AST.DT.069.c_en BOWEX - Assembling on fix support.pdf

BOWEX INSTALLATION ON FIX SUPPORT

AST.DT.069.c_en Rev. 1

Page 1 / 11 Date 02/03/2015

Last edit Approved Accessibility level: 2 INTERNAL SERVICE ORGANISATION

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The contents of this page is general and could be changed without prior notice

PURPOSE: Assemble the PMG with BOWEX coupling assuring the correct alignment installation without alignment plate ( PMG seat machined directly into the generator cover ) [see AST.MV.001 for video instruction]

1. EQUIPMENT SPARE PARTS

N1 shim gauge

N1 dial gauge

N1 sliding gauge ( caliper )

Each PMG Bowex retrofit kit includes:

1. Components ( Bowex PMG Kit )

o Shaft adapter ( cod. TBD depends from generatore code ) + n4 screws 8 ( cod.

251112220 ) and washers ( cod. 333610184)

o N2 Bowex coupling ( cod. ZWM023434A ZWM02344A )

o N1 screw and washer 12 ( cod. 251112750 333610230 )

o N2 bearings ( cod. 346111440 346111450 )

o N1 plastic sleeve ( cod. 342478001 )

o N1 pin 8x16 ( cod. 332530188 )

o PMG shield ( cod. M00FA306B )

2. N 2 spring dowel pins 6x16 ( cod. 332491232 ) + N 2 spring dowel pins 8x20 ( cod. 332490020 )

3. N 1 drill 6 mm + N 1 drill 8 mm

4. Alignment kit AT0297 ( AST.DW.022.VM ) : alignment tool + straight edge bar

5. Screw bar M12 + nuts & washers

6. N 6 spacers ( AST.DW.018.VM.b )

Components (1) + alignment kit (4-5)

Metallic spacers (6)



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2. PMG DISASSEMBLING

2.1. Open the small box above the PMG, disconnect the 3 cables inside the box and the connection

cable from the same box before taking out the PMG frame, and disassemble the PMG housing by

removing the 4 screws M8.

NOTE: the three cables are not signed and they can be mixed

During this operation take care that:

The PMG stator and rotor will be taken out with the housing

There is a high magnetic force that attracts the components

2.2. Take out the PMG shield by removing the 4 screws M8x30.



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3. COUPLING ADAPTER REPLACEMENT

3.1. Disassemble the half coupling by removing the central screw ( if accessible ) and the coupling

adapter from the shaft by removing the 4 screws

HALF COUPLING + COUPLING ADAPTER

3.2. Mount the new coupling adaptor (Pos.10) on the shaft and fix it with 4 screws M8x40 and washers

(Pos.20-30) with a tightening torque of 23 Nm.



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New PMG Bowex installation

4. PMG ALIGNMENT

4.1. Mount the alignment kit device on the coupling adaptor



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4.2. Fix the alignment kit device with the M12 screw bar and the relative nut:

4.3. .Verify the alignment with the dial gauge, as shown in the picture:

sign with a marker the four position 1 2 3 4 on the device

measure and register in the format attached ( Appendix A ) the oscillation in four positions:

D1 D2 D3 D4

4.4. Assemble the new PMG shield using the tool as guide to center the shield with the rotor shaft;

fix the PMG shield to the generator shield with the 4 screws M8 with a tightening toque of 23 Nm.

set the dial gauge at 0.00 mm in

position 1

Its reccomended that the total

oscillation is not greater than

0.1 mm



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4.5. Verify the perpendicularity between the alignment kit axis and the PMG shield plane

For this operation it is necessary a sliding gauge and the straight edge bar:

a) Put the straight edge bar in contact with the alignment kit device ( fix it with washer and nut ):

b) Measure with the sliding gauge the distance L in position 1.

c) Reset the depth caliper and measure the axial distance at position 3.

d) Repeat step a,b also for position 2-4, 5-7, 6-8

e) Register the values in the format attached ( Appendix A )

Planarity verification: The allowable maximum difference between the 8 measurement is 1 mm.

If needed, correct the perpendicularity using shims ( as for example brass band used for the alignment

of the machine ) between the PMG shield and the generator cover.

SHIELD SURFACE

FOR MEASUREMENT

L

STRAIGHT

EDGE BAR

If necessary, correct

the perpendicularity

with shims to apply

between PMG shield

and generator cover



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5. AXIAL OFFSET CHECK

Without removing the bar, its possible to verify the axial offset E, which must be within 3-5 mm.

The axial alignment is correct if the distance X between the bar and PMG shield surface is within 17-19 mm.

AXIAL OFFSET CORRECTION

6.A) In case of axial misalignment over the limit ( too much air gap between the two half-coupling ), use

the correct spacer as per AST.DW.018.VM.b and fix it between the half coupling and the coupling

adapter / PMG rotor.

The total thickness S of the spacer is quantified with the formula S = (X 18) 1 [mm]

E = 3 5

X = 17 19



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6.B) In case of misalignment below the limit, use the correct spacer as per AST.DW.018.VM.b and fix it

between the cover and the PMG shield

The total thickness S of the spacer is quantified with the formula S = (18 X) 1 [ mm ]

Just with the case 6.B, it is requested to re-check the perpendicular alignment as per paragraph 4.4.

NOTE 1: there are 3 different thickness ( 1-2-3 mm ) for each spacer type.

NOTE 2: Use the attached format to register all the alignment measures.

6. FINAL ASSEMBLING

6.1. Remove the alignment kit device, drill the PMG shield with 6 mm tool using the pre-holes 3.25,

and apply the 6 spring dowel pins



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6.2. Mount the new BOWEX internal half-coupling ( Pos. 50 ) and fix it with the screw M12 with a

tightening toque of 77 Nm.

6.3. Assemble the PMG:

Replace the two bearings of the PMG rotor

Mount the new coupling ( Pos. 80 ) on the PMG rotor and fix it with the pin 6 mm and the screw

Mount the plastic coupling sleeve ( Pos 70 ) on the PMG half-coupling



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Assemble the PMG rotor inside the PMG stator and mount the complete PMG on the shield and fix it

by using n4 screws M8 with a torque og 23 Nm

7. SPRING DOWEL PINS BETWEEN COVER AND STATOR EXCITER SUPPORT

7.1. Drill the NDE cover with 8 mm tool using the n2 pre-holes 3.25 mm ( if presents ) positioned at

965 mm and apply the n2 8 mm spring dowel pins.

< 180

The holes have to be positionated with

an angle of



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APPENDIX A: Record alignment table

IDENTIFICATION DATA

Protocol Gen. S/N Gen. Type

Technician Date:

RUN-OUT ALIGNMENT TOOL

Clearance measurement [ mm ]

D1 D2 D3 D4

Alignment check not performed due to the impossibility to rotate the generator shaft

Maximum acceptable value: 0.1 mm

PLANARITY PMG SHIELD

Planarity measurement [ mm ]

L1 L3 L2 L4 L5 L7 L6 L8

Delta [ mm ]

The maximum delta must be less than 1 mm

AXIAL ALIGNMENT

Axial alignment measurement [ mm ]

X

Acceptable value range: 17-19 mm

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AST.DT.069.c_en BOWEX - Assembling on fix support.pdf