Air-to-air and air-to-water coolers for wind generators
Wind Turbine Generator Cooler
Elevating global standards with exceptional, unmatched Dutch craftsmanship in advanced industrial heat exchange.
What is a Wind Turbine Generator Cooler?
A wind turbine generator cooler removes the heat from the closed air circuit inside the generator. Copper and iron losses in the stator and rotor heat the internal air, and a shaft-mounted or separate fan circulates that air through the cooler. The cooler transfers the heat either to outside air or to a water-glycol circuit, and returns cool, clean air to the windings.
Most wind generators are totally enclosed, so the cooler is the only path for the heat to leave the machine. A cooler that is too small, fouled or corroded raises winding temperatures, shortens insulation life and forces the turbine to derate. ICARUS designs and builds generator coolers for new turbine platforms and as drop-in replacements for existing fleets.
Dutch excellence in heat exchange
At ICARUS Industrial, we blend Dutch craftsmanship with innovative technology, redefining the gold standard for industrial heat exchangers. Dive into the future of sustainable manufacturing, where our Dutch-engineered solutions elevate energy efficiency to unparalleled heights.
Lower total cost of ownership (TCO)
We go beyond performance with our heat exchangers, sculpting an unbeatable blend of.
Direct manufacturer benefits
Your unique needs are our command. We offer tailored heat exchanger solutions.
Customized solutions
With ICARUS Industrial, you're not just buying a product, you're engaging a partnership. Our direct sales model
Superior durability
Built from robust materials, our heat exchangers are a testament to resilience. They reduce maintenance
Generator Coolers Built Around Your Machine
Generator coolers are mounted directly on the generator housing or on the nacelle structure, with fixed flange and connection positions. A catalog unit rarely fits. ICARUS calculates and builds every generator cooler around your generator data: losses, internal air flow, allowable pressure drop, mounting envelope and site conditions. The cooler is designed to work together with the other parts of the wind turbine cooling system, next to the nacelle heat exchanger and the gearbox lube oil cooler.
Air-to-Air Generator Coolers (IC 6A1A6)
In an air-to-air cooler, also known as a TEAAC design or IC 6A1A6 according to IEC 60034-6, the internal generator air flows through one side of the exchanger and outside air through the other. The two air streams never mix, so salt, dust and moisture stay out of the windings. ICARUS builds these as tube-type or plate-type air-to-air heat exchangers with optimized flow paths, so both fans can work at a low pressure drop. This concept is common on doubly fed induction generators and squirrel cage generators in the 2 to 5 MW range.
Air-to-Water Generator Coolers (IC 8A1W7)
For higher power densities and offshore turbines, the generator air is cooled by a water-glycol circuit. The air-to-water cooler, IC 8A1W7 or IC81W in short notation, sits on top of or beside the generator. Internal air passes over finned tubes, and the coolant carries the heat to the roof cooler, often in the same loop as the converter cooling. ICARUS builds these coolers as compact glycol heat exchangers with single or double tube walls, so a leak can be detected before coolant reaches the windings.
Thermal Design for Hot Days and High Loads
A generator cooler has to deliver its full duty at the worst moment: rated power on the hottest day, with a partly fouled surface. ICARUS sizes the cooler on the generator losses at rated load, the maximum ambient or coolant temperature, and a fouling margin that fits the site. We optimize tube rows, fin pitch and circuiting to keep the air-side pressure drop low, because every pascal costs fan power and internal air flow. For uprated generators, we calculate how much extra capacity a new cooler can deliver in the same envelope.
Materials for Onshore and Offshore Sites
Onshore generator coolers are usually built with copper tubes and aluminum fins. Coastal and offshore turbines need more: copper/copper, coated aluminum or fully stainless steel AISI 316 executions, with frames that avoid crevices where salt water collects, as in our high corrosion environment heat exchangers. ICARUS matches the material choice to the corrosion class of the site and the remaining design life of the turbine. See also our offshore finned tube heat exchangers.
