VM3.12 Measuring Chains with LIN-300 Signal Conditioner

VM3.12 Measuring Chains with LIN-300 Signal Conditioner Front End Installation Manual (P/N: 9428-25I4A-300) Applies to measuring chain model : LIN-331-15Q-2/20 This manual divides into the following sections: Section 1: Overview of the AGMS Measuring Chains Section 2: Installation of the VM3.12 Air Gap Capacitive Sensors Section 3: Installation of the Triaxial Cable for the VM3.12 Sensor Section 4: Installation of the Protection Box 14 x 12 x 8 Section 5: Installation of the LIN-300 Series Module Section 6: Installation of the Synchronization Probe Section 7: Commissioning of the AGMS - Air Gap Monitoring System Section 8: Data Sheets: VM3.12 Sensor LIN-331-15Q-2/20 Module Synchronization Probe Copyright VibroSystM Inc., 2007 VM3.12 Measuring Chains with LIN-300 Signal Conditioner_Table of Contents_Rev. 0 1

TABLE OF CONTENTS 1. OVERVIEW OF THE AGMS (AIR GAP MONITORING SYSTEM) MEASURING CHAINS 2. INSTALLATION OF THE VM3.12 AIR GAP SENSOR 2.1 Preliminary considerations... 5 2.1.1 Supplies needed... 6 2.2 Preparation of Stator Surface... 6 2.3 Installation of the VM3.12 Sensor... 6 2.4 Application of Silicone... 7 3. INSTALLATION OF THE TRIAXIAL CABLE FOR THE VM3.12 3.1 Preliminary considerations... 9 3.2 Installation of the triaxial cable... 10 3.2.1 Supplies needed... 10 3.2.2 Tools needed... 10 3.2.3 Step 1) Installation of the protective conduit... 10 3.2.4 Step 2) Connection of the triaxial cable... 12 3.2.5 Step 3) Grounding and fastening the cable... 13 4. INSTALLATION OF THE 14x12x8 PROTECTION BOX 4.1 Preliminary considerations... 16 4.2 Installation of the Protection Box... 17 4.2.1 Supplies needed... 17 4.2.2 Tools needed... 17 4.3 Preparing the holes for the liquidtight connectors and grounding assembly... 18 4.4 Fastening the protection box... 20 4.5 Grounding the protection box... 22 5. INSTALLATION OF THE LIN-300 SERIES MODULES FOR AIR GAP SENSORS 5.1 Preliminary considerations... 23 5.2 Installation of the protective conduit... 24 5.3 Installation the extension cable (Power Input and Signal Output)... 24 5.3.1 Supplies needed... 24 5.3.2 Tools needed... 24 5.3.3 Preparation of a field-assembled extension cable... 25 5.4 Cable connections to the LIN-300 module... 26 5.4.1 Connection of the Triaxial Cable... 26 5.4.2 Connection of the extension cable (Power and Output)... 27 5.5 Verification... 27 6. INSTALLATION OF THE SYNCHRONIZATION PROBE 6.1 Preliminary considerations... 28 6.2 Installation of the synchronization probe... 29 6.2.1 Supplies needed... 29 6.2.2 Installation of the synchronization cable... 30 Copyright VibroSystM Inc., 2007 VM3.12 Measuring Chains with LIN-300 Signal Conditioner_TOC ii

6.2.3 Installation of the synchronization probe... 30 6.2.4 Connection of the Synchronization Cable to the Synchronization Probe... 31 6.2.5 Installation of the Target... 34 6.2.6 Verification and adjustment of the Synchronization Probe... 38 7. COMMISSIONING OF THE LIN-300 AIR GAP MONITORING SYSTEM 7.1 Visual inspection of all the measuring chains... 40 7.2 Visual inspection of the synchronization probe... 42 7.3 Power up of the ZPU... 44 Copyright VibroSystM Inc., 2007 VM3.12 Measuring Chains with LIN-300 Signal Conditioner_TOC iii

1. OVERVIEW OF THE AGMS (AIR GAP MEASURING SYSTEM) MEASURING CHAINS BASED ON LIN-300 SERIES CONDITIONERS Power Supply & 10 m [32.8 ft] - standard or 15m [49 ft] - option Figure 1 : Typical installation of measuring chains with a ZOOM Processing Unit (ZPU) data acquisition instrumentation Copyright VibroSystM Inc., 2007 LIN-300 Series Measuring Chains_Overview - Rev. 0 4

2. INSTALLATION OF THE VM3.12 AIR GAP SENSOR 2.1 Preliminary considerations Air gap sensors must be installed as symmetrically as possible around the stator wall. The length of the integral coaxial cable of the sensor, 50 cm (19.7 in) limits the depth at which the sensor can be glued, since the connector must remain on top of the stator at all times. The sensors must be glued against the stator wall at a position where they will face the plane area of the rotor poles, usually beneath the second ventilation hole. The cable attached to the sensor must also be glued tight against the wall of the stator. It is important to note that in hydrogen-cooled turbogenerators, the use of silicone and PVC must be avoided. A physical location on the stator will serve as a reference to determine where to install the sensors. Usually, the first sensor is installed at 0 upstream. Other sensors are then installed symmetrically around the stator wall, all facing a similar reference location in between poles. Figure 2 : Sensors aligned to their reference location Handle the sensor with great care. Never pull on the coaxial cable or on the connector. Do not apply paint or silicone on the sensor sensing surface. Copyright VibroSystM Inc., 2007 VM3.12 Air Gap Capacitive Sensor_Installation_Rev.4 5

2.1.1Supplies needed clean dry cloth fine sandpaper (with non metallic particles) a sensor installation kit including: - glue (Loctite 330) and its activator (Loctite 7387) or equivalent - silicone (3145RTV) or equivalent Figure 3 : VM 3.12 installation supplies 2.2 Preparation of Stator Surface It is imperative that the stator surface be thoroughly cleaned before the sensor can be glued on to it. This step must not be neglected as sensor adherence depends on the preparation of the surface. 1. After choosing the location where the sensor should be installed, run a clean dry cloth over the stator surface to remove oil and carbon deposits. 2. Run fine sandpaper on the stator surface, straight along the laminations. Make sure non-metallic paper is used. 3. After sanding, clean the stator surface again with a dry cloth. Make sure that none of the laminations sticks out since the sensor must be glued against a flat surface. 2.3 Installation of the VM3.12 Sensor The glue bonds and sets quickly. Stator and sensor preparation must be completed before applying the glue. Handle the glue with care to avoid skin contact. Take precautions to prevent the sensor from falling into the air gap. Copyright VibroSystM Inc., 2007 VM3.12 Air Gap Capacitive Sensor_Installation_Rev.4 6

