AC & DC MACHINES

(ADM)

Learner Guide
 TABLE OF CONTENTS

OBJECTIVES PAGE 1

ADM-1: SINGLE-PHASE CAPACITOR MOTORS

LEARNING OBJECTIVES PAGE 2
RESOURCE NOTES PART ONE PAGE 3
SELF-TEST EXERCISE TASK NO. 1 PAGE 6
RESOURCE NOTES PART TWO PAGE 7
SELF-TEST EXERCISE TASK NO. 2 PAGE 9
RESOURCE NOTES PART THREE PAGE 11
SELF-TEST EXERCISE TASK NO. 3 PAGE 14
RESOURCE NOTES PART FOUR PAGE 16
SELF-TEST EXERCISE TASK NO. 4 PAGE 18
RESOURCE NOTES PART FIVE PAGE 19
SELF-TEST EXERCISE TASK NO. 5 PAGE 23
RESOURCE NOTES PART SIX PAGE 25
SELF-TEST EXERCISE TASK NO. 6 PAGE 27

ADM-2: THREE-PHASE INDUCTION MOTORS

LEARNING OBJECTIVE PAGE 28
RESOURCE NOTES PART ONE PAGE 29
SELF-TEST EXERCISE TASK NO. 1 PAGE 31
RESOURCE NOTES PART TWO PAGE 32
SELF-TEST EXERCISE TASK NO. 2 PAGE 34
RESOURCE NOTES PART THREE PAGE 35
SELF-TEST EXERCISE TASK NO. 3 PAGE 38
RESOURCE NOTES PART FOUR PAGE 40
SELF-TEST EXERCISE TASK NO. 4 PAGE 42
RESOURCE NOTES PART FIVE PAGE 43
SELF-TEST EXERCISE TASK NO. 5 PAGE 45
RESOURCE NOTES PART SIX PAGE 46
SELF-TEST EXERCISE TASK NO. 6 PAGE 47

ADM-3: DC MOTORS AND GENERATORS

LEARNING OBJECTIVE PAGE 49
RESOURCE NOTES PART ONE PAGE 50
SELF-TEST EXERCISE TASK NO. 1 PAGE 52
RESOURCE NOTES PART TWO PAGE 53
SELF-TEST EXERCISE TASK NO. 2 PAGE 56
RESOURCE NOTES PART THREE PAGE 58
SELF-TEST EXERCISE TASK NO. 3 PAGE 64
RESOURCE NOTES PART FOUR PAGE 66
SELF-TEST EXERCISE TASK NO. 4 PAGE 71
RESOURCE NOTES PART FIVE PAGE 73
SELF-TEST EXERCISE TASK NO. 5 PAGE 75

CONTACT DETAILS:
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[email protected]
 AC & DC MACHINES

OBJECTIVES
o This series of 3 modules will give you a practical working understanding of the basic
operating principles of AC & DC machines and of the routine electrical and mechanical
checks that should be performed as part of a good maintenance policy.

WHAT YOU WILL LEARN IN THIS SERIES

o Module 1 (ADM 1) - Single phase capacitor motors.
o Module 2 (ADM 2) - Three phase motors.
o Module 3 (ADM 3) - DC motors and generators.

HOW WELL YOU WILL PERFORM

o Through Self-Check Exercises you will be able to assess your performance at each stage of
learning based upon Must Know or Must Do principles.
o Obtaining a YES response to Criteria checklist.

LEARNING PROCEDURE
Tech A.V. has supplied you with 2 main resources namely:
o This Workbook.
o Video programmes (ADM-1 to ADM-3).

The recommended general procedure for learning is as follows:

o Read your workbook, following any simple instructions as you read.
o View the relevant video material, as given in the reading.
o Practice (where applicable) performing the tasks demonstrated by the video. This is done in
your Practical Training area under the Supervision of your Facilitator (or Mentor / Tutor).
o Each module begins with a Learning Objective. In this way you will be clear about where
the module is taking you and what you will achieve after successfully completing it.
o Resource notes provide you with valuable information. Not all information is given on the
video. Certain facts (e.g. Expansion of details mentioned in the video) are given to you.
Read your resource notes before viewing the video, as you will obtain a clearer
understanding, especially in theoretical aspects.

Back to Table of Contents 1

 LEARNING OBJECTIVE
ADM-1: SINGLE PHASE CAPACITOR MOTORS

OBJECTIVE
Upon successful competition of this module you will be able to:
o Identify by name the key components and state their functions.
o Describe the basic operating principles of a capacitor motor.
o Perform the basic electrical and mechanical test procedures on a capacitor motor.

PROCEDURES
1. Read the Resource Notes beginning on the next page.
2. View the video ADM-1 all the way through.
3. View the video again but this time STOP each time you see a REVIEW section.
4. Complete the Self-Test Exercise that follows the relevant section in the resource notes.
5. When you have mastered that section, by honestly receiving a YES response to each
criterion, continue to the next section.

RESOURCES
For this module you will require:
o This workbook.
o Video Programme ADM-1.
o Capacitor motors in your training centre or workshop.

Back to Table of Contents 2

 RESOURCE NOTES (PART ONE)
CONSTRUCTION OF A CAPACITOR MOTOR

INTRODUCTION
Capacitor motors are single -phase induction motors where use is made of capacitors to create the
rotating field necessary to turn the rotor. They range in size from 37 watts to 26 kW, operating all
types of loads from small fans to large compressors.

This programme features the three types of capacitor motor, namely:

o Capacitor start motor.
o Capacitor-run (permanent split) motor.
o Capacitor start & run (two-capacitor) motor.

CONSTRUCTION OF THE MOTOR

The diagram below illustrates a typical capacitor motor. Study this and become familiar with the
various part names, as we will frequently refer to them during the programme.

