GE

i
Power Conversion

ADDENDUM TO INSTRUCTION BOOK

SYNCHRONOUS GENERATOR PERMANENT MAGNET GENERATOR

OPERATION & MAINTENANCE INSTRUCTION

Image for representation purposes only.

Actual machine will vary.

Author: Fobbester, Paul

Design Office:
Reason for new revision: Initial Issue
(see last page for modification record)
Document Export Control, Source of Original Technology: GB
Document Export Control Tag: UK EUDUL NLR

©COPYRIGHT 2017 GENERAL ELECTRIC COMPANY AND/OR ITS AFFILIATES. All rights reserved. This document and
the information it contains is the property of the General Electric Company and/or its affiliates. It has been
provided solely for private use. Copying, reproducing, selling, importing, exporting, displaying, transmitting or
distributing this document and any of the information it contains is strictly prohibited except as expressly
authorized in writing by the General Electric Company and/or its affiliates.

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 GE
ii
Power Conversion

GE POWER CONVERSION SUPPORT

GE Power Conversion
Rotating Machines – Rugby
Rugby
Warwickshire
CV21 1BD
United Kingdom

24 Hr. Support: +44 (0)1788 563800

Email: escc.geem@ge.com

SAFETY WARNING
Though the instructions and information given in this book are as explicit as is practicable, expertise is still required
to install and maintain the machine. If trouble-free service is to be obtained, the machine must be installed, set
and checked correctly.

It is strongly recommended that the services of GE Power Conversion Rotating Machines’ staff be employed for the
installation and commissioning of the equipment supplied, as they have special knowledge of design details and of
suitable installation and checking techniques.

This equipment is designed to be operated in a safe area. If it is exposed to flammable/explosive gases it must not
be used. It is the responsibility of the operator to ensure that the internals of the generator are completely free of
gas before it is next started.

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 iii GE
Power Conversion

CONTENTS
1. SAFETY INSTRUCTIONS ................................................................................................................................. 4
1.1 PRESENTATION OF INFORMATION ........................................................................................................................... 5
1.1.1 USER TIPS..................................................................................................................................................................... 5
1.2 DESCRIPTION ...................................................................................................................................................................... 6
1.2.1 GENERAL ...................................................................................................................................................................... 6
1.2.2 PERMANENT MAGNET GENERATOR ................................................................................................................ 6
1.2.3 BEARING REPLACEMENT....................................................................................................................................... 6
1.2.4 BEARING REFERENCES .......................................................................................................................................... 7
2. MODIFICATION RECORD ............................................................................................................................... 8

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 4
GE
Safety Instructions Power Conversion

1. SAFETY INSTRUCTIONS

Section 1

Safety Instructions

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 5
GE
Safety Instructions Power Conversion

1.1 PRESENTATION OF INFORMATION

The following danger safety notes are used throughout this manual:

DANGER
WARNS AGAINST AN UNSAFE SITUATION OR PRACTICES THAT, IF NOT AVOIDED, WILL
RESULT IN SEVERE INJURY, DEATH OR SERIOUS DAMAGE TO THE MACHINE.

WARNING
WARNS AGAINST AN UNSAFE SITUATION OR PRACTICES THAT, IF NOT AVOIDED, COULD RESULT IN SEVERE
INJURY, DEATH OR SERIOUS DAMAGE TO THE MACHINE.

CAUTION
Warns against an unsafe situation or practices that, if not avoided, could result in minor or moderate injury,
or damage to the machine.

IMPORTANT
Warns against an unsafe situation or practices that, if not avoided, could result in damage to property or
surrounding area.

All notices and symbols directly attached to the product, such as safety signs, rotation arrows, component
identification markings, etc., may not be removed and must be maintained in a fully legible condition. They
must be observed without fail.

1.1.1 USER TIPS

NOTE
Notes include user tips and useful information.
The notes should be observed in the interests of proper use as well as with regard to optimized operation and
maintenance

 FURTHER INFORMATION 

This note indicates that further information pertaining to the topic is available in the referenced documentation.