Figure 4 : Lateral view of VM 3.12 sensor installed below second ventilation hole 1. If necessary, clean the back of the sensor with a clean dry cloth. 2. Apply glue on the back surface of the sensor. Spread glue to a thin and even coat, which will not run down when the sensor is pressed against the stator. 3. Apply the catalyst over the glue on the sensor. 4. Position sensor on the clean surface of the stator. The top of the sensor must face the plane area of the rotor poles, usually beneath the second ventilation hole. 5. Pivot sensor slightly in order to spread the glue evenly and then reposition vertically. Hold in straight position for 60 seconds. 6. Temporarily fasten the sensor cable with adhesive tape so that it does not hang into the air gap or gets pulled inadvertently. 2.4 Application of Silicone When applying silicone, keep the face of the sensor free of any trace of silicone. DO NOT APPLY SILICONE IN A HYDROGEN-COOLED ENVIRONMENT. Copyright VibroSystM Inc., 2007 VM3.12 Air Gap Capacitive Sensor_Installation_Rev.4 7

1 2 1. Apply a fine bead of silicone around the sensor edges to prevent dirt and particles accumulation around and behind the sensor. It also protects the sensor edges from deterioration. 2. Apply silicone on the sensor cable to keep it tight against the wall of the sensor. Figure 5 : Application of silicone Copyright VibroSystM Inc., 2007 VM3.12 Air Gap Capacitive Sensor_Installation_Rev.4 8

3. INSTALLATION OF THE TRIAXIAL CABLE FOR LIN-300 SERIES MODULES 3.1 Preliminary considerations This triaxial cable links VM Series sensors to LIN-300 Series Modules. Installation of this cable usually follows that of the sensor. Before installing the triaxial cable, it is important to determine where the protection box (usually containing two LIN Modules) will be installed, keeping in mind that the maximum length of the standard triaxial cable is 10m [33ft]. A longer 15m [49 ft] triaxial cable is available as an option. The cable must be protected by a combination of semi-rigid or flexible conduit and heat-shrinkable tubing. Figure 6 : Detailed view of triaxial cable terminations Figure 7 : Triaxial cable terminations The flexible conduit runs from the protection box to the top of the stator wall near the sensor connections. A heat-shrinkable tubing must be placed over the SMA connection to prevent accidental short-circuits between SMA connector and metalic parts such as flexible conduit, stator frame, etc. On top of the stator wall up to the edge of the air gap, a length of tubing protects the triaxial cable and its connection to the sensor. A 90 3/8 elbow adaptor connects the flexible conduit to the tubing and serves as an exit point for the ground wire located on the sensor side of the triaxial cable. Figure 8 : Protective tubing, elbow adaptor,ground wire Copyright VibroSystM Inc., 2007 Triaxial Cable for LIN-300_Installation_Rev.0 9

Cable clamps must be used to secure protective conduits, triaxial cable, tubing, ground wires, etc. This step of the installation must be done with care to prevent early damage from abrasion and wear to conduits, triaxial cable, and grounding wire. Figure 9 : Protective conduit secured with cable clamps The protective tubing supplied with the intallation kit must be installed as close to the stator (ground potential) as possible to avoid disrupting the equipotential. 3.2 Installation of the triaxial cable 3.2.1 Supplies needed triaxial cable watertight connector 90 3/8 elbow 3/4 to 3/4 coupling 3/4 to 1/2 reducer rigid or flexible conduits heat-shrinkable tubing nuts for grounding stud protective tubing 3.2.2 Tools needed assorted drill bits and taps heat gun cutters or saw for protective tubing fish-tape standard wrench set screwdriver (flat or Philips # 2) Copyright VibroSystM Inc., 2007 Triaxial Cable for LIN-300_Installation_Rev.0 10

3.3 Installation of the protective conduit Protection tubing with integral and extension cables must be correctly installed and seated directly on the stator core to avoid disrupting the equipotential. 1. Determine the run of the flexible conduit, from the protection box to the location of the elbow. Always keep in mind the maximum length of the triaxial cable. 2. Unroll the flexible conduit following the planned course of the triaxial cable. Cut the conduit to desired length. 3. With a fish-tape, carefully pull the triaxial cable into the conduit. Notice the direction of the cable: the female SMA connector must be end up on the sensor side. Figure 10 : Installation of protective tubing 4. Assemble the elbow at the end of the flexible conduit. Don't tighten the connection yet. The sensor installation kit contains all the parts needed for this assembly. At the protection box end, the flexible conduit will be terminated by a watertight 19mm (3/4") connector. Figure 11 : Elbow assembly Copyright VibroSystM Inc., 2007 Triaxial Cable for LIN-300_Installation_Rev.0 11

5. Cut a section of plastic tubing to the desired length. Make sure the tubing does not stick out into the air gap. This tubing can be heated and lightly bent to adapt to the stator contour. 3.4 Connection of the triaxial cable The triaxial cable is calibrated and must never be cut or altered. 1. Insert the triaxial cable into the conduit and push it slightly beyond the connection leaving enough space to complete the connection. 2. Slide the heat-shrinkable tubing onto the sensor end of the triaxial cable near the connector. 3. Attach the SMA threaded plug from the sensor cable to the SMA jack at the end of the triaxial cable. Use pliers to tighten the connection firmly. Copyright VibroSystM Inc., 2007 Triaxial Cable for LIN-300_Installation_Rev.0 12