1. Drive End End-shield 19. Fan Cowl

2. Drive End Ball-bearing 20. Centrifugal Switch Holder Screw
3. Key 21. Loading Spring
4. Rotor 22. Non-Drive End Ball Bearing
5. Capacitor Cover Fastening Screw 23. Stator
6. Capacitor Cover Base 24. Terminal Board
7. Running Capacitor 25. Terminal Board Screw
8. Capacitor Cover 26. Gasket
9. Starting Capacitor 27. Terminal Box Cover
10. Mounting Screw 28. Terminal Box

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11. Non-Drive End-shield 29. Terminal Box Holder Screw
12. Centrifugal Switch 30. Earth Screw & Washers
13. Centrifugal Mechanism 31. Gasket
14. Gasket 32. Terminal Board Holder Screw
15. Cover 33. Nut
16. Fan 34. Stay Bolt
17. Circlip 35. Key
18. Fan Cowl Holder Screw

The principle components in terms of operation are the rotor and the stator.

ROTOR
The purpose of the rotor is to produce the turning effect or torque. This is achieved by
electromagnetic induction as electrical energy from the stator is converted into mechanical energy
at the rotor shaft.

The rotor consists of a laminated iron core (laminated to reduce the losses caused by circulating or
eddy currents produced in the core). The rotor windings consist of a number of aluminium bars
(rotor bars) inserted into the core and joined together at each end by Aluminium shorting rings.
These components are pressed onto a shaft, which is supported by bearings that are contained in
end-shields. The end of the shaft that is coupled to the load is called the "driving end” (DE), and the
opposite end, the non-drive end (NDE), usually supports a cooling fan.

STATOR
The purpose of the stator is to produce a rotating magnetic field to turn the rotor. It is composed
of a laminated iron core (laminated to reduce the electrical losses produced by eddy currents)
which is pressed into the stator frame. Two separate insulated copper windings are placed into
slots in the core to produce the rotating magnetic field system when AC is passed through them.

One winding is called the main or run winding and consists of a number of turns of thick insulated
copper wire. The other winding called the auxiliary or start winding has less turns of thinner gauge
wire. When measuring the resistance of each winding, the run winding will display a lower value of
resistance than the start winding, making it easy to identify each winding. We will explain the
characteristics of the windings later on.

START CAPACITOR
This device is attached to the stator frame and its purpose is to enable the motor to be self-
starting. The capacitor is generally a low duty non-polarised electrolytic type intended for
intermittent operation. This means that its physical size can be made small in spite of its large
value (typically 80 - 160 F).
The capacitor is connected in series with the start winding at power-up. A few seconds later, the
capacitor and start winding are automatically disconnected from the supply. Since the motor is not
self-starting, the capacitor is instrumental in providing the starting torque.

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CENTRIFUGAL SWITCH
The purpose of the switch is to disconnect the start winding and start capacitor from the supply
once the motor has achieved 80% of its rated speed.

The switch consists of two parts, namely:

1. An assembly of spring loaded weights that are attached to the rotor shaft.
2. A single-pole single-throw switch, which is attached to, but insulated from , the stator
frame.

The switch is operated by centrifugal force. The weights are flung outwards making momentary
contact with the switch lever, which causes the switching contacts to open at a pre-determined
speed. As a result, the start winding and capacitor are disconnected from the supply by the switch
(contacts -normally closed, now open).

NOW VIEW THE VIDEO UP TO REVIEW NO. 1.

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 SELF-TEST EXERCISE NO. 1

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. List the main components of a typical capacitor type induction

motor.
_______________________________________________________
_______________________________________________________

2. What is the purpose of the rotor?

_______________________________________________________
_______________________________________________________

3. What is the purpose of the stator?

_______________________________________________________
_______________________________________________________
_______________________________________________________

4. Name the two sets of stator windings.

_______________________________________________________
_______________________________________________________
_______________________________________________________

5. What is the purpose of the start capacitor?

_______________________________________________________

6. What is the purpose of the centrifugal switch?

_______________________________________________________
_______________________________________________________
_______________________________________________________

Back to Table of Contents 6

 RESOURCE NOTES (PART TWO)
BASIC OPERATING PRINCIPLES

INTRODUCTION
In the previous section, we identified the stator and the rotor as the key components of an
induction motor.

Consider a very simply constructed two-pole stator. When AC power is applied to the field coils,
two things happen, namely:
o A magnetic field is produced in the coils which changes polarity at the rate of the AC supply
(typically 50 times/sec.), and
o The intensity of the magnetic field follows the sinusoidal waveform of the AC supply.

A pulsating magnetic field is produced in the stator concentrated between the two poles.

Now, we place a "squirrel cage" type rotor within the stator, and by electro-magnetic induction,
poles are formed in the rotor, which react with the stator poles. As a result two equal, but
opposed, torque's are produced in the rotor, and the rotor pulsates (on rotation). In other words,
the motor is unable to "self-start".

This problem might be overcome by applying a momentary force, such as a flick by hand to the
rotor, at right angles to it. An imbalance is produced in the rotors' torque and the resulting torque
will cause the rotor to start turning in the direction in which it was rotated.

Since it would be impractical to apply a mechanical impulse every time the motor was to be
started, we use an auxiliary phase or start winding to achieve self-starting. The start winding is
placed at 90 degrees (geometrically displaced) to the run winding. A capacitor is connected in
series with this winding. When AC is applied to the two circuits, an "out of phase" condition is
produced in the windings.

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The current in the start winding "leads" the current in the run winding. This means that the fields
produced by these two windings, are similarly displaced and a "two-phase" type rotating field
system is produced.

The action of the start winding is only required to initiate rotation. In practice the capacitor and
start winding are disconnected once the motor has reached about 80% of its rated speed. The
rotor will then maintain rotation by the "pulsating field" produced by the run winding.

CHANGING THE DIRECTION OF ROTATION

Since the motor is not self-starting but relies on an impulse to set it moving, it follows that the
direction of the impulse will determine the direction of rotation. Therefore, if we swap the
connections of the start winding at the supply, we will cause the motor to start in the opposite
direction.

As a rule then, to change the direction of rotation, we swap the start winding connections around
without making any changes to the run winding.

NOW VIEW THE VIDEO TO REVIEW NO. 2.

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 SELF-TEST EXERCISE NO. 2

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. Describe the nature of the field produced by the run winding.

