ADWEL WTD-501 Bedienungsanleitung

Wedge Tightness Detector

Model WTD-501

Operating Manual

WTD MODEL 501

Version 2.4

Software Version 3.x

May, 2006.

ADWEL International Ltd.

HEAD OFFICE EUROPEAN OFFICE

50 Ironside Crescent, Unit 6

Scarborough, Ontario M1X 1G4

CANADA

Telephone: 1- 416-321-1988

Toll Free: 1-800-463-9371

Fax: 1-416-321-1991

e-mail: [email protected]

Website: http://www.adwel.com

Park House, Greenhill Crescent

Watford Business Park

Watford, Herts WD18 8PH

UNITED KINGDOM

Telephone: 44-(0) 1923-254433

Fax: 44-(0) 1923-218278

e-mail: [email protected]

information supplied by other parties.

No reproduction in whole or in part is to be made without the written authorization of

ADWEL International Limited.

LIST OF CONTENTS

1. INTRODUCTION 8

1.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . 9

2. HAND-HELD PROBE ADJUSTMENT 10

2.1 Electronic Case Overview . . . . . . . . . . . . . . . . . 12

2.2 Computer Set-up . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2.1 RS-232 Port Set-up 13

2.3 Calibration Block . . . . . . . . . . . . . . . . . . . . . . 15

3. OPERATIONS OVERVIEW 16

3.1 Wedge Tightness Detector Setup . . . . . . . . . . . . . . . 16

3.2 Probe Placement on Wedges . . . . . . . . . . . . . . . . 17

3.3 Calibration References. . . . . . . . . . . . . . . . . . . . 18

3.4 Values for Colour Defaults . . . . . . . . . . . . . . . . . . 19

3.5 File Management . . . . . . . . . . . . . . . . . . . . . . . 19

4. SOFTWARE OVERVIEW 20

4.1 File Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2 Unit Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.3 Reference Menu . .. . . . . . . . . . . . . . . . . . . . . . 22

4.4 View Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.5 Options Menu . . . . . . . . . . . . . . . . . . . . . . . . 22

4.6 Help Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.7 Action Menu (Test Mode) . . . . . . . . . . . . . . . . . 23

4.8 ICONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5. STEP-BY-STEP SOFTWARE USE 26

5.1 Overview of Use . . . . . . . . .. . . . . . . . . . . . . . . . . 26

5.1.1 Creating a Unit . . . . . . . . . . . . . . . . . . . . 26

5.1.2 Opening a Unit . . . . . . . . . . . . . . . . . . . . 29

5.1.3 Generating Calibration Reference . . . . . . . . . . . 30

5.1.4 Test Set-up . . . . . . . . . . . . . . . . . . . . . . . 31

5.1.5 Sequential Test . . . . . . . . . . . . . . . . . . . . 31

5.1.6 Random Test . . . . . . . . . . . . . . . . . . . . . 33

5.1.7 Starting the Test . . . . . . . . . . . . . . 33

5.1.8 Repeat, Delete, Go To and View Commands . . . . 34

5.1.9 Importing and Finishing the Test . . . . . . . . . . . 36

5.2 Viewing Test Results . . . . . . . . . . . . . . . . . . . . . . . 37

5.2.1 Comparing Test Results . . . . . . . . . . . . . . . . . . . . . 39

5.3 Exporting Test File to Text Format . . . . . . . . . . . . . . . . 41

5.4 Creating Calibration References . . . . . . . . . . . . . . . . . 42

5.5 Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.6 Default Data Folder Selection. . . . . . . . . . . . . . . . . . . 46

