Before installation, remove all original/OEM shaft grounding system equipment and clean the shaft of any surface defects, rust, and other contaminants. Review the documentation for the original/OEM shaft grounding system to plan its removal.
The following figure shows the Shaft Grounding Assembly installed. The installation consists of these main parts:
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Rope Guide (A): The portion of the Shaft Grounding Assembly that lays over the shaft and holds the grounding and metering ropes.
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Attachment Arm (B): A pipe that connects the Shaft Grounding Assembly to the unit housing.
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Junction Box (C): An enclosure that houses the ground current sensing circuitry.
These are the main tasks in the installation procedure:
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Installing the attachment arm. The length of the attachment arm varies with each installation, so you must temporarily place the Shaft Grounding Assembly on the shaft in order to measure the required length of the attachment arm. The attachment arm is then cut to size, inserted into the mounting hardware, and locked in position with set screws.
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Securing the rope guide. The rope guide must be precisely positioned to match the contour of the shaft. This is accomplished by tightening bolts at the top of the rope guide.
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Mounting the Junction Box. The Junction Box must be mounted to a secure structure within 4 ft of the Shaft Grounding Assembly.
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Place the 1/16" thick rope guide spacer (A) over the shaft (B). The arrow indicates the shaft rotation direction.
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Set the Shaft Grounding Assembly (C) on the rope guide spacer as shown the following figure. Orient the Shaft Grounding Assembly such that the mid-point of the rope guide is at the 12 o’clock position.
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Temporarily attach the assembly to the shaft using hands, clamps, tape, banding, or a wooden frame.
The location of the connector plate (A) that mounts to the unit may vary, but it must be within reach of the 18" attachment arm pipe that will extend between the connector plate and the Shaft Grounding Assembly (B).
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Using the connector plate as a template, drill and tap four holes (5/16"-18 x 3/4" deep) for mounting to the unit.
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Attach the connector plate to the mounting location using the provided 5/16"-18 x 3/4" hex bolts and Nordlock washers.
Insert one elbow assembly into the connector plate and one into the adapter located on the Shaft Grounding Assembly. Position the elbow assemblies (A) so they face each other, as shown in the following figure.
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To determine the length of the attachment arm (steel tubing), measure the exact distance between the flanges on each elbow assembly and add 1.25" (3.18 cm) (the pipe will insert into each elbow assembly .625" (1.588 cm)).
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Cut the attachment arm pipe, ensuring that the cut is perpendicular to the length of the pipe, to the measured length and install it.
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Using a 1/4" hex key wrench, tighten, but do not torque, the two SGA-to-Attachment Arm bolts (A).
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Using a 3/16" hex key wrench, tighten, but do not torque, the three bolts on the SGA ball joint (B). Tighten each bolt in small increments, alternating from bolt to bolt until all three are secure. Fully tightening one bolt before beginning the others may result in unintended misalignment of the rope guide.
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Using a 5/32" hex key wrench, tighten, but do not torque, the elbow-to-pipe and adapter fasteners (C).
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Using a 5/16" hex key wrench, tighten, but do not torque, the center pivot fastener (D) of each elbow.
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Do not yet tighten the pivot set screw (E) between the two halves of the elbows.
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Remove the four hex bolts from the connector plate (F) and the two bolts from the attachment arm adapter (A) connecting to the rope guide.
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Carefully remove the attachment arm assembly, while taking care not to disturb the elbow assemblies, as this will cause misalignment.
Drill holes for set screws one at a time using the custom bushing and drill bit (A) provided with the Shaft Grounding equipment.
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Begin with the pivot set screws (B), making sure that each set screw is fully seated to lock in the position, but not torqued, before moving on to the next hole.
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Next, move on to the elbow-to-pipe and adapter fasteners (C), making sure that each set screw is fully seated to lock in position, but not torqued, before moving on to the next hole.
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If needed, elbow pivots may be rotated by loosening the large center pivot bolt (D) as long as the pivot set screw hole (B) was previously drilled so that the elbow position will be maintained.
Perform final torques on Attachment Arm fasteners:
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Torque the elbow-to-pipe and adapter fasteners (C) to 150 in-lbs. If needed, elbow pivots may be rotated by loosening the large center pivot bolt (D) as long as the pivot set screw hole (B) was previously drilled so that the elbow position will be maintained.
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Torque the elbow’s center pivot bolt (D) to 70 ft-lbs. If the elbow pivot was previously loosened and rotated, check the elbow orientation with the pivot set screw (B), but do not tighten the set screw until the center pivot bolt has been torqued. (Note: Once the elbow’s center pivot bolt is torqued, it will be difficult to loosen the joint; be sure of the position).
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Torque the elbow’s pivot set screws (B) to 150 in-lbs.
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After assembling the attachment arm, place the Shaft Grounding Assembly back onto the shaft, over the rope guide spacer.
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Connect the attachment arm to the Shaft Grounding Assembly by tightening the two screws (A) shown in the following figure. Torque to 300 in-lbs (or 25 ft-lbs).
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Check the gap between the shaft and the contact points on the rope guide to make sure there are no misalignments.
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Torque all four of the 5/16"-18 x 3/4" hex bolts (A) with Nordlock washers to 240 in-lbs.
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Make any needed fine-tuning adjustments to the orientation to the Shaft Grounding Assembly before locking the rope guide ball and socket joint in place by tightening the three 1/4"-28 socket head cap screws (B) shown in the following figure. Tighten these bolts by first getting each one snug, then torquing each bolt to 110 in-lbs. Note that the joint gives 10 degrees of final fine adjustment to the shaft in any direction.
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Adjust each rope guide section so that the contact points (A) are touching the 1/16" rope guide spacer.
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Tighten all the 5/16"-18 x 5/8" bolts (hex head or IP40 Torx button head) (B) on the rope guide starting closest to the attachment arm side of the assembly, and then work around from there. Torque all the bolts to 220 in-lbs.
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When all rope guide bolts are torqued and the rope guide is secured, remove the rope guide spacer.
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Drill and tap two 5/16"-18 x 1/2" deep holes into a secure structure within 4 ft of the Shaft Grounding Assembly (A).
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Use the supplied 5/16"-18 bolts and Nordlock washers to secure the Junction Box (B) in place. Torque to 240 in-lbs.
If drilling and tapping is not desired, it is acceptable install the Junction Box using an alternative mounting structure, such as Unitstrut.
Drill and tap a 5/16"-18 x 1/2" deep (1.27 cm) hole in a suitable grounding location on the outside of the unit case (A) to attach the grounding ring terminal (B). The metal surface to which the grounding ring terminal will be mated must be smooth and free of any paint, rust, oil, or other contaminants that may inhibit the electrical connection. The maximum wire length for the ground run from the Shaft Grounding Assembly to the unit case ground location is 5 ft (1.5 m).
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Connect the signal cables to the Junction Box by plugging the 20-pin connector into the opening in the lid of the Junction Box. Make sure the connector is fully inserted.
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Route the signal cables (A) to the intended monitoring system location through conduit (provided by the electrical contractor).
Refer to your specific monitoring system operations manual for further instructions on wiring and mounting the monitoring system.