_______________________________________________________
_______________________________________________________
_______________________________________________________

2. How can we get the rotor to turn?

_______________________________________________________
_______________________________________________________
_______________________________________________________

3. How is it possible to get the rotor to self-start?

_______________________________________________________
_______________________________________________________
_______________________________________________________

4. What is the function of the start capacitor?

_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________

5. What happens to the start circuit once the motor reaches 80% of its
rated speed?
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________

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6. How is the direction of rotation changed?
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________

7. What do you suppose would happen if the start and run windings
were both swapped together?
_______________________________________________________
_______________________________________________________

Back to Table of Contents 10

 RESOURCE NOTES (PART THREE)
BASIC OPERATING PRINCIPLES

INTRODUCTION
In the previous section we explained the necessity for an auxiliary or start winding and a start
capacitor. Without these two components, the motor would not be able to self-start.

In Section 1, we identified the run winding as having many turns of thicker wire; thus the run
winding tends to be more reactive than resistive. This means that the current in the run winding
lags the applied AC voltage.

The start winding on the other hand has less turns of thinner wire, making it more resistive than
reactive. The current is therefore more in phase with the applied voltage.

Now, when a capacitor of a specific value (typically 80 - 160 F) is connected in series with the start
winding, the current leads the applied voltage.

This manipulation is necessary to cause the current in the start winding to lead the current in the
run winding by 90 degrees. If the currents are so displaced, then the magnetic fields produced by
these two currents will also be displaced, so creating a rotating magnetic field to turn the rotor.

By induction, poles are formed in the rotor as the magnetic fields cut the rotor bars. The rotor

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poles react (unlike poles attract) with the stator poles and the rotor follows the rotating field
produced by the stator windings.

SYNCHRONOUS SPEED AND SLIP

The rotor never achieves the same speed as the stator field , but lags behind a small amount. We
call this slip. Slip is usually expressed as a percentage of the synchronous speed. Synchronous
speed is determined by the mains supply frequency and the number of pairs of pole pairs in the
stator.

R.P.M. = Hz x 60
No. of Pole Pairs

Example: A two pole machine running at a power line frequency of 50 Hz. will have a synchronous
speed of 3000 revs/min. (speed = frequency x 60 / number of pole pairs). If the rated speed of the
motor is 2860 rpm and the synchronous speed is 3000 rpm, then the % slip = 3000 - 2860 / 3000 x
100% which represents a slip of 4,7%.

When the motor has reached 80% of its rated speed, the start circuit is disconnected.

Although we have discussed the mechanically operated centrifugal switch, other types do exist,
such as the electrically operated "potential relay" switch.

POTENTIAL RELAY (cut-out switch)

The switch consists of a voltage-operated relay. The relay coil is connected across (in parallel with)
the start winding and the start circuit is connected to the supply via the relay's contact. At power-
up, the rotor quickly accelerates and in doing so, the rotor poles induce a voltage into the start
windings which adds to the applied voltage. When the voltage across the windings rises to 130% of
the supply voltage, the relay coil energises, so disconnecting the start winding and capacitor from
the motor circuit.

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CURRENT OPERATED RELAY (cut-out switch)
The current relay coil is connected in series with the run winding and senses the current drawn by
the runwinding. Initially, the heavy starting current taken by the winding is sufficient to keep the
relay coil energised and its contacts remain closed, connecting the start winding and start capacitor
to the supply. When the motor reaches 80% of its rated speed, the current in the run winding falls
below the holding current required by the relay, and the contacts open, disconnecting the start
circuit. This type of cut-out is usually found in domestic refrigeration compressor motors.

NOW VIEW THE VIDEO UP TO REVIEW NO. 3.

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 SELF-TEST EXERCISE NO. 3

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. The run winding has more turns of thicker wire. How does this affect
the electrical characteristic of the winding?
_______________________________________________________
_______________________________________________________

2. The start winding has less turns of thinner wire. How does this affect
the electrical characteristic of the winding?
_______________________________________________________
_______________________________________________________

3. The windings are designed to enable the motor to self-start.

Describe how this is achieved with respect to applied voltage and
current.
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________

4. The speed of the rotor is always less than the speed of the rotating
magnetic field. How is the speed difference expressed?
_______________________________________________________

5. The synchronous speed of an induction motor is dependent on two

parameters. Name them.
a) __________________________________________________
b) __________________________________________________

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6. What is the synchronous speed of a 4-pole motor operating from a
60 Hz. supply?
_______________________________________________________
_______________________________________________________

7. The start circuit is usually disconnected by a centrifugal switch.

Name another type of switch.
_______________________________________________________
_______________________________________________________

Back to Table of Contents 15

 RESOURCE NOTES (PART FOUR)
THE CAPACITOR RUN MOTOR

INTRODUCTION
The capacitor run motor is also known as a permanent split motor. It is almost identical to the
capacitor start motor except for two key differences, namely:
1. The start capacitor is replaced with a smaller capacitor (smaller capacitance) called a run
capacitor, and
2. The start winding remains permanently connected to the main supply.

The capacitance of the "run" capacitor is typically 20 F and it is continuously rated since it must
remain in circuit whilst the motor is running. Remember that a start capacitor is only rated for
intermittent operation and frequent stop/start operations could possibly damage the device.

The start winding of a permanent split motor is also continuously rated, since it remains in circuit
whist the motor is in operation.

Although the motor has a reduced starting torque (no start capacitor), it does display a good
running torque. The motor is ideally suited for frequent stop/start applications and for driving
flywheel type loads (e.g. a cooling fan).

CAPACITOR START/CAPACITOR RUN MOTOR (two-capacitor motor)

As the name suggests, this motor produces a good starting torque together with a good run torque
characteristic, for example an air compressor unit, where the motor must start frequently against a
load and run efficiently under load.

The motor incorporates all the same major components found in the other two types, however
both a start and a run capacitor are fitted.

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The schematic diagram shows two parallel circuits namely the run circuit and the start circuit. At
switch-on, both capacitors are connected in series with the start winding. When the motor reaches
80% of its rated speed, the cut-out switch opens, and the start capacitor is disconnected. The run
capacitor and the start winding remain connected providing a high running torque.

NOW VIEW THE VIDEO UP TO REVIEW NO. 4.

