Caps Off Inspections
What side of the damper finger gets the burndy applied before installing?
Top side - for electrical contact with the slot wedge
At what intervals are the 10 AC impedance values recorded?
Bonus: How do you calculate 'Z' ohms?
For every amp, record amount of volts
Bonus: Volts divided by amps
What is the gap tolerance of two halves of nomex in a factory setting?
3-6mm
What temperature is NOT to be exceeded during fan removal?
180 degrees Celsius
If Rey was a toy and had a pull string on his back, what would the toy say when you pulled it?
"What's for lunch?" or "Lunche!"
What is the purpose of a caps off inspection?
Clean, inspect, repair
What initial electrical tests are done on the rotor windings when it arrives?
Insulation resistance, winding resistance, pole balance, AC impedance
What is the gap tolerance between halves of nomex in a field setting? Why?
12-16mm. After components are removed, windings "relax" and spring up slightly. Increased gaps are made to allow for the halves to compress without overlapping.
What temperature is NOT to be exceeded while heating caps?
400 degrees Celsius
What task in the winding division does Rey despise the most?
Tying in blocks
While bore scoping the alignment pins in the subslot, what are you looking for?
If the pin is stressing or tearing the liner, proving coil migration
What four electrical readings complete the electrical testing for an exciter armature?
What is the Baseload procedure gap target for the Nomex halves?
10mm
What is the target temperature for heating up windings during a heat run?
145 degrees Celsius
If Rey had the choice of tying in blocks on the exciter end or tying in blocks on the drive end, what would he do?
Jump off a cliff / in front of a bus
Why is carbon / oil buildup on the rotor considered very dangerous for the rotor?
When coil comes into contact with the slot liners, the chance for insulation resistance revival significantly drops. Oil soaks the liners and degrades them.
What environmental condition affects the winding resistance (DLRO) reading the most?
Temperature
What is the last step that must be done to under-cap insulation before it is installed onto the end-windings?
Wax the inside
While heating a cap on a rotor to remove it, what are you racing against?
The temperature of the rotor body / forging
What was Rey's position at Baseload before becoming a winder?
Parts warehouse
Scenario: A rotor initially electrically tests at 11/500 volts during an insulation resistance test. The caps of removed, end windings cleaned, covered and heated at end of shift everyday, and now the insulation resistance test reveals 345/500 volts. What would be the next step for revival?
DC / welder heating
Scenario: Completed windings are pole balanced after press. If there is a short between two turns on pole 1, how would you know it is on pole 1 from the test results?
If the P1 reading ('D' lead to reverse lead) is lower than the P2 reading. For example, P1: 47.89 volts & P2: 52.33 volts
After cutting the radius on a Nomex half and reinstalled into the vent ring, how is the perpendicular line marked to be cut?
Mark the 10mm gap on the alignment pin hole or the center vent on the vent ring - transfer the inside mark to the insulation - level the vent ring - level a ruler in line with the mark to match the vent ring
What is the maximum allowable temperature difference between hottest coil and body temperature on a heat run?
30 degrees Celsius
What does Rey have a collection of?
Halloween / Horror Masks