Exercise 2-2 Gerbox, Coupling, nd Alignment EXERCISE OBJECTIVE When you hve completed this exercise, you will be fmilir with the high-speed prt of the drive trin system between the gerbox nd the genertor. More specificlly, you will check gerbox temperture t rest nd during opertion, nlyze vibrtion on the gerbox, chnge gerbox oil, nd lign the shfts. DISCUSSION OUTLINE The Discussion of this exercise covers the following points: More informtion bout the gerbox Ger rtio. Oil. Temperture sensor. Fstening. High-speed shft Coupling nd lignment with the genertor. Alignment procedure. DISCUSSION More informtion bout the gerbox Ger rtio You lredy know (s the nmes indicte) tht the high-speed shft runs fster thn the low-speed shft. In fct, the gerbox provides rtio of 38.45 between these rottionl speeds. Therefore, low-speed shft rotting t 47 RPM will drive the high-speed shft t 1800 RPM. An inductive sensor similr to tht on the low-speed side is lso locted on the high-speed side nd updtes the number of rottions per minute (RPM) of the Gerbox Output Speed prmeter on the min screen. Knowing these two ngulr speed vlues (displyed on the interfce screen), the controller cn verify tht the speed rtio remins constnt (i.e., t 38.45). Oil The triner gerbox comes pre-filled with bout 1.3 L (0.34 gl U.S.) of synthetic oil. A norml oil level should be round the middle of the see-through cover, like on Figure 2-46. Do not underfill or overfill the gerbox. Refer to Appendix G for oil specifictions. Two types of oil (synthetic nd minerl) re recommended. Be sure to use one or the other, but not both t the sme time. Festo Didctic 88765-00 99
Ex. 2-2 Gerbox, Coupling, nd Alignment Discussion Oil level Drin plug See-through cover Figure 2-46. Norml oil level. As with ny oil, you my hve to chnge it fter certin number of hours of opertion if it chnges color or ppernce, or just for the ske of prcticing the procedure since it is prt of trining system. You my be sked to reuse the sme oil or to use new oil, depending on your instructor s choice. Figure 2-47. Drin plug (left) nd mgnetic drin plug (right). Tke note tht the drin plug of this gerbox my feture mgnet (s shown in Figure 2-47) to collect metllic residues so tht they don t circulte with the oil nd cuse dmge to the gers. Should you chnge the oil, be sure to clen the plug to remove these residues. Also, mke sure tht you dispose of the used oil in proper mnner, in ccordnce with locl regultions. This principle pplies here in the clssroom s well s in rel life. Beside the drin plug, other openings in the housing re: A brether vlve to equilibrte ir pressure without letting dirt in. This is lso the oil filling opening. A sight glss locted just bove norml oil level. It is pure luxury to hve both see-through cover nd sight glss to check the oil level. In mny cses, you will only find plug tht you need to remove in order to evlute the oil level. Temperture sensor A thermocouple is ttched to the gerbox enclosure to provide feedbck regrding the ctul gerbox temperture t ny time to mintin the system in resonble conditions of opertion. High oil temperture cn cuse dmge just s serious s oil contmintion does. 100 Festo Didctic 88765-00
Ex. 2-2 Gerbox, Coupling, nd Alignment Discussion Gerbox oil temperture elevtion during opertion is common phenomenon. When surfce cooling is not sufficient, n dditionl cooling system might be required. An offset cn be dded to the gerbox nd genertor temperture vlues through the Service screen (Figure 2-48). Unless otherwise specified, you should lwys leve these vlues t zero. leve to zero Figure 2-48. Temperture offset on the Service screen. Fstening The gerbox of your trining system is shft mounted. It is mintined in position by two elements: the low-speed shft nd the torque rm bolt (Figure 2-49). The low-speed shft mintins the gerbox long its longitudinl xis while the torque rm bolt secures the gerbox in the remining degree of freedom. The height of the gerbox is djustble through the torque rm bolt. Low-speed shft Torque rm bolt Figure 2-49. The two gerbox nchors. Festo Didctic 88765-00 101
Ex. 2-2 Gerbox, Coupling, nd Alignment Discussion High-speed shft The high-speed shft of the triner is solid, just like the low-speed shft. In fct, the only hollow shft on the system is the shft inside the gerbox through which the low-speed shft psses nd to which it is fstened using shrink disk (the sme shrink disk tht you ccessed in Ex. 2-1). Coupling nd lignment with the genertor The ncelle triner fetures the double disk coupling presented in Figure 2-50. It permits mximum ngulr mislignment of 1.4 (0.7 per disc) when no rdil or xil mislignment is present. The mnufcturer tble of tolernces is given in Appendix G for reference. Figure 2-50. Disk brke nd coupling. Alignment procedure The ncelle trining system comes with stylus indictor lignment kit (Figure 2-51). The procedure on how to lign shfts using this kit is detiled in the exercise procedure to follow. Figure 2-51. Stylus indictor lignment kit. The rrngement of the high-speed shft nd disk brke does not llow for full rottion of the lignment kit. However, hlf-turn rottion permits sufficient ccurcy for the ppliction. 102 Festo Didctic 88765-00