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 SELF-TEST EXERCISE NO. 4

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. Name two other types of capacitor motor.

a) __________________________________________________
b) __________________________________________________

2. Mention two important points concerning the run capacitor.

a) __________________________________________________
__________________________________________________
b) __________________________________________________
__________________________________________________

3. Name two features of the capacitor start / capacitor run motor.

_______________________________________________________
_______________________________________________________
_______________________________________________________

Back to Table of Contents 18

 RESOURCE NOTES (PART FIVE)
ELECTRICAL TEST PROCEDURES

INTRODUCTION
In this section we will discuss basic but important electrical test procedures that should be
performed after a motor has been serviced, repaired, or are simply being tested for integrity,
namely:
1. Continuity of windings.
2. Test capacitor/s for open or short circuit.
3. Insulation resistance between windings.
4. Insulation resistance between windings/components to earth (frame).

For this section you must know how to use an analogue or digital multi-meter to measure
resistance, as well as how to use a high voltage insulation tester (megger).

SAFETY FIRST!
Two important points to mention before attempting any testing:
1. Ensure that the motor is completely isolated from the main supply, and
2. Adhere to the safety procedures specified by your Company and the relevant code of
practice.

TERMINAL BOX & TERMINAL BLOCK

Access to all electrical components is made in the motor's terminal box. The windings, centrifugal
switch and capacitors are connected inside the box to a terminal block. Usually a wiring diagram is
affixed to the inside of the lid indicating how the motor should be connected for the required
direction of rotation.

PREPARING THE MULTI-METER TO MEASURE RESISTANCE

Use a good quality analogue or digital multi-meter to check the resistance of the circuits.
Remember with an analogue meter to adjust the meter to read zero ohms when the test leads are
shorted together.

NOTE: That there is no zero-ohm adjustment on a digital meter and the meter will read
approximately 0,3 ohms when the test leads are shorted together. This value represents the
resistance of the test leads. For a very accurate reading, subtract the resistance of the test
leads from the meter reading. For example, if the meter reads 2,4 ohms, the actual
resistance of the circuit under test is (2,4 -0,3) = 2,1 ohms.

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ELECTRICAL CHECK LIST
We suggest that you make / obtain a checklist to record all measurements and comments as the
tests are carried out. (See suggested checklist.) A sketch of the terminal block will help you to
create a picture of all the electrical circuits in the motor.

Before commencing the tests, ensure that all bridge pieces (brass links) have been removed.
Failure to do this will affect the resistance readings.

1. CONTINUITY TESTING
(To identify and determine the condition of the windings / components by resistance
measurement).

Clip one of the test leads to the top left hand post.
Probe all the remaining posts until a reading is obtained.
Note the position and the resistance reading and record this information on the checklist.
Move the test lead to the next post along, and repeat the procedure until all the posts have
been mapped.

The resistance measured (assuming the circuits are in a healthy condition) will help to
identify the windings or components -for example:
o the run winding resistance will always be less than the start winding resistance.
o the centrifugal switch will measure approximately zero ohms.

2. TESTING THE CAPACITORS

A capacitor stores electrical energy and we can use this characteristic to check its condition.
When connected to a DC source, a capacitor will charge (at a rate determined by its
capacitance) to the supply voltage. Once it has reached this voltage, the charging current
will cease. If the supply is swapped over and re-connected, the capacitor will discharge and
re-charge again (current now flows in the opposite direction).

We can observe this movement using an analogue multi-meter set to the "ohms x
100" position (the meter needle will show the charge and discharge current).

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 PROCEDURE
Ensure that there are no other circuits connected to the capacitor under test. Connect the
meter to the cap. The needle should deflect towards the zero-ohm position on the scale,
and then move back towards infinity position. Swap the leads over and check the deflection
again. The needle should kick past zero (discharging), and then return to infinity (charging).

NOTE: That the rate at which the needle swings, gives an indication as to the size (capacity)
of the capacitor. When testing a large capacitor the deflections will be slow, whilst a small
capacitor will produce quicker deflections (shorter discharging / charging time).

If, when testing, the meter deflects to the zero-ohm position and remains there, the
capacitor could be faulty, being internally short-circuited. If however the needle remains at
the infinity position, the capacitor could be open circuit.

Remember to record this information on your checklist as you complete each test.

3. INSULATION RESISTANCE TESTING - AN INTRODUCTION

Continuity tests tell us whether or not windings are continuous (no breaks or shorts).
Sometimes, due to overheating or moisture, the insulation breaks down between the
windings causing a burnout, and for this condition we must perform an insulation test.

To test for an insulation breakdown, we apply at least twice the normal operating
voltage across the windings and check the resistance (a leakage path) between the
windings.

To perform this test, we require an insulation resistance tester (sometimes referred to as a

megger). Since this instrument generates a high voltage (typically 500 volts) which we
apply across the windings, the meter displays the resistance in megohms. At this level of
potential difference, a weakness or fault in the insulation is likely to provide a measurable
reading on the scale. An infinity reading indicates a good circuit. Readings below 1 megohm
indicate an insulation fault.

4. PROCEDURE FOR TESTING THE WINDINGS (INSULATION)

Clip a test lead onto one end of the run winding, and the other lead to one end of the
start winding. Activate the megger and note the resistance reading on the megohm
scale. The reading must be at least 1 megohm to be acceptable.

Remember not to touch the probe tips when testing (500 volts is available to shock
you).

Move the lead (which was connected to the start winding) to the other end of the
start winding. Test again for a resistance, which must be greater than 1 megohm.
Move the lead (which was connected to the run winding) to the other end of the run
winding and test again for a resistance reading, which must be greater than 1 megohm.

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 Move the lead (which was connected to the start winding) to the other end of the
start winding and repeat the test over again. All readings must be greater than 1 megohm.

Record the results and your comments on the checklist.

5. INSULATION RESISTANCE BETWEEN WINDINGS/CENTRIFUGAL SWITCH /

CAPACITOR & EARTH (FRAME)
The purpose of this test is to ensure that all electrical circuits (windings/components) are
insulated from earth (motor frame). To test for this condition, we once again use an
insulation tester. Test voltage is applied between the electrical part and earth. A resistance
less than 0,5 megohm indicates a possible leakage path from the winding or component to
earth.

PROCEDURE
Connect one end of the insulation tester to a good earth point (free from paint / grease) on
the frame. Test the ends of each winding, the centrifugal switch and the capacitor/s and
confirm that the resistance measured is greater than 0,5 megohm.

NOW VIEW THE VIDEO UP TO REVIEW NO. 5.