4. Slide the heat-shrinkable tubing over the connection and heat with a heat gun. The heat-shrinkable tubing must cover the whole SMA connection to ensure insulation and secure the connection. 5. Gently pull the connection inside the tubing, just enough to straighten the cable and eliminate slack. Do not add stiffness to the cable. Figure 12 : SMA connection inside the protective tubing 3.5 Grounding and fastening the cable Before proceeding to the next step, pull the ground wire out of the elbow through the opening near one of the screws. 1. Once the cable has been straightened inside the tubing, you can permanently fit together the parts of the elbow. In the resulting assembly, the tubing must be solidly clamped inside the elbow, with the grounding wire sticking out. Adequate installation of the ground wire to the grounded structure is essential for reliability of results. Copyright VibroSystM Inc., 2007 Triaxial Cable for LIN-300_Installation_Rev.0 13

2. Within reach of the ground lug, drill a hole and tap it in the stator casing. 3. Attach the ground lug with a screw. 4. The sensor cable must be glued and secured against the stator wall with silicone, from the top of the sensor to the edge of the protective tubing. 5. To prevent cable deterioration, and dust and debris from entering, apply silicone inside the tubing to form a plug. Figure 13 : Attaching the grounding wire 6. As the triaxial cable is calibrated and cannot be cut, any surplus length of cable must be pulled back and stored inside the protection box. At this stage, installation of the sensor and its triaxial cable is almost complete. Make sure that all components are firmly secured with cable clamps. Figure 14 : Surplus cable stored in a protection box containing LIN-200 modules A Clamp kit has been added to complete the installation kit of the above mentioned measuring chains. The clamps will be used to secure the protective tubing and the coupling firmly against the installation surface to make sure they remain flat and immobile. The Clamp kit is comprised of: Clamps for 1 conduits Clamps for 3/8 conduits Flat washers ¼ Spring lockwashers ¼ Hexagon cap screws ¼ - 20 x 5/8 Copyright VibroSystM Inc., 2007 Triaxial Cable for LIN-300_Installation_Rev.0 14

1. Drill holes according to Figure 15 : Attaching the cable clamps. Figure 15 : Attaching the cable clamps 2. Secure the protective tubing and the coupling. Figure 16 : Securing the protective tubing and coupling Protection tubing with integral and extension cables must be correctly installed and seated directly on the stator core to avoid disrupting the equipotential. Copyright VibroSystM Inc., 2007 Triaxial Cable for LIN-300_Installation_Rev.0 15

4. INSTALLATION OF THE 14x12x8 PROTECTION BOX 4.1 Preliminary considerations The standard protection box is a watertight, dust-tight and corrosion-resistant metal enclosure that protects the electronic components of the acquisition units. Outer dimensions are 356 x 305 x 203mm (14 x 12 x 8 in.). To prevent damage to the electronic components, always remove the mounting panel before working on a protection box. Note: Except for the ground wire, all connected cables must be protected by flexible protective conduits and attached with liquidtight connectors. Prepare the openings on the protection box and set the liquidtight connectors in place before fastening the protection box. Figure 17 : Front view of the 14x12x8 protection box To determine the best location for the protection box, survey all potential locations with respect to the following limitations: The protection box must be installed within the appropriate distance according to the specifications of the components mounted inside; All cables should be placed inside 19mm (3/4 ) flexible protective conduits or equivalent when possible; Sufficient space must be allowed around the protection box for the installation of the protective conduits; Sufficient clearance is necessary to open the door for easy access of components. Figure 18 : Suitable location for a protection box Copyright VibroSystM Inc., 2006 Protection box 14 x 12 x 8 _Installation_Rev. 4 16

4.2 Installation of the Protection Box 4.2.1 Supplies needed Figure 19 : Protection Box -Installation kit (4) 3/4 flexible conduit liquid tight connectors (2) hex machine screw nuts 1/4-20 (6) spring lockwashers 1/4 (4) tooth lockwashers 1/4 (5) bolts 1/4-20 x 5/8 (1) bolt 1/4-20 x 1-1/4 (4) concrete anchors (2) copper lugs (1) ground copper wire (5m) (2) liquidtight strain relief connector (2) nylon locknuts 3/4 (2) rubber adapters for liquidtight strain relief connectors 4.2.2 Tools needed Drill bits 5mm (13/64 ) and 8mm (5/16 ) Tap drill 1/4-20 Hammer drill Drill Concrete drill bit 8mm (5/16 ) Punch Ratchet set 3/4 conduit hole saw or knockout punch set for 3/4 liquidtight fittings The installation of the protection box involves three main steps: 1. Preparing the holes for the connectors and grounding assembly; 2. Fastening the protection box; 3. Grounding the protection box. Copyright VibroSystM Inc., 2006 Protection box 14 x 12 x 8 _Installation_Rev. 4 17

4.3 Preparing the holes for the liquidtight connectors and grounding assembly 1. As a precaution before drilling the protection box, remove the mounting panel to prevent metal particles infiltration. Do not misplace the anti-vibration rubber mounts added to the mounting panel assembly. Figure 20 : Removing the mounting panel and anti-vibration mounts 2. Drill a grounding hole inside the protection box according to Figure 21 : Typical location for inner grounding wire. Figure 21 : Typical location for inner grounding wire Copyright VibroSystM Inc., 2006 Protection box 14 x 12 x 8 _Installation_Rev. 4 18

To determine the location for the holes, keep in mind the components on the mounting panel. Make sure the components will not get in the way of the connectors once the mounting panel is reinserted. 3. After visualizing the routing of all cables, drill holes for the liquidtight connectors. Refer to Figure 22 : Mounting the liquidtight connectors. 4. Install the connectors. Figure 22 : Mounting the liquidtight connectors When using conduit other than the 19mm (3/4 ) conduit, use the appropriate liquidtight strain relief connectors according to the size of the cable. 5. Drill holes for the appropriate liquidtight strain relief connectors. Refer to Figure 23 : Mounting the liquidtight strain relief connectors. 6. Install the connectors. 7. Reinsert the mounting panel. Figure 23 : Mounting the liquidtight strain relief connectors Copyright VibroSystM Inc., 2006 Protection box 14 x 12 x 8 _Installation_Rev. 4 19