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure Outline PROCEDURE OUTLINE The Procedure is divided into the following sections: Accessories needed Bsic sfety procedure Preprtion question Setting up the ncelle Checking gerbox oil level, qulity, nd possible spill. Strting the triner in utomtic mode Gerbox temperture t rest Strting the wind simultion Vibrtion on the ncelle. Gerbox temperture during ctive control. System shutdown Lockout/tgout Gerbox oil chnge Filling with some new, clen oil. High-speed shft nd genertor lignment Result of the lignment End of the procedure PROCEDURE Accessories needed For this exercise, you will need the following ccessories: Lockout device (hsp) One pdlock nd one tg per student 8 mm hex key (gerbox drin plug) 17 mm wrench (brether vlve plug) Blck plstic drin pn Glvnized steel funnel with striner Rgs (not included) Alignment kit Shims Two 13 mm wrenches (high-speed inductive sensor) Two 9/16 wrenches (lignment kit) Two 3/4 wrenches (torque rm bolt, stylus points, nd sight glss plug) Two 1/2" wrenches (genertor foot bolts) 2 Bsic sfety procedure Before using the trining system, complete the following checklist: You re wering sfety glsses nd sfety shoes. You re not wering nything tht might get cught such s tie, jewelry, or loose clothes. 2 It is esier to use wrench nd rtchet (not included) for the bolts of the genertor. Festo Didctic 88765-00 103
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure If your hir is long, tie it out of the wy. The working re is clen nd free of oil or wter. Preprtion question 1. Where is the gerbox thermocouple locted? Setting up the ncelle 2. Mke sure the min switch is off nd everything is secure inside nd round the ncelle. 3. Open the sfety pnels nd position the vibrtion sensor on the gerbox (Figure 2-52). Never let the vibrtion sensor cble run ner moving prts s it could get stuck nd become dmged. Figure 2-52. Vibrtion sensor on the gerbox. 104 Festo Didctic 88765-00
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure Checking gerbox oil level, qulity, nd possible spill 4. Is the gerbox oil level similr to wht you see in Figure 2-46? Yes No If not, sk your instructor if you should dd/remove oil before strting the ncelle triner. 5. Is the oil drk or blck, indicting therml decomposition or contmintion? Yes No If yes, sk your instructor if you should chnge the oil before strting the ncelle triner. 6. Do you observe ny unusul oil lek in, round, or under the triner? Yes No 7. If there is lek, wht is the possible origin of the lek? Do you suspect prticulr sel? 8. If necessry, clen ny spilled oil ccording to the procedure estblished in your clssroom. 9. Close ll sfety pnels. Strting the triner in utomtic mode 10. Notify ll the people working round the ncelle tht the system is bout to be energized nd sk your instructor for permission to power the ncelle trining system. 11. Turn on the min power switch. Wit for the pnel PC to boot nd log into Windows. The HMI should strt utomticlly. 12. Press the green (physicl) strt button under the min switch to strt the system. Festo Didctic 88765-00 105
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure 13. Press Strt Triner in the HMI MAIN screen. 14. If the ALARMS button is flshing red t this point, press it. In the opening ALARMS screen, cknowledge ech current lrm. Next, press RESET ALARMS, if necessry. Gerbox temperture t rest 15. Wht is the gerbox temperture t this time, s indicted on the min screen? Strting the wind simultion 16. Progrm the following steps in the WIND SIMULATION screen: Tble 2-4. Wind steps. Step #1 Step #2 Durtion (s) 60 60 Wind Direction ( ) 0 10 Wind Speed [m/s (mph)] 10 (22.4) 12 (26.8) 17. Enble the two steps nd strt the wind simultion. 18. Press START AUTOMATIC in the min screen to chnge Opertion Sttus to Automtic. Vibrtion on the ncelle 19. Open the TRENDS screen nd select ROTOR VIBRATION. At this point, it is quite possible tht the vibrtion level triggers wrning (t 15 mm/s [0.6 in/s]) or n lrm (t 24 mm/s [0.8 in/s]) on the triner, stopping opertion ltogether. If this hppens, continue the procedure even though the triner is stopped. High vibrtion level might be nother good reson to perform the lignment check tht is coming. 20. Observe the evolution of the curve. Wht is the mximum vibrtion level tht you cn observe? 106 Festo Didctic 88765-00