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 SELF-TEST EXERCISE NO. 5

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. Tick the correct statement.

a) Motors should be tested as a routine part of a good
maintenance schedule.
b) Motors should be tested in order to find out when they will fail.
c) Motors should be tested to improve their performance and save
on electricity.

2. List the three main electrical tests that are discussed in this section.
a) __________________________________________________
b) __________________________________________________
c) __________________________________________________

3. What type of measuring instrument would you use to measure the

resistance of the windings (continuity)?
_______________________________________________________

4. When using an analogue multi-meter what must you do before

taking any readings?
_______________________________________________________
_______________________________________________________

5. When the test leads of a digital multi-meter are shorted together,

the resistance reading is not zero. Explain why this is so.
_______________________________________________________
_______________________________________________________

Back to Table of Contents 23

6. If the resistance of the run winding were say 25 ohms, would the
resistance of the start winding be greater or less than 25 ohms?
_______________________________________________________
_______________________________________________________
_______________________________________________________

7. What would you expect the resistance of the centrifugal switch to

measure?
_______________________________________________________

8. When testing a capacitor, you find that the meter needle deflects to
zero ohms and remains there. What conclusion would you come to?
_______________________________________________________
_______________________________________________________

9. When testing a capacitor the meter needle remains at the infinity

position even when the test leads are swapped around. Would you
say that the capacitor was open circuit, short circuit or fully
charged?
_______________________________________________________
_______________________________________________________

10. When measuring the insulation resistance between windings, what

is the minimum acceptable resistance value?
_______________________________________________________
_______________________________________________________

11. What is the minimum resistance value when testing between a

winding or centrifugal switch terminal or capacitor terminal, and
earth?
_______________________________________________________
_______________________________________________________

PERFORM A MOTOR TEST, AND REPORT ON A MOTOR IN YOUR WORKSHOP.

Back to Table of Contents 24

 RESOURCE NOTES (PART SIX)
BASIC MECHANICAL INSPECTION

INTRODUCTION
In this section we will discuss mechanical checks that should be performed after a motor has been
serviced, repaired or is simply being tested for integrity. You will need to know how to use a dial
gauge indicator.

BEARINGS
The condition of bearings will provide clues to many mechanical problems, so rotate the shaft and
listen carefully for any abnormal noise which may indicate worn or damaged bearing surfaces. Test
for excessive lateral play by moving the shaft from side to side. Test for excessive float by moving
the shaft in and out. There should be no appreciable movement if the bearing is in good order.

SHAFT AND KEY-WAY

A visual inspection of the key and keyway will indicate excessive wear or damage to the surfaces.
The key should fit snugly into the keyway.

MOTOR SHAFT
Using a dial gauge indicator, test the alignment of the shaft. Under normal circumstances, there
should be no deflection beyond approximately 0,02 mm.

STATOR FRAME AND END-SHIELDS

Check these parts for cracks, breaks or missing through-bolts or fixings.

FAN
The fan prevents the motor from overheating and broken or damaged blades will affect the air-
flow over the stator frame. Check the fan carefully for damaged or broken blades.

TERMINAL BOX
It is important that the terminal box is sealed from the ingress of dust, dirt and moisture. Check the
terminal box for cracks, breaks or missing parts especially the gasket, which seals between the box
and its cover.

NAMEPLATE
The motor nameplate is like a character reference. It records all the important information that the
user requires to safely operate the motor. Check that the nameplate is firmly secured to the stator
frame and that all the information contained on the plate is legible.

Back to Table of Contents 25

NOW VIEW THE VIDEO UP TO REVIEW NO. 6.

Back to Table of Contents 26

 SELF-TEST EXERCISE NO. 6

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTION YES NO

1. Name six key components that must be checked, stating briefly

what you would be on the lookout for.
i) _________________________________________________
ii) _________________________________________________
iii) _________________________________________________
iv) _________________________________________________
v) _________________________________________________
vi) _________________________________________________

PERFORM A MECHANICAL CHECK ON A CAPACITOR MOTOR.

Back to Table of Contents 27

 LEARNING OBJECTIVE
ADM-2: THREE PHASE INDUCTION MOTORS

OBJECTIVE
Upon successful competition of this module you will be able to:
o Identify by name the key components and state their functions.
o Describe the basic operating principles of a typical 3-phase induction motor.
o Perform the basic electrical and mechanical test procedures on a 3 -phase induction motor.

PROCEDURES
1. Read the Resource Notes beginning on the next page.
2. View video ADM-2 all the way through.
3. View the video again but this time STOP each time you see a REVIEW section.
4. Complete the Self-Test Exercise that follows the relevant section in the resource notes.
5. When you have mastered that section, by honestly receiving a YES response to each
criterion, continue to the next section.

RESOURCES
For this module you will require:
o This workbook.
o Video Programme ADM-2.
o 3-Phase induction motors in your training centre or workshop.

Back to Table of Contents 28

 RESOURCE NOTES (PART ONE)
CONSTRUCTION OF AN INDUCTION MOTOR

INTRODUCTION
The electric motor is a machine that is capable of converting electrical energy into mechanical
energy, and since electrical energy is normally supplied as an alternating current, AC motors are
widely used for many applications.

The Three Phase AC Induction motor is a simple, efficient and cost effective machine which
operates at near constant speed. It is therefore widely used in industry to drive a variety of loads.
These motors range in size from fractional power machines to outputs of hundreds of kilowatts, at
voltages ranging from 380 to 11 000 volts.

This programme features two types of induction motor, namely:

o 3 - Phase squirrel cage induction motor, and the
o 3 - Phase wound rotor or slip-ring induction motor.

CONSTRUCTION OF THE MOTOR

The diagram below illustrates a typical three-phase cage-motor. Study this and become familiar
with the various part names, as we will frequently refer to them during the programme.

14. Terminal Board Screw

1. Drive End Endshield
15. Gasket
2. Flange
16. Terminal Box Cover
3. Drive End Ballbearing
17. Terminal Box
4. Key
18. Terminal Box Holder Screw
5. Rotor
19. Earth Screw & Washers
6. Stator

Back to Table of Contents 29

7. Non-Drive End Ball Bearing 20. Gasket
8. Loading Spring 21. Terminal Board Holder Screw
9. Non-Drive End Endshield 22. Stay Bolt & Nut
10. Fan 23. Fan Cowl Screw
11. Circlip 24. Key
12. Fan Cowl 25. Front Mounting Flange
13. Terminal Board 26. Circlip

The principle components in terms of operation are the rotor and the stator.

