AST - DT.069.c - en BOWEX - Assembling On Fix Support PDF

AST.DT.069.
c_en
BOWEX
INSTALLATION ON FIX SUPPORT
Rev.
Date
02/03/2015
Page 1 / 11
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)
N2 Bowex coupling ( cod. ZWM023434A ZWM02344A )
N1 screw and washer 12 ( cod. 251112750 333610230 )
N2 bearings ( cod. 346111440 346111450 )
N1 plastic sleeve ( cod. 342478001 )
N1 pin 8x16 ( cod. 332530188 )
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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The contents of this page is general and could be changed without prior notice
BOWEX
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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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AST.DT.069.c_en
BOWEX
Rev.
Date
02/03/2015
New PMG Bowex installation
4. PMG ALIGNMENT
4.1. Mount the alignment kit device on the coupling adaptor
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BOWEX
AST.DT.069.c_en
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Page 5 / 11
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
set the dial gauge at 0.00 mm in

position 1
Its reccomended that the total

oscillation is not greater than
0.1 mm
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.
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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 )
STRAIGHT
EDGE BAR
SHIELD SURFACE
FOR MEASUREMENT
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.
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.
X = 17 19
E=35
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
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S = (X 18) 1
[mm]
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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.
The holes have to be positionated with

an angle of <180 between them.
Do not drill all along the thickness;
holes depth must be as per sketch
below.
< 180
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APPENDIX A: Record alignment table
IDENTIFICATION DATA
Protocol
Gen. S/N
Gen. Type
Technician
Date:
RUN-OUT ALIGNMENT TOOL
D1
Clearance
measurement
[ mm ]
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
Delta [ mm ]
The maximum delta must be less than 1 mm
AXIAL ALIGNMENT
Axial
alignment
measurement
[ mm ]
Acceptable value range: 17-19 mm
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L7
L6
L8

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AST.DT.069.

1. EQUIPMENT SPARE PARTS

N1 sliding gauge ( caliper )

Each PMG Bowex retrofit kit includes:

N2 Bowex coupling ( cod. ZWM023434A ZWM02344A )

N1 screw and washer 12 ( cod. 251112750 333610230 )

N2 bearings ( cod. 346111440 346111450 )

N1 plastic sleeve ( cod. 342478001 )

N1 pin 8x16 ( cod. 332530188 )

PMG shield ( cod. M00FA306B )

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

Metallic spacers (6)

INTERNAL SERVICE ORGANISATION

During this operation take care that:

There is a high magnetic force that attracts the components

INTERNAL SERVICE ORGANISATION

3. COUPLING ADAPTER REPLACEMENT

HALF COUPLING + COUPLING ADAPTER

INTERNAL SERVICE ORGANISATION

New PMG Bowex installation

INTERNAL SERVICE ORGANISATION

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

set the dial gauge at 0.00 mm in

Its reccomended that the total

INTERNAL SERVICE ORGANISATION

INTERNAL SERVICE ORGANISATION

5. AXIAL OFFSET CHECK

AXIAL OFFSET CORRECTION

INTERNAL SERVICE ORGANISATION

INTERNAL SERVICE ORGANISATION

6.3. Assemble the PMG:

Replace the two bearings of the PMG rotor

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

INTERNAL SERVICE ORGANISATION

7. SPRING DOWEL PINS BETWEEN COVER AND STATOR EXCITER SUPPORT

The holes have to be positionated with

INTERNAL SERVICE ORGANISATION

APPENDIX A: Record alignment table

RUN-OUT ALIGNMENT TOOL

PLANARITY PMG SHIELD

Acceptable value range: 17-19 mm

INTERNAL SERVICE ORGANISATION

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