4.4 Fastening the protection box Choose the location for installing the protection box. The protection box can be mounted on a concrete wall or, whenever possible, directly onto the structure of the stator or machine casing. Figure 24 : Mounting holes template Mounting a protection box on the stator or machine casing: 1. Drill and thread into the structure according to Figure 25 : Fastening the protection box on steel. 2. Fasten the protection box. Figure 25 : Fastening the protection box on steel Copyright VibroSystM Inc., 2006 Protection box 14 x 12 x 8 _Installation_Rev. 4 20

Mounting a protection box on concrete: 1. Drill into the concrete wall and drive the anchor bolts according to Figure 26 : Fastening the protection box on concrete. Figure 26 : Fastening the protection box on concrete 2. Use a punch to fix the concrete anchor permanently according to Figure 27 : Punch for concrete anchors. 3. Fasten the protection box. Figure 27 : Punch for concrete anchors Copyright VibroSystM Inc., 2006 Protection box 14 x 12 x 8 _Installation_Rev. 4 21

4.5 Grounding the protection box Grounding is essential for protection against hazardous voltage as well as for system operation integrity. For best grounding, provide the shortest path possible between the protection box and the grounded structure. 1. Drill and tap a hole in a grounded structure. Make it as close as possible to the 6mm (1/4 ) hole in the bottom of the protection box. 2. Fasten the AWG #8 copper wire to the structure according to Figure 28 : Fastening the ground wire to grounded structure. Figure 28 : Fastening the ground wire to grounded structure 3. Cut the copper wire and fasten it to the outside of the protection box as shown in Figure 29 : Fastening the grounding wires to the protection box. Figure 29 : Fastening the grounding wires to the protection box Copyright VibroSystM Inc., 2006 Protection box 14 x 12 x 8 _Installation_Rev. 4 22

5. INSTALLATION OF THE LIN-300 SERIES MODULES FOR AIR GAP SENSORS 5.1 Preliminary considerations Figure 30 : LIN-300 Series module The LIN-300 Series modules are signal conditioning units designed to process the raw output signal originating from air gap sensors. The raw signal is sent from the sensor to the LIN-300 module through a triaxial cable with a SMA connector. Input power and output signal are both carried through an extension cable with a M12 connector. The module delivers a 4 to 20 ma linearized raw air gap output signal which can be used by AGMS and ZOOM systems, a PCU-100 Programmable Monitor, or third-party instrumentation. The LIN-331 processes a signal from the VM3.12 sensor LIN-300 modules are installed in pairs on a mounting plate enclosed in a wall-mounted protection box. +24 VDC power input is required to power up the LIN-300 modules. The LIN-300 conditioner usually connects to the XPSP Series Power Supply through the M12 extension cable. The length of the standard M12 extension cable is 30m (100 ft.). This cable is rated for a maximum operation temperature of 80 C (176 F). Since this cable is not calibrated, it can be cut. The cable should be protected by flexible or rigid conduit. Figure 31 : Pair of LIN-300 Series modules inside a protection box The installation of the LIN protection box, power and signal output cables and triaxial cables from the sensors should be completed before proceeding to the connection of the LIN-300 modules. Copyright VibroSystM Inc., 2007 LIN-300 Series Modules_Installation_Rev. 0 23

5.2 Installation of the protective conduit 1. Determine the run of the protective conduit, from the flange protection box to the location of the cabinet. Unroll the flexible conduit following the planned course of the cable. Cut the conduit to desired length. Cable clamps must be used to secure protective conduits. The maximum length of the cable from LIN-300 signal conditioner to instrument is 100m (330 ft.). With a fish-tape, carefully pull the cable into the conduit. Notice the direction of the cable: the connector must be placed on the LIN-300 signal conditioner side. Any surplus length of cable may be cut or pulled back and stored inside the protection box or cabinet. 5.3 Installation the extension cable (Power Input and Signal Output) to the LIN-300 Module 5.3.1 Supplies needed M12 extension cable (standard M12 or field-assembled) rigid or flexible conduits (not shown) cable clamps (not shown) Figure 32 : Preassembled M12 extension cable 5.3.2 Tools needed assorted drill bits and taps cutters or saw for protective tubing fish-tape wire-stripper wrench Copyright VibroSystM Inc., 2007 LIN-300 Series Modules_Installation_Rev. 0 24

5.3.3 Preparation of a field-assembled extension cable using Belden cable and M12 connector Wiring Side View The pin-out of the M12 connector is shown in Figure 33 : M12 Female Connector for field assembled extension cable - wiring assignment and Table 1: Extension cable pin-out. Figure 33 : M12 Female Connector for field assembled extension cable - wiring assignment Figure 34 : Connector assembly 1. Slip the various parts on the cable: pressure screw, retaining ring, clamp gasket, sleeve gasket with its rubber o-ring, and socket housing. 2. Strip 35 mm off the external sheathing of the cable. 3. Push shielding braid back. 4. Remove foil and nylon thread (under the shielding braid). 5. Strip 5 mm off the insulation of the wires. Install the wires to the female connector the pin-out table, push together and fasten all housing components. Copyright VibroSystM Inc., 2007 LIN-300 Series Modules_Installation_Rev. 0 25

Table 1: Extension cable pin-out Pin # Standard 30 m (100 ft.) pre-assembled M12 cable #9940 Belden* cable for field assembly Designation 1 Brown Red Power supply +24 VDC 2 White White Signal Output (I OUT ) 3 Blue Green Common (GND) 4 Black Black - Note*: the #9940 Belden cable may be replaced with any cable with similar characteristics. 5.4 Cable connections to the LIN-300 module To prevent damage to the LIN module and avoid risk of injuries: If the connection has already been completed at the other end of the power and output cable, make sure the power is turned off at the source before proceeding. 5.4.1 Connection of the Triaxial Cable 1. Insert the SMA male connector and engage by turning clockwise. 2. Insert the tooth lock washer, the round lug, the spring lock washer and the nut onto the grounding bolt. Screw the nut firmly to ensure the grounding connection. WARNING! The ground lug must never come in contact with the SMA connector or M12 connector. Figure 35 : Triaxial cable connected to a LIN-300 Series module Copyright VibroSystM Inc., 2007 LIN-300 Series Modules_Installation_Rev. 0 26