Drop-In Replacements and Life Extension
Generator coolers are a known weak point on aging turbines. Air-to-air cores clog with dust and corrode, and air-to-water coolers develop leaks after 15 years or more. With thousands of US turbines now in life extension programs, a reliable replacement cooler is a fast way to remove derating and protect the generator insulation. ICARUS reverse engineers the original unit and builds a drop-in replacement with the same flanges, connections and mounting points. Where the original failed early, we improve the materials or the thermal design at the same time.
Download a sample DWG
Discover precision engineering: Download a sample DWG of our top-notch heat exchangers.
Request a Generator Cooler for Your Turbine
ICARUS works with turbine OEMs, generator manufacturers, independent service providers and wind farm owners. As a direct manufacturer in the Netherlands, we handle thermal design, production and testing in house, from a single replacement unit to series production. You can see examples of our work in our project references.
To prepare a quotation quickly, send us:
- Generator type, rating and the heat load to be removed (kW)
- Cooling concept: air-to-air or air-to-water
- Internal air flow and temperatures, or coolant type, flow and temperatures
- Maximum ambient temperature and the site: onshore, coastal or offshore
- A drawing, nameplate or photos of the current cooler
- Required quantity and target delivery date
Missing some data? Send what you have and our engineers will help you complete the specification.
Request a quotation
Elevate your efficiency with Dutch-engineered solutions tailored for your needs. Fill out the details below, and our team will provide a personalized quote to help you harness the power of optimized energy in manufacturing. Step into the future, one quote at a time.
ICARUS Heat Exchangers
Quotation Form
Why choose ICARUS for generator coolers?
- Wind energy experience: ICARUS builds cooling coils and air coolers for wind turbines, onshore and offshore.
- Built to your interfaces: every cooler matches the flanges, connections and mounting points of your generator.
- Replacement specialists: we reverse engineer existing coolers and improve them where the original fell short.
- Direct manufacturer: thermal design, production and testing under one roof in the Netherlands.
Our specialized team at ICARUS
Transforming challenges into opportunities
An overheating generator means derated turbines, alarms and, in the worst case, a winding failure that takes a crane and months to fix. ICARUS turns that risk into a reliable cooling solution. Our engineers look at the full picture, from losses and air flows to corrosion class and access for installation, and deliver a generator cooler that keeps your turbine producing at full power.
Facts about ICARUS
> 27
With over 27 years in business, we’ve carved out a reputation for excellence and innovation.
> 120+
Our global presence is marked by a diverse clientele of over 120 customers worldwide.
> 850+
Moreover, our portfolio boasts more than 850 completed projects.
FAQ about Wind Turbine Generator Coolers
What is the difference between an air-to-air and an air-to-water generator cooler?
An air-to-air cooler (IC 6A1A6) transfers the generator heat directly to outside air through a heat exchanger that keeps both air streams separate. An air-to-water cooler (IC 8A1W7) transfers the heat to a water-glycol circuit, which releases it through a roof cooler. Air-to-water coolers are more compact and suit higher power densities, while air-to-air coolers need no liquid circuit.
How do I know if my generator cooler needs replacement?
Typical signs are rising winding temperatures at the same load, derating on warm days, visible corrosion or clogged fins, and for air-to-water coolers, coolant loss or moisture inside the generator. If cleaning no longer restores the temperatures, a replacement cooler is usually the most cost-effective fix.
Can ICARUS build a replacement without the original drawings?
Yes. We can reverse engineer the cooler from measurements, photos and the nameplate. We recalculate the thermal performance, check the original design for weak points and build a replacement that fits the same flanges and connections.
Do you build double-wall coolers for leak protection?
Yes. For air-to-water generator coolers we can supply double tube designs with leak detection, so coolant that escapes the inner tube is captured before it can reach the windings. This is common on offshore turbines and high-value generators.
What information do you need to quote a generator cooler?
We need the generator type and rating, the heat load, the cooling concept, the air flow and temperatures or the coolant data, the maximum ambient temperature, the site type and the mounting envelope. For replacements, a drawing, nameplate or photos of the existing cooler help us respond quickly.