ROTOR
The purpose of the rotor is to produce the turning effort or torque. This is achieved by
electromagnetic induction (hence the name "induction motor") as electrical energy from the stator
is converted into mechanical energy at the rotor shaft.

The rotor consists of a laminated iron core (laminated to reduce the losses caused by circulating or
eddy currents produced in the core). The rotor windings consist of a number of aluminium bars
(rotor bars) inserted into the core and joined together at each end by aluminium shorting rings.
These components are pressed onto a shaft, which is supported by bearings contained in the end-
shields. The end of the shaft that is coupled to the load is called the "driving end" (DE) and the
opposite end that usually supports a cooling fan is called the non-drive end (NDE).

STATOR
The purpose of the stator is to produce a rotating magnetic field to turn the rotor. The stator is
composed of a laminated iron core (laminated to reduce the electrical losses produced by eddy
currents) which is pressed into the stator frame. Three separate groups of insulated copper wire
(the windings) are placed into slots in the core to produce the rotating magnetic field system when
AC is passed through them.

NOW VIEW THE VIDEO UP TO REVIEW NO. 1.

Back to Table of Contents 30

 SELF-TEST EXERCISE NO. 1

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. List the two main components in a three-phase cage induction

motor.
_______________________________________________________

2. What is the basic purpose of the rotor?

_______________________________________________________
_______________________________________________________

3. What is the purpose of the stator?

_______________________________________________________
_______________________________________________________
_______________________________________________________

4. Complete the following sentence:

The stator has three windings. When connected to a three-
phase supply the coils produce a _____________________ field.

Back to Table of Contents 31

 RESOURCE NOTES (PART TWO)
BASIC OPERATING PRINCIPLES

INTRODUCTION
In the previous section, we identified the stator and the rotor as the key components of a three-
phase induction motor. Consider a very simply constructed stator with three poles displaced by
120 degrees.

When AC power is applied to the field coils:

o a magnetic field is produced in each coil, which changes polarity at the rate of the AC supply
(typically 50 times/sec.).
o the intensity of the magnetic field (current flowing in the coil) follows the alternating
voltage of the supply.

A rotating magnetic field is produced in the stator due to the mechanical displacement of the three
coils (120˚ offset) and the electrical displacement of the three-phase supply (each phase is
displaced by 120 degrees from the next).

To demonstrate the rotating field, we place a simple magnetic compass within the stator field.

When we replace the compass with a squirrel cage rotor, the rotor turns because of the rotating
magnetic field developed in the stator. Poles are formed (by electro-magnetic induction) in the
rotor. These poles react with the poles in the stator and the rotor turns, trying to keep in step with
the rotating field.

SYNCHRONOUS SPEED AND SLIP

The rotor never achieves the same speed as the stator field but lags behind by a small amount. This
lag is known as "slip". Slip is usually expressed as a percentage of the synchronous speed.
Synchronous speed (the speed of the rotating field) is determined by the mains supply frequency
and the number of pole pairs in the stator. For example a two pole motor running at a power line
frequency of 50 Hz. will have a synchronous speed of 3000 revs/min. (speed = frequency x 60 / no.
pole pairs).

Back to Table of Contents 32

In our example, if the rated speed of the motor is 2930 rpm and the synchronous speed is 3000
rpm , then the % slip = 3000 -2930 13000 x 100% = 2,3%.

CHANGING THE DIRECTION OF ROTATION

To change the direction of rotation in a three-phase motor, we simply swap any two phases
around. This will change the direction of rotation of the magnetic field, and the rotor.

NOW VIEW THE VIDEO UP TO REVIEW NO. 2.

Back to Table of Contents 33

 SELF-TEST EXERCISE NO. 2

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTION YES NO

1. What kind of field is produced when a three phase 50 Hz AC current

flows in the stator windings?
_______________________________________________________
_______________________________________________________

2. What is slip?
_______________________________________________________
_______________________________________________________
_______________________________________________________

3. The synchronous speed of an induction motor is determined by two

parameters. Name them.
_______________________________________________________
_______________________________________________________
_______________________________________________________

4. What is the synchronous speed of a B-pole motor operating from a

60 Hz. Supply?
_______________________________________________________
_______________________________________________________

5. How would you change the direction of rotation?

_______________________________________________________
_______________________________________________________

Back to Table of Contents 34

 RESOURCE NOTES (PART THREE)
ELECTRICAL TEST PROCEDURES

INTRODUCTION
In this section we will discuss basic but important electrical test procedures that should be
performed after a motor has been serviced, repaired, or is simply being tested for integrity. The
tests include:
1. Continuity of windings.
2. Insulation resistance between windings.
3. Insulation resistance between windings and earth (frame).

For this section you must know how to use an analogue or digital multi-meter to measure
resistance, as well as how to use a high voltage insulation tester (megger).

SAFETY FIRST!
Two important points to mention before attempting any testing:
1. Ensure that the motor is completely isolated from the main supply, and
2. Adhere to the safety procedures specified by your Company and the relevant code of
practice.

TERMINAL BOX & TERMINAL BLOCK

Access to all electrical components is made in the motor's terminal box. The windings are
connected inside the box to a terminal block. A wiring diagram is usually affixed to the inside of the
lid indicating how the motor should be connected for the desired direction of rotation.

PREPARING THE MULTI-METER TO MEASURE RESISTANCE

Use a good quality analogue or digital multi-meter to check the resistance of the windings. Adjust
the meter to read zero ohms with the test leads shorted together.

A digital meter will read approximately 0,3 ohms when the test leads are shorted together. This
value represents the resistance of the test leads. To calculate the true resistance of the windings,
subtract the resistance of the test leads from the meter reading, alternatively, refer to the
instrument manufacturer's instructions as to the zero reference setting procedure.

ELECTRICAL CHECK LIST

We suggest that you make / obtain a checklist to record all measurements and comments as the
tests are carried out. A sketch of the terminal block will help you to create a picture of all the
electrical circuits in the motor.