5.4.2 Connection of the extension cable (Power and Output) 1. Insert the M12 connector and engage by turning clockwise. 2. Insert the tooth lock washer, the round lug, the spring lock washer and the nut onto the grounding bolt. Screw the nut firmly to ensure the grounding connection. WARNING! The ground lug must never come in contact with the SMA connector or M12 connector. Figure 36 : Power and Signal output cable (right) connected to a LIN-300 Series module 5.5 Verification Output Signal Values The output is a provide linear current throughout the measuring range. The distance value expressed in mm or in mil is obtained by applying one of the following transfer formulas: LIN-331: D mm = (I output - 2,222) /0,889 over 4-20 ma output D mil = (I output - 2.222) /0.0226 over 4-20 ma output Copyright VibroSystM Inc., 2007 LIN-300 Series Modules_Installation_Rev. 0 27

5.6 LED functionality A colored LED provides a visual clue to the status of the LIN-300 Series signal conditioner. A green pulse (one brief flash per second) indicates normal operation (Status OK). The LED turns red and repeats a sequence of pulses to indicate an error condition: Error condition # 1 : the LED turns on for one second, followed by one brief flash, to indicate that the sensor is either not connected or the distance to the target is beyond the maximal detection range Error condition # 2 : the LED turns on for one second, followed by two brief flashes, to indicate that the distance to the target is below the minimal detection range. Copyright VibroSystM Inc., 2007 LIN-300 Series Modules_Installation_Rev. 0 28

6. INSTALLATION OF THE SYNCHRONIZATION PROBE 6.1 Preliminary considerations The synchronization probe is an inductive proximity sensor that detects a target glued on the shaft. Once every rotation, the target crosses the synchronization probe and a pulse is sent to the acquisition unit(s). This signal serves as a reference to correlate measurements obtained from all the air gap sensors installed around the stator wall. Mounting the synchronization probe and target requires precision, because the target must be detected at the precise moment the middle of the interpole between the first and last poles faces upstream. Once installed, small tangential and/or radial adjustment of the synchronization probe is still possible by moving the probe on its lockable slide plate. The synchronization probe is installed close to the shaft, preferably just above the turbine guide bearing cover. When installing the target on the shaft, the rotor should preferably be moved in the 0 upstream position. If the rotor cannot be moved, the relative distance between the target and the synchronization probe has to be calculated. Generators On units that rotate in a single direction, a single synchronization probe and target need to be installed. Figure 37 : Single synchronization probe installed Figure 38 : Two synchronization probes installed Reversible pump/storage units On reversible pump/storage units, two (2) synchronization probes and two (2) targets are needed. The two probes can be mounted on the same mounting bracket, as shown in the adjoining picture, each with its own target. The installation procedure for each probe is the same, except that one probe is installed for clockwise rotation, while the other is installed for counterclockwise rotation. Both probes send a signal to the acquisition unit, but only one signal is validated for the current rotation direction, through an internal relay that changes state depending on the rotation direction. Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 29

The synchronization probe can be installed at four levels: Pos. 1: Turbine Pos. 2: Lower Bearing Pos. 3: Upper Bearing Pos. 4: Exciter In most cases, it is best to install the synchronization probe at the turbine bearing level. Choose the safest and most accessible location for your installation. Figure 39 : Suggested locations for the synchronization probe 6.2 Installation of the synchronization probe 6.2.1 Supplies needed Kit for 1 synchronization probe: two (2) soft steel targets; two (2) 5/16-18 X 1-1/4 bolts, lockwashers and nuts one (1) protection cover for the connector one cable tie glue (Loctite 330) and its activator (Loctite 7387) or equivalent a synchronization cable (1-pair shielded AWG 22) or equivalent Other supplies: clean dry cloth an indelible felt pen flexible conduit kit Figure 40 : Synchronization probe installation kit Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 30

The installation of a synchronization probe is essentially divided into five steps: 1) Installation of the synchronization cable(s) 2) Installation of the synchronization probe(s) 3) Connection of the synchronization cable(s) to the synchronization probe(s) 4) Installation of the target(s) 5) Final adjustment of the synchronization probe(s) 6.2.2 Installation of the synchronization cable The synchronization cable connects the synchronization probe to one of the acquisition units located around the generator. There is one synchronization cable per synchronization probe. It is an approximately 30 meter (100 ft.) long shielded cable with one twisted pair. This cable must be mechanically protected by either a flexible or rigid conduit. The following instructions apply to flexible conduits: To run the synchronization cable, proceed as follows: 1. Determine the location of the synchronization probe and the acquisition unit enclosure to which the synchronization probe will be connected. 2. Determine the path that the flexible conduit must follow and cut it to length. 3. With a fish-tape, pull the synchronization cable through the conduit. 4. Fasten the flexible conduit with proper pipe straps to prevent any vibration. 5. Install a liquid tight connector on the acquisition unit side of the conduit and fasten the conduit to the acquisition unit enclosure. Install a liquidtight strain relief connector on the synchronization probe side of the flexible conduit. 6.2.3 Installation of the synchronization probe 1. The sensing face of the probe must be installed at a distance of 2 ± 0.5 mm from the target (80 mil ± 20 mil) or 5 mm (200 mil) from the shaft. A custom-made mounting bracket may have to be machined, as shown in the adjoining picture, to install the synchronization probe at the prescribed distance. Figure 41 : Probe installed on a custom mounting bracket Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 31

Figure 42 : Drawing of a two-piece mounting bracket 2. Drill two holes at the correct distance from the shaft according to the diagram on the left and thread these holes for the 5/16" x 18 bolts. 3. Fasten the probe with the supplied 5/16" - 18 X 1-1/4" bolts and lock washers. Figure 43 : Mounting holes for the synchronization probe 6.2.4 Connection of the Synchronization Cable to the Synchronization Probe 1. Cut the synchronization cable, leaving approximately 40 cm (16 in.), enough to form a loop. Figure 44 : Synchronization cable installation Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 32

Figure 45 : Synchronization cable (shielded cable with one twisted pair) Figure 7 illustrates the 3-screw terminal miniconnector with clip-on junction block fixed on the probe in order to minimize the risk of wire short and offer more flexibility in field use. The other end connected to the acquisition unit remains skinned with the three wires plugged into the terminal blocks labeled SYNCHRO. Table 2: Assembly of the Synchronization Cable Wire Function Terminal Block Number Shield Ground 1 Red or white + 5 V line 2 Black Synchronization signal 3 Figure 46 : Assembly of a miniconnector to the synchronization cable Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 33