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure 21. Is vibrtion constnt during ctive control? If not, when is it higher? Gerbox temperture during ctive control 22. Wht is the temperture inside the gerbox t this time? 23. How does this vlue compre to the temperture obtined t step 15? Wht does it men? System shutdown 24. Stop utomtic control nd the wind simultion. 25. Exit the HMI by pressing X on the top-right corner of the screen. 26. Press the Windows Strt button, select Shut Down, nd press OK. Wit for the system to turn off. You my hve to reset lrms before exiting the softwre. 27. Use the min power switch to turn ll system power off. Lockout/tgout For the opertions to follow, the ncelle needs to be secured first. 28. Instll the lockout hsp in the min switch. Next, instll the student pdlocks nd tgs in the hsp. 29. Try to turn on the min switch to verify tht the system is electriclly isolted. Press the strt push-button to test whether the system cn be energized. At this point, the system cn be considered secure. Festo Didctic 88765-00 107
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure Gerbox oil chnge Drining the old oil 30. Open the sfety pnels. 31. Remove the (brss) pressure brether vlve using the 17 mm wrench (Figure 2-53) to fcilitte drining nd pour new oil lter. The pressure brether vlve llows the gerbox to compenste for the chnge of oil volume by letting some ir in or out while keeping dirt prticles out. Figure 2-53. Opening the pressure brether vlve. 32. Position plstic drin pn under the gerbox from the lower sfety pnel. Use clen pn if you pln on reusing the oil. 33. Tke the 8 mm hex key nd remove the drin plug, s shown in Figure 2-54. The first time tht you unscrew the drin plug, you my need to remove some pint nd pply more force. Figure 2-54. Removing the drin plug. 34. Let the old oil drin completely. This should tke couple of minutes. You my wnt to strt the High-speed shft nd genertor lignment procedure now while you re witing for the oil to drin. 108 Festo Didctic 88765-00
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure If you chnge synthetic for minerl oil or vice vers, it is importnt keep the volume of old oil to minimum to void mixing different types of oil. Although it is not necessry here, keep in mind tht it is sometimes required to flush the oil completely more thn once when two oil types re highly incomptible. 35. Clen the drin plug, check the seling element, nd screw the plug bck into plce. 36. Either keep the old oil to reuse it lter, or dispose of it in mnner discussed with your instructor. Filling with some new, clen oil 37. Tke the 3/4 wrench nd remove the sight glss plug (Figure 2-55). The sight glss plug is locted just bove the norml oil level. Figure 2-55. Removing the sight glss plug. 38. Using the metl funnel, pour new (or recycled) oil into the gerbox through the brether vlve opening. If you do not reuse the sme oil, you will need pproximtely 1.3 L (0.34 gl U.S.) of oil. A filled gerbox will hve oil up to the bottom of the sight glss plug. The striner inside the metl funnel prevents residues from entering the gerbox. Festo Didctic 88765-00 109
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure Figure 2-56. Pouring new oil into the gerbox. 39. Verify tht there is no oil lek round the drin plug. 40. Check the condition of the pressure brether vlve nd sight glss plug. Chnge their seling element if necessry, nd screw them bck into plce. High-speed shft nd genertor lignment 41. Prepre your tools for the lignment procedure. 42. (Optionl necessittes feeler guge) Check for soft foot nd plce shims under the fulty foot if necessry. 110 Festo Didctic 88765-00
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure 43. Uninstll the inductive sensor (Figure 2-57) using pir of 13 mm wrenches. Figure 2-57. Removing the sensor on the disk brke. 44. Relese the prking brke mnully. To do so, screw the knob of vlve SV6 completely nd then rotte the knob of vlve SV4 by qurter turn, s shown in Figure 2-58. A minimum pressure of 51.7 br (750 psi) is required t port GB2 to relese the brke. Use the hnd pump to increse pressure if necessry. Figure 3-51 in Unit 3 shows how to use the hnd pump. Figure 2-58. Relesing the prking brke mnully. 45. Instll one prt of the kit on either side of the coupling s shown in Figure 2-59. Insert the bolts in the bottom holes of the red brcket nd use the 9/16 wrenches to secure them. Festo Didctic 88765-00 111