Before commencing the tests, ensure that all bridge pieces (brass links) are removed. Failure to do
this will affect the resistance readings.

Back to Table of Contents 35

1. CONTINUITY TESTING

The purpose of this test is to identify the termination points and the resistance of
each winding. For convenience begin the test procedure as follows:
o Clip one of the test leads to the top left hand post.
o Probe all the remaining posts until a reading is obtained.
o Note the position and the resistance reading and record this information on the
checklist.
o Move the test lead to the next post along, and repeat the procedure until all the
posts have been mapped.

The resistance of the three windings should be of similar value and within 5% of each other
(i.e. the 3 windings would be balanced), for example:
A1 - A2 = 10,70Ω
B1 - B2 = 10,85Ω
C1 - C2 = 10,50Ω

The difference between the highest & lowest reading is 0,35 (10,85 - 10,5)
% difference = 0,35/10,85 x 100 = 3,2%.

INSULATION RESISTANCE TESTING

Continuity tests tell us that the stator windings are continuous (no breaks or shorts), but
sometimes, due to overheating or moisture, the insulation breaks down between the
windings, causing a high current to flow. As a result the windings may overheat, causing a
burnout.

To test for an insulation breakdown, we must apply at least twice the normal operating
voltage across the windings and check the resistance (a leakage path) between the
windings.

We use an insulation resistance tester (sometimes referred to as a megger). This

instrument generates a high voltage (typically 500-volt output) which we apply across the
windings. The meter on the instrument displays the resistance in megohms. At this level of
potential difference, a weakness or fault in the insulation is highly likely to show as a low
resistance reading.

Back to Table of Contents 36

2. PROCEDURE FOR TESTING THE INSULATION RESISTANCE BETWEEN WINDINGS
o Indicated below is a typical sequence to test the insulation resistance of each of the
three windings.
o Keep hands clear of the probes when measuring! (500 volts across the probe tips
will give you a nasty shock!).
o Connect the meter probes between the test-points and record the values.

TEST POINTS RESISTANCE

A1 – B1 >1 MΩ
A1 – C1 >1 MΩ
B1 – C1 >1 MΩ
A2 – B2 >1 MΩ
A2 – C2 >1 MΩ
B2 – C2 > 1 MΩ

In each case, the resistance measurement must be greater than 1 meg-ohm.

3. INSULATION RESISTANCE BETWEEN WINDINGS & EARTH (FRAME)

The purpose of this test is to ensure that all three windings are free (Le. insulated) from
earth (motor frame). To test for this condition, we once again use an insulation tester. This
time we apply the high voltage between the electrical part and earth. A resistance less than
0,5 megohm indicates a possible leakage path from the winding or component to earth.

The measurement procedure is as follows:

o Connect one end of the insulation tester to a good earth point (free from paint /
grease) on the frame.
o Probe the ends of each winding and confirm that the resistance measured in each
case is greater than 0,5 megohm.

NOW VIEW THE VIDEO UP TO REVIEW NO. 3.

Back to Table of Contents 37

 SELF-TEST EXERCISE NO. 3

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTION YES NO

1. Tick the correct statement.

a) Motors should be tested as a routine part of a good
maintenance schedule.
b) Motors should be tested in order to find out when they
will fail.
c) Motors should be tested to improve their performance
and save on electricity.

2. List the three main electrical tests that are discussed in this
section.
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________

3. Name the type of measuring instrument would you use to

measure the resistance of the windings.
_________________________________________________

4. When using an analogue multi-meter what must you do

before making any resistance measurements?
_________________________________________________
_________________________________________________

5. When the test leads of a digital multi-meter are shorted

together, the resistance reading is greater than zero ohms.
Why is this is so?
_________________________________________________
_________________________________________________

Back to Table of Contents 38

6. When measuring the insulation resistance between
windings, what is the minimum acceptable resistance value?
_________________________________________________

7. What is the minimum resistance value when testing between

a winding and earth?
_________________________________________________
_________________________________________________

Back to Table of Contents 39

 RESOURCE NOTES (PART FOUR)
BASIC MECHANICAL INSPECTION

INTRODUCTION
In this section we will discuss mechanical checks that should be performed after a motor has been
serviced, repaired or is simply being tested for integrity. Mechanical checks are necessary to ensure
that the motor is operating at its maximum level of efficiency and safety. You will need to know
how to use a dial gauge indicator.

BEARINGS
The condition of bearings will provide clues to many mechanical problems, so rotate the shaft and
listen carefully for any abnormal noise which may indicate worn or damaged bearing surfaces. Test
for excessive lateral play by attempting to move the shaft from side to side. Test for excessive float
by moving the shaft in and out. There should be no appreciable movement if the bearing is in good
order.

SHAFT AND KEYWAY

A visual inspection of the key and keyway will indicate excessive wear or damage to the surfaces.
The key should fit snugly into the keyway.

MOTOR SHAFT
Using a dial gauge indicator, test for "run-out" on the shaft. Under normal circumstances, there
should be no deflection beyond approximately 0,02 mm.

STATOR FRAME AND END-SHIELDS

Check these parts for cracks, breaks or missing through-bolts or fixings.

FAN
The fan prevents the motor from overheating. Check the fan carefully for damaged or broken
blades, as these will affect the airflow over the stator frame, and result in vibration.

TERMINAL BOX
It is important that the terminal box is sealed from the ingress of dust, dirt and moisture. Check the
terminal box for cracks, breaks or missing parts, especially the gasket, which seals between the box
and its cover.

Back to Table of Contents 40

NAMEPLATE
The motor nameplate is like a character reference. It displays all the important information that
the user requires to safely operate the motor. Check that the nameplate is firmly secured to the
stator frame and that all the information contained on the plate is legible.

NOW VIEW THE VIDEO UP TO REVIEW NO. 4.

Back to Table of Contents 41

 SELF-TEST EXERCISE NO. 4

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTION YES NO

1. Name six key components that must be checked, stating briefly

what you would be on the lookout for.
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________

PERFORM A MECHANICAL INSPECTION, AND REPORT ON A MOTOR IN YOUR WORKSHOP.