2. Connect the cable to the synchronization probe as shown. Signal (Black) +V DC (Red) Ground (Shield) Figure 47 : Synchronization probe connector detail 3. Secure the loop with a cable tie and install the protective cover over the connector. Figure 48 : Completed installation of a synchronization probe Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 34

6.2.5 Installation of the Target Mounting the synchronization probe requires precision, as the target must be detected at the exact moment the middle of the interpole between the first and last poles (called P-1) faces upstream. To ensure precise position of the target, it is advisable to move the rotor so that the middle of the P-1 interpole is facing upstream. As shown on the left, when the P-1 interpole is facing upstream, the target is glued to the shaft next to the tip of the synchronization probe. Clockwise rotation: place the target to the right of the synchronization probe Counterclockwise rotation: place the target to the left of the synchronization probe Figure 49 : P-1 position on rotor is facing upstream If the P-1 interpole cannot be placed to face upstream, the position of the target must be calculated in relation to the synchronization probe. Figure 50 : P-1 position on rotor is not facing upstream Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 35

Suggested method of calculation for positioning the target Call distance d the relative distance between the edge of the target and the edge of the synchronization probe. To calculate d, use the following formula: d p P NP p : circumference of shaft (if only diameter D of the shaft is known, p = X D); P : total number of rotor poles; NP : number of poles from the interpole (P-1) to the upstream position (counting in the same direction of rotation); ex. : d = p x 18 24 If the upstream position does not correspond exactly to the middle of an interpole, a fraction will have to be added to the number of poles (NP) separating the interpole position (P-1) from the upstream position. This fraction corresponds to the distance between the upstream position and the middle of the last interpole, divided by the width of a pole plus an interpole. Glueing the target Handle glue with care to avoid skin contact. The glue bonds quickly (in 60 seconds). The surface preparation must be completed before applying glue. Take precautions to keep the target from falling into the generator. Figure 51 : Masking tape used to avoid losing the target in case of accidental drop 1. Clean the area where the target will be glued with a dry cloth. As a precaution, it is recommended to temporarily block, with masking tape, any opening into which the target may accidentally drop. 2. Move the synchronization probe so that it touches the shaft. With an indelible felt pen, mark the shaft where the edge of the target will reach the edge of the synchronization probe: edge of target to the right of synchronization probe if shaft turns clockwise, to the left if shaft turns counterclockwise. If the interpole (P-1) is not facing upstream, add the previously calculated distance d. Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 36

3. Spread a thin layer of the glue on the target (provided with the probe installation kit). If the instructions given here differ from those specified by the glue manufacturer, follow those given by the manufacturer. 4. Apply the catalyst over the glue spread on the target. 5. Position the target with precision in relation to the felt mark made on the shaft. Rotate the target to help spread the glue. Straighten it up and maintain it firmly in this position for 60 seconds. Figure 52 : Applying glue on the target 6. With the help of a filler gauge, adjust the distance between the sensing face and the shaft to 5 mm (200 mil). Since the target has a thickness of approximately 3 mm (120 mil), a gap of 2 mm ±0.5 mm (80 mil ±20 mil) should remain between the target and the sensing face. Figure 53 : Adjustment of the synchronization probe Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 37

7. Tighten the adjustment screws to lock the adjustable slide plate and set the probe in this position. Figure 54 : Final adjustment of the synchronization probe Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 38

6.2.6 Verification and adjustment of the Synchronization Probe This step is very important, as the adjustment of the synchronization probe determines the moment when the pulse is generated. This pulse serves as a reference to all measurements obtained. Therefore, the position of the probe must be very precise. Using the ZOOM software, take a sampling measurement and print an XY graph for the airgap sensor installed at the 0 upstream position. Case A) Pulse is sent at the correct moment 22 20 18 16 [AGMS - GENERATOR 1] XY graph - Sampling measurement The pulse corresponds to the precise moment when the sensor detects the middle of the space between the first and the last pole. No adjustment is required. 14 12 10 8 Correct 6 4 0 2 4 6 8 10 12 14 16 18 20 Time [ms] Ãß ª Õª ±Æ ± ø ± fl ª Æ ±Æ Õø Æª ø ª fl Æ ø flÿ Ÿª ªÆø ±Æ Ã± p ÛÛÛ Ë Ò Ó ÍÛ ÓÛÔÏ Ô VibroSystM Inc. ZOOM Application 5.2 Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 39

Case B) Pulse is sent too early 22 20 18 16 14 12 10 8 Not correct [AGMS - GENERATOR 1] XY graph - Sampling measurement The graph starts with the end of the passage of the pole preceeding the space between the first and the last pole. Solution: Loosen the adjustable slide plate and make a lateral adjustment in the same direction to that of the rotation. Note: An adjustment can also be effected by adding a delay in the ZOOM Configuration program. 6 4 0 2 4 6 8 10 12 14 16 18 20 Time [ms] Ãß ª Õª ±Æ ± ø ± fl ª Æ ±Æ Õø Æª ø ª fl Æ ø flÿ Ÿª ªÆø ±Æ Ã± p ÛÛÛ Ë Ò Ó ÍÛ ÓÛÔÏ Ô VibroSystM Inc. ZOOM Application 5.2 Case C) Pulse is sent too late 22 20 18 16 14 12 10 [AGMS - GENERATOR 1] XY graph - Sampling measurement The graph starts with the passage of the pole next to the middle of the space between the first and the last pole. Solution: Loosen the adjustable slide plate and make a lateral adjustment in the direction opposite to that of the rotation. 8 6 Not correct 4 0 2 4 6 8 10 12 14 16 18 20 Time [ms] Ãß ª Õª ±Æ ± ø ± fl ª Æ ±Æ Õø Æª ø ª fl Æ ø flÿ Ÿª ªÆø ±Æ Ã± p ÛÛÛ Ë Ò Ó ÍÛ ÓÛÔÏ Ô VibroSystM Inc. ZOOM Application 5.2 Copyright VibroSystM Inc., 2006 Synchronization Probe_Installation_Rev. 4 40

