Brushless Exciter Alignment

• Brushless exciter alignment begins with the exciter rotor sitting in the shipping
brace in place supporting the rotor.
• Have the shaft sitting on the shipping brace with metal to metal contact and not
on gasket material or brass stock.
• Check exciter for any added shims under the bearing pedestal and remove any
added or excess shims.
o The bearing pedestal is normally sitting on a sheet of insulating material
like G-11. In some instances a single shim was added during
manufacture. The single shim is approximately the size of the insulating
material under the bearing pedestal.
o It is not uncommon to find various sizes and shapes of shims under the
bearing pedestal where people have attempted to correct exciter to
generator alignment by shimming the bearing pedestal and not shimming
between the exciter frame and the sole plate. Remove the added and
usually incorrect size shims between the bearing pedestal and the
insulation.
• Remove the outer oil seal (EE) on the bearing pedestal if it has not already been
removed.
• Clean the oil seal surface on the bearing pedestal and the opposite surface on
the fan hub.
• Use an inside micrometer on the top and bottom of the gap between the bearing
pedestal oil seal surface and the fan hub to determine that the shaft is
perpendicular to the bearing pedestal and hence, parallel to the exciter base. The
ratio of shim change under the shipping brace to gap is roughly 10 to 1. For
every 10 mils of shim under the shipping brace there will be about 1 mil of gap
change between the bearing pedestal and the fan hub.
• Shim between the shipping brace and the exciter frame to achieve making the
rotor parallel to the exciter base and perpendicular to the bearing pedestal.
• Check and adjust if necessary the clearances between the rotor windings and the
stationary poles.
o In cases where shims were added under the bearing pedestal it is also
likely that shims were added under the exciter stator to maintain
symmetry.
• Run a tap through the jack bolt holes.
o There are usually three or four per side depending on the size of the unit.
• Install jack bolts.
• Rig and set brushless exciter in place on sole plate behind generator.
o Match marks on generator and exciter rotor up.
• Align exciter to generator using jack bolts for elevation.
o A straight edge across the generator and exciter couplings can be used
across to determine correct elevation for the exciter.
o Check side to side level of the exciter with a bubble level.
• Once the exciter coupling is at the same elevation as the generator rotor, use
jack bolts to slide the exciter rotor onto the spigot fit of the generator.
• Align the exciter using feeler gauges between the generator and exciter
coupling face.
o Even on the sides.
o Open on the bottom .003 or 0.004. (Original design called for -0.000 to
+0.001 to assure that exciter bearing would not be unloaded in
operation.)
• When correct exciter base elevation is attained, measure gap and install Quick
Shims (Or equivalent) around each of the 6 or eight hold down bolts.
• Back off jack bolts.
• Check elevation by checking coupling gap.
• Check for soft foot at each hold down bolt. For any deflection over 0.002, add
appropriate shims.
• Check coupling gap to assure alignment.
o Make any changes necessary.
• Use tool to slide top coupling sleeves in towards generator coupling.
• Put a light coat of turbine oil on coupling bolts and install top bolts. Snug one or
two.
• Unbolt and remove shipping brace.
• Use tool to slide bottom coupling bolt sleeves in towards generator coupling.
• Install bottom coupling bolts and snug all coupling bolts.
• Using alternating pattern, tighten all coupling bolts to 100 foot pounds.
• Using alternating pattern, tighten all coupling bolts to 200 foot pounds.
• If possible put unit on turning gear if the generator has not been rolled for an
extended period of time.
• Take the unit off turning gear.
• Install blank in the oil supply line.
• Remove bearing pedestal cover.
• Remove top half of bearing.
• Install dial indicator on top of shaft and lift shaft 0.010 using crane or jack
under shaft.
• Roll out bottom half of bearing.
• Support shaft with strap using crane or install bracket to support shaft.
o This is a good time to megger the bearing pedestal for the last time.
• Lower the shaft to the running position.
• Install dial indicator at horizontal point in the vicinity of bearing journal.
• Provide an oil supply to the journal support and put the unit on turning gear.
o This can be a drip can or just someone keeping a small amount of oil on
the shaft support by hand.
• Put the unit on turning gear and observe dial indicator on the horizontal plane.
• You are going to try to tighten the coupling bolts and achieve a zero run out on
the shaft at the journal.
• Tighten bolts as required to “pull” high places in and minimize run out. This
will probably mean that the bolts are not tightened equally. This is okay. The
goal is to achieve zero run out, not equally tightened coupling bolts.
• Continue tightening coupling bolts until 1,250 foot pounds is achieved or as
close as possible while maintaining zero run out or deflection on the horizontal
dial indicator.
o It is better to be slightly loose as opposed to over tightened and pulling a
gall between the bolt head and the coupling.
• The exciter rotor can exhibit a double high spot on one or both poles due to the
shape of the generator rotor. This double deflection can be ignored if a
resolution is not readily seen.
• The goal is to achieve zero deflection. The instruction book calls for a
maximum of 0.005 TIR.
• Once the coupling bolts are tightened, roll the lower half of the bearing back in.
• Have the thermocouple wires connected.
• Install the bolts on the internal main leads.
• Continue with exciter reassembly.