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure () 0 degrees (b) 90 degrees (c) 180 degrees Figure 2-59. Alignment kit positions. 46. One stylus cn be moved verticlly nd the other one horizontlly on the brcket. Align the styluses in both directions, nd use the screws to move the styluses closer or frther prt until the points lmost touch in the 0 position. 47. (Verticl plne ngulr mislignment) Rotte the shft between the 0 nd 180 positions. If the points move closer or frther prt (ignore verticl trvel for now), this mens there is ngulr mislignment (Figure 2-60). Plce or remove shims under the front or bck of the genertor to reduce ngulr displcement by bout hlf of the mximum seprtion distnce. Figure 2-60. Angulr mislignment. 48. Reposition the stylus points when the shft is t the 0 position. Rotte the shfts nd verify tht the distnce between styluses remins the sme (ignore verticl trvels for now). Repet the previous step if necessry. 112 Festo Didctic 88765-00
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure 49. (Verticl plne prllel mislignment) Rotte the shft between the 0 nd 180 positions gin. This time, correct the verticl offset (Figure 2-61) by moving the torque rm bolt up or down (Figure 2-62) or by plcing shims under ll four feet of the genertor for n djustment of bout hlf of the observed offset. Figure 2-61. Verticl offset. Use two 3/4" wrenches to djust the torque rm bolt height (Figure 2-62). () bottom nut rottion (bolt remins sttic) (b) second nut rottion (bolt remins sttic) Figure 2-62. Moving the torque rm bolt by rotting the two lower nuts. Do not rotte the torque rm bolt or the top nut. Squeezing the blck rubber wshers my dmge them. Only rotte the bottom two nuts nd hold the bolt in plce if necessry to modify the gerbox height. Do not forget to retighten the bottom nuts to void dmge next time the triner is strted. 50. Reposition the stylus points when the shft is t the 0 position. Rotte the shfts nd verify tht the verticl distnce remins miniml. Repet the previous step if necessry. If the points move closer or frther prt, this is sign of ngulr mislignment nd you my need to repet step 47. Festo Didctic 88765-00 113
Ex. 2-2 Gerbox, Coupling, nd Alignment Procedure 51. (Horizontl plne mislignment) Rotte the shft between the 0 nd 90 positions. Correct for ny ngulr offset (Figure 2-63) by loosening the genertor bolts nd slowly moving the genertor sidewys. Retighten the bolts. Figure 2-63. Horizontl offset (view from the top). 52. Reposition the stylus points when the shft is t the 0 position. Rotte the shfts nd verify tht the horizontl distnce remins miniml. Repet the previous step if necessry. 53. Rotte the shft between the 0, 90, nd 180 positions once more nd verify tht no ngulr or prllel mislignment remins. Repet pproprite procedure steps if necessry. Record ny relevnt observtions such s mjor difficulties or remining mislignment. 54. Remove the lignment kit nd reinstll the inductive sensor t the top of the slot. The distnce between the sensor nd the perforted disk should be bout 3 mm (0.12 in). If you instll the sensor t the bottom of its slot, the sensor will detect only hlf of the perfortions it should normlly detect. This will generte n error the next time the ncelle opertes in utomtic mode. 55. Return the mnul overrides of vlves SV4 nd SV6 to their originl position nd verify tht the brke is on. 56. Close the sfety pnels. 114 Festo Didctic 88765-00
Ex. 2-2 Gerbox, Coupling, nd Alignment Conclusion Result of the lignment 57. Ask everyone to remove their individul pdlock nd tg. Next, remove the hsp from the min switch. 58. Restrt the triner nd compre the vibrtion level to wht you hd before the lignment. Tell your instructor bout ny unusul sitution. Note your observtions below. 59. Hve you succeeded in diminishing the vibrtion level? Yes No End of the procedure 60. Perform finl system shutdown. 61. Clen the re nd, more specificlly, the pn nd the funnel tht were used to chnge the gerbox oil. CONCLUSION In this exercise, you becme fmilir with the high-speed prt of the drive trin system between the gerbox nd the genertor. More specificlly, you checked gerbox temperture t rest nd during opertion, nlyzed vibrtion on the gerbox, chnged the gerbox oil, nd ligned the shfts. REVIEW QUESTIONS 1. When should you chnge the oil of gerbox? 2. Wht re the two elements supporting the gerbox on the ncelle trining system? Festo Didctic 88765-00 115
Ex. 2-2 Gerbox, Coupling, nd Alignment Review Questions 3. Wht is the speed of the high-speed shft of the trining system if the lowspeed shft is running t 40 RPM? 4. Why is there thermocouple ttched to the gerbox? 5. Which type of mislignment is corrected by plcing shims under the front feet of the genertor? 116 Festo Didctic 88765-00