7. COMMISSIONING OF THE LIN-300 AIR GAP MONITORING SYSTEM This procedure divides into the following steps: Step 1) Visual inspection of the measuring chains installation Step 2) Visual inspection of the synchronization probe installation Step 3) Power up of the ZPU 7.1 Visual inspection of all the measuring chains (Refer to the Front end Installation sheets for more information) 1) The sensor: glued below the second ventilation hole of the stator glued in a vertical straight line 2) The coaxial cable of the sensor: fixed to the stator with silicone 3) The protective tubing: fixed with silicone on the sensor side and normally fixed to the stator plate with cable clamps on the other side 4) The black ground wire of the sensor: connected to the stator plate 5) The connections of the flexible or rigid conduits leading to the LIN protection box: all mechanical connections are tight 6) The installation of the protection box: the ground wire between the LIN mounting plate and Protection Box is tightly fastened the enclosures are tightly fastened to the chosen surface the Protection Box is grounded to the grounding grid of the power house 7) The triaxial cables connected to the LIN module: all mechanical connections are tight the ground wire on the triaxial cable is connected to the ground stud on the LIN Module SMA connector is connected to SMA of LIN Copyright VibroSystM Inc., 2007 Air Gap Monitoring System AGMS_Commissioning_Rev. 4 41

8) The connections of the triaxial cable from the LIN module to the acquisition/monitoring instrumentation: Pin number Color code Description 1 Brown Power supply +24VDC 2 White Signal output (Iout) 3 Blue Common (GND) 4 Black - Copyright VibroSystM Inc., 2007 Air Gap Monitoring System AGMS_Commissioning_Rev. 4 42

7.2 Visual inspection of the synchronization probe (Refer to the Synchronization Probe Installation Sheets for more information) 1) The target is glued to the generator shaft 2) The synchronization probe is positioned so that the proximity detector is 2 ± 0.5 mm (80-120 mils) from the target 3) The synchronization cable is connected to the probe 4) The protective cover of the connector is installed Signal (Black) + Vdc (Red) Ground (Shield) Figure 55 : Detail of synchronization probe terminals Figure 56 : Detail of synchronization cable Copyright VibroSystM Inc., 2007 Air Gap Monitoring System AGMS_Commissioning_Rev. 4 43

A) In this sampling graph, the synchronization probe is aligned properly. The synchronization probe sends one pulse per turn. The pulse is used as a reference to identify the beginning of a new rotation and the system starts recording measurements at that point. A good alignment is when the interpole of the first and last pole is facing 0 upstream as is represented by the arrow in the sampling graph below. Õø ŸÆø Û Ô Î fl Æ ø ÏÎ Ï ÌÎ Ì Ó Ï Í Ú ÎÓÚËÎ Ó ÏÒ ÓÒ Ï ÔÔÊÓÍÊÏ fl Ï fl Æ ø Æª ªÆ Ï Ÿª ªÆø ±Æ Ã± ÚÔ ª Ú ß Â ææ±õß Ú r fl ø ± Û ªÆ ± ÏÚ Ô ø ª Ô Figure 57 : Signal sent at correct moment B) In the following sampling graph, the synchronization probe is not aligned properly. The arrow clearly shows that the pulse is sent on the pole rather than when the interpole of the first and the last pole is facing 0 upstream. In a case such as this, the synchronization probe must be readjusted. Õø ŸÆø Û Ó Î fl Æ ø ÏÎ Ï ÌÎ Ì Ó Ï Í Ú ÏÈÚÈ Ó ÏÒ ÓÒ Ï ÔÔÊÓÎÊÓÓ fl Ï fl Æ ø Æª ªÆ Ï Ÿª ªÆø ±Æ Ã± ÚÔ ª Ú ß Â ææ±õß Ú r fl ø ± Û ªÆ ± ÏÚ Ô ø ª Ô Figure 58 : Signal sent too early Copyright VibroSystM Inc., 2007 Air Gap Monitoring System AGMS_Commissioning_Rev. 4 44

7.3 Power up of the ZPU 1. Open the fuse terminals at the ZPU before closing the voltage source circuit breaker in the control panel. 2. Verify voltage source: 1) The voltage between the live wire (black) and the neutral wire (white)* 2) The voltage between the live wire and the ground wire (green)* 3) The voltage between the neutral and the ground wire is 0Vac *voltage range from 90V-250Vac (47-63 Hz) or 110-330 VDC 3. Close the fuse terminals to power up the ZPU - Check voltages and LED 4. Verify the Synchronization probe signal 1) With a short wire, create a brief short circuit between the COM and the SIGNAL on the synchronization terminal (1 and 3). The green LED on the Synchronization card as well as the one on the CPU card should blink. 2) Remove the probe cover. Place a metallic object, such as a screwdriver, in front of the probe. The red LED on the back of the proximity switch should blink. 5. Take dynamic measurements (to do this, the machine should turn at nominal speed): 1) Take dynamic measurements in sampling mode. (1 measurement in 0.1 sec.) 2) Verify if the synchronization probe is well adjusted. If not, adjust it accordingly. (Refer to the Synchronization Probe Installation Module) 3) Take measurements in signature mode 4) Verify if the sensors are aligned 5) Take measurements in pole mode (at least one at maximum number of turns) 6) Verify that there is no loss of sensor signal during measurements Copyright VibroSystM Inc., 2007 Air Gap Monitoring System AGMS_Commissioning_Rev. 4 45

