata, O. Labath, A. Chertok and D. Hablanian, Northern power systems windPACT drive train alternative design study report, NREL, Golden, Colorado, report No. NREL/SR-500-35524, October 2004. [3] A. Grauers, Design of direct-driven permanent-magnet generators for wind turbines, Ph.D. dissertation, Chalmers University of Technology, Gteborg, Sweden, 1996. [4] M. Dubois, Optimized permanent magnet generator topologies for direct drive wind turbines, Ph.D. dissertation, Delft University of Technology, Delft, The Netherlands, 2004. [5] P. Lampola, Directly driven, low-speed permanent-magnet generators for wind power applications, Ph.D. dissertation, Helsinki University of Technology, Finland, 2000. [6] A.S. McDonald, M.A. Mueller and H. Polinder, Comparison of generator topologies for direct-drive wind turbines including structural mass, in Proc. of the International Conference on Electrical Machines(ICEM), pp. 360.1-7, September 2006. [7] ENERCON GmbH, http://www.enercon.de/en/_home.htm, last accessed November 2006. [8] S. Engstrm and S. Lindgren, Design of NewGen direct-drive generator for demonstration in a 3.5 MW wind turbine, EWEC (European Wind Energy Conference & Exhibition, Milan, Italy, May 7-10 2007. [9] Harakosan Europe BV, http://www.harakosan.nl/products/, last accessed November 2006. [10] http://www.grc.nasa.gov/WWW/RT/2005/RX/RX59M-oswald.html [11] Bosch Rexroth AG, http://www.boschrexroth.com/mobile-hydraulicscatalog/Vornavigation/Vornavi.cfm?Language=DE&PageID=m3844 [12] H. Polinder, D. Bang, R.P.J.O.M. van Rooij, A.S. McDonald, and M.A. Mueller, 10 MW Wind turbine direct-drive generator design with pitch or active speed stall control, IEEE Int. Electric Machines and Drives Conf., Antalya, Turkey, May 3-5 2007.135.

[13] A. Grauers, and P. Kasinathan, Force density limits in low-speed PM machines due to temperature and reactance, IEEE Transactions on Energy Conversion, vol. 19, pp. 518525, Sept. 2004. [14] A. Grauers, P. Kasinathan, and E.S. Hamdi Force density limits in low-speed permanent magnet machines due saturation, IEEE Transactions on Energy Conversion, vol. 20, pp. 37-44, Mar. 2005. [15] D. Bang, H. Polinder, G. Shrestha, J.A. Ferreira, and R.P.J.O.M. van Rooij, New active speed stall control compared to pitch control for direct-drive wind turbines, EWEC (European Wind Energy Conference & Exhibition, Milan, Italy, May 7-10 2007.