6. MAINTENANCE 47

6.1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7. SPECIFICATIONS 48

8. KIT CONTENTS 50

APPENDIX 1 51

LIST OF FIGURES

1. WTD 501 and Hand Held Probe . . . . . . . . . . . . . . . . . . . . . 8

2. Front View Showing Allen Screws for Width and Angle Adjustment . . 10

3. Probe Without Bars or Sidecars . . . . . . . . . . . . . . . . . . . . . 11

4. WTD Electronics Case Back Panel . . . . . . . . . . . . . . . . . . . . 12

5. Power Entry Module on Back Panel; Closed and Prying Open . . . . . . 12

6. Electronics Case Front Panel . . . . . . . . . . . . . . . . . . . . . . . 13

7. Communication Port Selection . . . . . . . . . . . . . . . . . . . . . . 14

8. Communication Port Testing . . . . . . . . . . . . . . . . . . . . . . 14

9. Communication Port Confirmation . . . . . . . . . . . . . . . . . . . . 14

10. Hand Held Probe Near Tight Calibration Board Placement . . . . . . 15

11. Hand Held Probe at Loose Calibration Board Placement . . . . . . . . 15

12. Close Up View of Hand Held Probe on Wedges in a Generator . . . . . 17

13. WTD Software Main Window . . . . . . . . . . . . . . . . . . . . . . 20

14. File Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

15. Unit Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

16. Reference Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

17. View Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

18. Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

19. Help Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

20. Action Menu (Test Mode) . . . . . . . . . . . . . . . . . . . . . . . . . 23

21. Test Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

22. General Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

23. Slot and Wedge Description Tab . . . . . . . . . . . . . . . . . . . . . 27

24. Nameplate Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

25. Open Existing Unit Dialog Box .. . . . . . . . . . . . . . . . . . . . . 29

26. Browse Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

27. Generate New Calibration File Dialog Box . . . . . . . . . . . . . . . 30

28. Selecting How Many Wedges to Test. . . . . . . . . . . . . . . . . . . 30

29. Sequential Test Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . 31

30. Random Test Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . 33

31. Delete Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

32. Repeat Measurement .. . . . . . . . . . . . . . . . . . . . . . . . . . 34

33. Go To specified location . . . . . . . . . . . . . . . . . . . . . . . . . 34

34. Quick Test View (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

35. Quick Test View (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

36. Select Test File to Import Data . . . . . . . . . . . . . . . . . . . . . . 36

37. Exit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

38. Open Test File Window. . . . . . . . . . . . . . . . . . . . . . . . . . 37

39. Header File Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

40. Test Statistics Window . . . . . . . . . . . . . . . . . . . . . . . . . . 39

41. Compare Test Results Dialog Box . . . . . . . . . . . . . . . . . . . . 39

42. Two File Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

43. Effect of Different Calibration Files . . . . . . . . . . . . . . . . . . . 40

44. Extract Reference Wizard . . . . . . . . . . . . . . . . . . . . . . . . 42

45. Extract Loose Reference . . . . . . . . . . . . . . . . . . . . . . . . 43

46. Extract Tight Reference . . . . . . . . . . . . . . . . . . . . . . . . . . 43

47. Extract Reference in File Display. . . . . . . . . . . . . . . . . . . . . 43

48. Calibration Reference Warning . . . . . . . . . . . . . . . . . . . . . . 44

49. Page Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

50. Print Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

51. Default Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

52. Browse for Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

53. Power Selector and Power Switch in Power Entry Module . . . . . . . 47

LIST OF TABLES

1. Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1. INTRODUCTION

The Wedge Tightness Detector (WTD) was originally developed under contract to the

Electric Power Research Institute (EPRI). The WTD is designed to measure stator slot

wedge tightness in turbo-generators, hydro-generators, and motors. The main components

of this instrument are a manual probe, calibration block, electronics case, software and

computer. A remote version of the probe is also available for use with robotic inspection

vehicles, for rotor in-situ wedge tightness testing.

Figure 1: WTD Model 501 and Hand Held Probe

1.1 DESCRIPTION

The WTD probe is designed to be manually pushed along each slot, riding on wheels on the

iron core surface, and magnetically supported so that the operator is not burdened when

testing side and overhead slot positions on turbo-generators and motors or vertical positions

on hydro-generators.

The two “sidecar” parts of the probe house the support magnets with the wheels holding

them a small distance from the iron core surface. The center part of the probe houses the

impact hammer and accelerometer pick-up which ride on curved “shoes” to accommodate

surface roughness and irregularities.

The impact hammer is designed to strike the wedge approximately 10 times per second and

each wedge is struck for a period of approximately three (3) seconds. The accelerometer

pick-up and electronics transmit the wedge tightness data to the electronics case over a

multiwire cable. Power to the probe electronics is provided through the cable. Offset holes

allow the center section of the probe to be lowered to one of three depths. This allows

recessed wedges of varying depths to be tested.

The probe shoes are spring-loaded to accommodate smaller differences in slot recess sizes.

In addition to housing the system power supplies, the electronics case includes the

electronics for receiving the accelerometer data and filtering data from selected parts of the

frequency spectrum.

1.2 REQUIREMENTS

An IBM compatible computer (486DX2, 66MHz, 8MB RAM or better) running W95, W98,

NT or W2000 and a minimum of 20 MB of hard disk drive space for program and data

storage is required. The convenient size and portability of a notebook computer makes it

ideal for use with the Wedge Tightness Detector. The flexible software design allows for

different data acquisition settings and multiple choices for data display. The WTD stores

measured data on the hard drive and provides display of RELATIVE TIGHTNESS INDEX

(RTI) on the computer screen. The RTI is the result of a comparison of the measured data

with calibration references for tight and loose condition and can be any number between 0-

100. Selecting different values for tight and loose condition (i.e. different calibration files)

will affect only the displayed RTI. It will NOT change the stored measured values.

NOTE: The WTD is designed to be operated by one person. During the test, the screen

saver program will be automatically deactivated. Therefore, the operator can monitor

progress on the computer display from a distance without needing to change the existing

screen saver settings.

2. HAND-HELD PROBE ANGLE AND HEIGHT ADJUSTMENT

The sidecars on the probe assembly allow the probe to be used with generators/motors of

almost all sizes. The sidecars slide in and out on and are supported by round rails that come

in 75 mm (3”), 150 mm (6”) and 225 mm (9”) lengths. The sidecars can be raised or lowered

by inserting the rails into one of the three holes at each end of the probe. Each rail must be

at the same height. The height of the probe above the slot should be adjusted so that the

impact hammer presses slightly against the wedges. In addition, the sidecars can be angled to

track the surface of the iron core more accurately. Silver stripes on the side of the probe

indicate the center of the hammering and sensing units. They are there to ensure that the

probe is properly positioned along the testing points of the wedges.

To assemble the probe and adjust its height, follow the steps below. A 3 mm Allen-key

supplied with WTD kit is the only tool required.

1. Ensure that all Allen bolts are loosened but not completely free. This will allow for

easy adjustment of the sidecars spacing and angle. Insert the two round rails in the

holes on probe body. Slide on sidecars, one on each side.

Figure 2: Front View Showing Allen Screws for Width and Angle Adjustment

top

bolts

bottom

bolt

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