ÌÚÔ Ÿª ªÆø Õ ª ø ± Operation ø ø ± ª Æø øæ ª { ªøÆ ªø Æ Œø ª Ó ± Ó ø ºøÆº { ± ªÆ Õ± Æ ª ÏÎÎ µÿ { ÆªØ ª ß Œª ± ª ªº æß ª ÛÓÌÔ ªøÆ ø ± ±º ª { ªÆ ø ªøæ ß oî Ÿ ªº ± ø ø ± ø ø ± Rotor Pole ÌÚÔ Õª ±Æ ªº ª Õ ø ±Æ ±Æª Œ± ±Æ ± ª Õª ±Æ Environmental { Ãª ªÆø Æª Œø ª ± ÔÓÎ { ø ª ª º À ± ÔÚÎ ª ø Î ÿ ±Æ Í ÿ { ø º ± ø ø ± Õ ø ºª ± ø ª ± ª ª Ù ø æ ºÛ øß ø ª ªÆ ±Æ ø ª Dimensions Ã { ÿª ÓÓ ÚÎ { º ÌÌÚÓÎ { Ã µ ª ÔÚÈÈ { ªøÆø ª ÌÚÏ Õ Connection { ª Æø øæ ª Ãß ª Ãª ± ±ø ø Û ± ª ±Æ ø ª Õ fl Û ª Î Ú { ª ± øæ ª Ãß ª fiª ºª ÃÆ ø ø Û ± ª ±Æ ª ø ª Õ flø º Æ± º ± ª ±Æ ª ºÂ ø ª fi ±ø ø ø º Æ± º ± ª º Û ª ªºÙ Ô ææ±õß Æª ªÆ ª ª Æ ± ø ª ª ø ± ± Æ± ª Æ±º ± ± ø ± Ú x ø º flÿ Õx øæª Æª ªÆªº Æøºª øæµ ± ææ±õß Ú ø ª ªº ªø Æ ª ± ± ß Published: ËÁÚ ÁÚÓÔ Revised: ÏÚÔÓÚ È ÿªøº ª P ÓÈÓÈ ø Ø ª Û øæ ªÆ Ú fi º ± ª œ ªæª ø øºø Ï Ô È ± ªÊ ÏÎ ÍÏÍÛÓÔÎÈ ÔÛË ÛÍÍÌÛËÌÈÁ ÀÚÕÚ ± Æªª ø Ê ÏÎ ÍÏÍÛÓÔÍÏ Û ø Ê ø ª ææ± ß Ú ± Web: www.vibrosystm.com

Õß Æ± ø ± Æ±æª ÔÒÆª Ú Œª ªÆª ª fl ø ± { Æ± ºª ± ª ªÒÆª Ú Æª ªÆª ª ± ß Æ± ª ºø ø ø Ø ± ª Æ ± Ã ª Õß Æ± ø ± Æ±æª ø º ª ºª ª ø ø ± ø ªº øæ ª Ú Æ± ºª ø ± ª ªÒÆª Ú Æª ªÆª ª ± ß Æ± ª ª ºø ø ø Ø ± ± ºß ø Æ± ø ª ªÆø ±Æ ±Æ ø Æ± ø ø ªÚ Ã ª Æ±æª ø ªº ø ª ø ø º øæ ª ± ªº ± ª Æ± ø øæ Ú ª ª Æ±æª ºª ª ª ø øæ ª Ù Æø ø ª ø ± ø ± ª ªº ø Ø ± Ú Ã ª ø ø æª øæªº ø ± øæ ± ø Ø ± Ú Ã ª Õß Æ± ø ± Æ±æª ø æª ªº flÿ ÕxÙ x ø º ææø ø ß ª Ú { Ÿª ªÆø ±Æ Ê Ô Õß Æ± ø ± Æ±æª ø º Ô øæ ª { Û ª ªÆø ±Æ Ê Ó Æ±æªÛ øæ ª ø Æ Ù ± ª ±Æ ± µ ª ø º ± ª ±Æ ± ªÆ ± µ ª Æ± ø ± ªø Æª { Æ± ß { ø ß ± ø ± ø ª ø ø ß æª ± ª ªÆø ±ÆÂ ª ªÆ ø ª { ª øº ª ø øæ ß { ø æª ªº flÿ ÕxÙ x ø º ææø ø { Û ª ªÆø ±Æ µ Ê Ó ø Æ ± Æ±æª ø º øæ ª Ù ± ª ±Æ ªø Æ± ø ± ø º Æª ± { Õ ª ø ±ºª ø ø øæ ª ±Æ ßºÆ± ª Û ±± ªº ø ª ª ± ÔÍ ± ª ±Æ ø ª ÃªÆ ø ËÔ ÓÓ ÌÍ ÈÍ ÃøÆ ª ± Õ ø Õ ªÊ Ó Ô ÌÚÓ ± ª ±Æ ª ø ª ± µª Æ±æª flº ª Õ Æª ÍÌÚÎ Ô Ë ±Æ ø ø ± ºª ø Ù ªª ± æø µ ºª

Õß Æ± ø ± Æ±æª Ÿª ªÆø Õ ª ø ± Input Characteristics { ªø Æ Œø ª Ï o ÚÎ { ø Õ Î k ª Ú ø øæ ª ± Æ± ± Æ±æª Electrical { Õ ß Î ± Ì { Œ ª Ô { ± ± ÓÏ fl ø Ú { ±øº Œª ø ª ÔÎ Ú ø ø ± ÏÔ Æ± ± ª ª ªÆ ± ø ø ª» fl fl Shaft» fl fl ÃøÆ ª ªº ± Õ ø»ê ÔÁ «Ê Ê ÌÔ Ó o ÚÎ o Æ± Æ±æª ± øæ ª ø ª Æ±æª flº ª Environmental { ªÆø ± Ãª ªÆø Æª ÛÓÎ ± ÈÎ Dimensions { ª ËÔ { º Ô Ë { ÿª ÌÍ { ª ÚÓÎÎ µ ææ±õß Æª ªÆ ª ª Æ ± ø ª ª ø ± ± Æ± ª Æ±º ± ± ø ± Ú x ø º flÿ Õx øæª Æª ªÆªº Æøºª øæµ Ù ææø ø v ø Æøºª øæµ ± ææ±õß Ú Published: Á Ú ÓÚ Í Revised: ÍÚ ÌÚ Ë Web: www.vibrosystm.com ÿªøº ª P ÓÈÓÈ ø Ø ª Û øæ ªÆ Ú fi º ± ª œ ªæª ø øºø Ï Ô È ± ªÊ ÏÎ ÍÏÍÛÓÔÎÈ ÔÛË ÛÍÍÌÛËÌÈÁ ÀÚÕÚ ± Æªª ø Ê ÏÎ ÍÏÍÛÓÔÍÏ Û ø Ê ø ª ææ± ß Ú ±