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 6
GE
Safety Instructions Power Conversion

1.2 DESCRIPTION
1.2.1 GENERAL
The Permanent Magnet Generator (or PMG) is a device affixed to the non-drive end (NDE) of a Beta generator
which provides power to the AVR to be used to drive the machine excitation system. It therefore allows operation
of the machine whenever the shaft is turning.
1.2.2 PERMANENT MAGNET GENERATOR
The PMG itself is a self-contained rotor and stator assembly complete with its own bearings. It is affixed to the
shaft by bolts connecting the PMG rotor to the primary machine shaft. The stator then freely floats on the bearings,
and is prevented from rotating by a bar set in the case of the stator. This anti-rotation bar mates with a bracket
mounted to the NDE of the primary machine casing (typically the bearing housing).

A cable connected to the PMG stator carries the generated power to an auxiliary terminal box located on the
primary machine.

This PMG was initially supplied with bearings requiring replacement after 9500 operating hours. Any replacement
bearings supplied by GE will be suitable for an operating life of 20000 hours.

1.2.3 BEARING REPLACEMENT

The PMG bearings have finite life and will require periodic bearing replacements. Instructions for replacing the
bearings are in the PMG Operation & Maintenance manual and bearing replacements must be logged in the
maintenance log.

PMG bearings must be replaced prior to a PMG bearing reaching 9500 or 20,000 hours of operating life (depending
on the installed bearings).

WARNING
FAILURE TO REPLACE THE PMG BEARINGS WHEN THEY ARE WEARING COULD RESULT IN SEIZURE OF THE PMG
AND RESULTING ROTATION OF THE STATOR AND ANTI-ROTATION ARM, CAUSING DAMAGE TO THE MACHINE
AND A HAZARD TO NEARBY PERSONNEL.

PMG bearing maintenance is of utmost importance. When the grease reaches end of life, the PMG bearings may
fail. Failure of a PMG bearing may cause seizure of the PMG stator. This seizure may result in breakage of the anti-
rotation bracket mounting bolts and subsequent liberation of the mounting bolts and bracket. The seizure may
also result in breakage of the cabling connection resulting in uncontrolled movement of the cable.

The two bearings installed within the PMG are sealed bearings. GE requires that in order to provide at least 20,000
hours of bearing operation in normal conditions the PMG bearings shall be replaced with bearings that are
lubricated with high temperature grease. Suitable high temperature grease lubricated replacement PMG bearings
are available from GE. Please refer to the contact information provided at the front of this manual and quote the
relevant part number stated in the following table for the PMG fitted.

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 7
GE
Safety Instructions Power Conversion

1.2.4 BEARING REFERENCES

PMG Model GE Bearing part No. GE Bearing part No.
Drive End Non Drive End
H132 ATR 65 MF PC000079965 PC000079951
H132 ATR 80 MF PC000079965 PC000079951
H132 ATR 90 MF PC000079965 PC000079951
H132 ATR 120 MF PC000079965 PC000079951
H160 API 160 PC000079967 PC000079963
PMI 814 – F8255 PC000079965 PC000079965

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 8
GE
Modification Record Power Conversion

2. MODIFICATION RECORD

Section 2

Modification Record

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 9
GE
Modification Record Power Conversion

Revision Date Author Details

000 2017-08-02 Fobbester, Paul Initial Issue
001 2017-09-06 Fobbester, Paul Clarify bearing life clause 1.2.3

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©COPYRIGHT 2017 GENERAL ELECTRIC COMPANY AND/OR ITS AFFILIATES. All rights reserved.
Publication No 1625

PERMANENT MAGNET ALTERNATORS

PMI 814, PMI 824 & PMI 1128

CONTENTS
Page

Description .......... 2
Storage .......... 2
Installation .......... 2
Maintenance .......... 2
Dismantling .......... 3
Re-assembly .......... 4
Testing .......... 4
Spare Parts List …….. 5
Drawings
Outline P.M. Alternator PMI 814, PMI 824, PMI 1128 Drawing No. J401161
Sectional Arrangement PMI 814 Drawing No J401254
Sectional Arrangement PMI 824 Drawing No J401255
Sectional Arrangement PMI 1128 Drawing No J401256

___________________________

newton derby
Grangefield House, Richardshaw Road
Pudsey, Leeds, LS28 6QS, United Kingdom

T. +44 (0) 0113 2555666

1
Publication No 1625

DESCRIPTION

The alternator is a totally enclosed, two bearing machine in which the excitation is provided by a multi pole
permanent magnet rotor. The unusual mechanical construction is designed to allow direct coupling to the main
drive shaft of a large generator or motor without the need for a flexible coupling or interface adaptor.

The stator case is provided with a single immobilisation boss to which a flexible mount can be attached to
prevent it rotating

The alternator produces a 3 phase output. The 3 phase output terminals marked U1, V1, W1 are contained
within the terminal box.

STORAGE

Machines should be stored in a clean dry atmosphere, Before installation, turn rotor by hand and ensure the
rotor revolves freely, some resistance will be felt due to the effect of the magnets.

Check the insulation resistance with a 500 volt insulation tester. An insulation resistance of not less than 10 M 
should be obtained.

INSTALLATION

This type of P.M. generator is for direct coupling to the main drive shaft of a large generator or motor via
mounting studs.

The main shaft must include a centralising spigot to ensure that the P.M. generator is installed concentrically
with the main shaft.

A flexible mounting arrangement should be connected to the immobilisation boss to prevent the stator case
rotating.

MAINTENANCE

Very little maintenance will be required since there are no bushes or slip rings to be serviced and the bearings
are sealed for life.

2
Publication No 1625

DISMANTLING

Access to the DE bearing and the NDE Bearing can only be achieved by first removing the rotor from its stator
housing. It is therefore, necessary to follow procedure A) before proceeding to procedure B)

A) (Removal of Rotor):-

i) Remove four hexagon screws holding stator case to DE bracket.

ii) To free DE Bracket from the stator case use the same screws as jacking screws utilising the adjacent
threaded holes on the end bracket.

iii) Remove the stator case. Take care not to lose the wave washer which is situated inside the stator case
bearing housing.

B) (Removal of the DE Bearing):-

i) Remove the 8 high tensile cap headed screws which hold the drive plate to the rotor hub. Gently tap
the
drive plate to remove it from the rotor.

ii) Remove the bearing spacer tube.

iii) The bearing is located in the DE bracket.

Strike the rear of the bracket evenly around its perimeter to remove DE bracket and bearing from the
rotor.

iv) After the DE bracket is free remove the 3 screws holding the bearing washer.

v) The bearing can now be removed from the bracket.

If resistance is felt use a tube drift on the outer race to tap out the bearing.

C) (Removal of the NDE Bearing):-

i) To remove the NDE bearing use a standard bearing extractor to pull off the bearing.

3
Publication No 1625

RE - ASSEMBLY

D) (NDE Bearing Replacement):-

i) Position the NDE bearing on the rotor hub. If a suitable press is not available, drive into position
using a piece of tube over the rotor in contact with the inner race only.

E) (DE Bearing Replacement):-

i) Position the DE bearing into the DE Bracket and press home. If a press is not available use a tube to
gently tap the outer bearing race only. When the bearing is fully home fit the bearing washer and
replace the three securing screws.

ii) Slide the Bearing/End Bracket Assy onto the Rotor Hub. Although this is a sliding fit it may be
necessary to gently tap the inner bearing race with a suitable tube until the bearing is up against
the rotor shoulder.

iii) Slide the bearing spacer tube onto the rotor hub.

iv) Fit the Drive End Plate onto the rotor, secure with the 8 high tensile cap head screws and tighten to a
torque of 55 Nm.

F) (Re-Assembly of Rotor into Stator case):-

i) Ensure Wave Washer is placed flat and square to the inside face of the Stator Case bearing housing.

ii) With both bearings fitted assemble the stator case to the NDE Bracket and Rotor Assembly.

Secure with the four Hexagon headed screws.

iii) Check the rotor for freedom of movement.

TESTING

1) Couple the machine to a suitable driving unit.

2) Run the machine at rated speed and check that open circuit voltage is in accordance with the data
sheet.

3) Check the insulation resistance with a 500 volt insulation tester. The insulation resistance should
not be less than 10 Megohms.

4
Bearing & Replacement Instruction:

List of PMG types:

H132 ATR 65 MF
H132 ATR 80 MF
H132 ATR 90 MF
H132 ATR 120 MF
H160 API 160

Disassembling:

The following operations are critical and should be performed by specialist.

Please wear all the safety protections to avoid any accident.

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