Back to Table of Contents 42

 RESOURCE NOTES (PART FIVE)
SLIP RING MOTORS (CONSTRUCTION & OPERATION)

INTRODUCTION
The main difference between a cage motor and a slip ring motor lies in the construction of their
rotors. The same stator is used for both types of motor.

APPLICATION OF A WOUND ROTOR OR SLIP-RING MOTOR

In many cases it is necessary to have a measure of control over the torque/speed characteristics of
a motor depending on the nature of the load it is driving e.g. a crane. Adding resistance to the
stator or rotor circuits can vary the torque/speed characteristics of an induction motor. It is
preferable (more manageable and efficient) to add the resistance in the rotor circuit, (low voltage
side of the machine). This fact led to the development of the "wound rotor", since it is not possible
to change the characteristics of a cage rotor. Resistance is added into the rotor circuit via slip rings.

CONSTRUCTION OF A WOUND ROTOR

Instead of aluminium bars (which constitute the windings in a squirrel cage rotor) sets of coils
made from insulated copper wire are placed into slots in the rotor core. These coils are arranged to
form three windings. The windings are internally connected together in "star" (wye) and the
remaining ends are terminated into slip rings attached to the rotor shaft.

Three brushes (the brush-gear) attached to the stator frame (but insulated from it) ride on the slip
rings making the electrical connection between the rotor windings and the external control-circuit.
The control circuit typically consists of a three-phase resistor bank. From start-up, the resistance is
progressively switched out, in stages, until the rotor windings are short-circuited together. The
rotor then behaves as though it was a cage rotor and maximum power is transferred to the load.

Back to Table of Contents 43

NOW VIEW THE VIDEO UP TO REVIEW NO. 5.

Back to Table of Contents 44

 SELF-TEST EXERCISE NO. 5

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. Complete the following sentence:

The difference between a cage induction motor and a slip ring
motor lies in the construction of the _______________________.

2. How can the output characteristics of an induction motor be

changed?
_______________________________________________________
_______________________________________________________

3. Complete the following sentence:

Increasing the resistance in the rotor circuit will affect the
______________________ and the ________________________
characteristics of the motor.

Back to Table of Contents 45

 RESOURCE NOTES (PART SIX)
SLIP RING MOTORS
(ELECTRICAL & MECHANICAL CHECKS)

ELECTRICAL CHECKS
CONTINUITY CHECKS
The rotor of a slip-ring motor carries three sets of windings. Our first test is to test for continuity in
the windings. This involves measuring the resistance of each winding. The windings must be
continuous and balanced (not more than 5% difference between the resistance of any winding).

A suitable analogue or digital multi-meter is required for these tests. Ensure that the meter is
correctly set up (as previously explained) to measure resistance. Note your results and comments
on a suitable checklist.

INSULATION RESISTANCE CHECKS TO EARTH

The next test is to ensure that the windings do not contact "earth" (shaft). Once again a potential
of at least twice the rated voltage is required to effectively test for a breakdown between the
windings and earth (shaft). Test (using an insulation resistance tester or "megger") between each
slip ring and the shaft. All readings must be greater than 0,5 megohm to be acceptable.

After the motor has been assembled, we can check the insulation resistance between the brush-
holders and earth. Lift the brushes away from the slip rings to measure the insulation resistance
between the brush-holders and the motor frame. The readings must be greater than 0,5 meg-ohm
to be acceptable.

MECHANICAL CHECKS
Since the rotor circuit depends on a good electrical connection between the slip rings and brushes,
these components must be carefully checked.

To begin with, slip rings must be checked for uneven wear, and the surfaces must be free from
grease, oil or grit. Then, brush holders, pigtails and brush length must be checked.
o Pigtails must not be loose or damaged.
o The length of each brush should not be less than specified limits, (wear factor).
o Brush holders must be clean so that the brush can move freely inside the holder.
o Spring pressure must be firm -loss of tension will result in poor contact between the brush
and slip-ring.
o The tip of each brush should be shaped to ensure maximum contact between the slip ring
and the brush.
o brush alignment must be checked to ensure that each brush runs in the centre of its slip
ring.

NOW VIEW THE VIDEO UP TO REVIEW NO. 6.

Back to Table of Contents 46

 SELF-TEST EXERCISE NO. 6

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. How do we get electrical access the rotor windings?

_______________________________________________________
_______________________________________________________

2. Name two electrical tests to be performed on the rotor.

_______________________________________________________
_______________________________________________________

3. Complete the following sentence.

The windings must be balanced. This means that the ohmic
resistance of all three windings must be within _________ of each
other.

4. When performing an insulation test between the windings and

earth, what is the accepted minimum resistance?
_______________________________________________________

5. Complete the following sentences.

Slip rings must be free from _________________________ ,
________________________ and ________________________.

6. When checking the brush rigging, look out for the following:
Pigtails must not be ________________ or _________________.

7. The length of each brush should not be ________________ beyond

specified limits.

Back to Table of Contents 47

 8. Brush holders must be clean so that the _______________ can
move __________________ inside the holder.

9. Spring pressure must be firm: -loss of tension will result in

___________________________________ between the brush and
slip ring.

10. The tip of each brush should be shaped to ensure

___________________ _________________ between the slip-ring
and the brush.

11. Brush alignment must be checked to ensure that the brush

rides __________________________________ of the slip ring.

PERFORM ELECTRICAL TESTS ON A SLIP-RING MOTOR IN YOUR WORKSHOP, AND REPORT YOUR RESULTS.
PERFORM A MECHANICAL INSPECTION, AND REPORT ON A MOTOR IN YOUR WORKSHOP.

Back to Table of Contents 48

 LEARNING OBJECTIVE
ADM-3: DC MACHINES

OBJECTIVE
Upon successful competition of this module you will be able to:
o Identify by name the key components and state their functions.
o Describe the basic operating principles of a DC motor / generator.
o Perform the basic electrical and mechanical test procedures on a DC motor / generator.

PROCEDURES
1. Read the Resource Notes beginning on the next page.
2. View video ADM-3 all the way through.
3. View the video again but this time STOP each time you see a REVIEW section.
4. Complete the Self-Test Exercise that follows the relevant section in the resource notes.
5. When you have mastered that section, by honestly receiving a YES response to each
criterion, then continue to the next section.

RESOURCES
For this module you will require:
o This workbook.
o Video Programme ADM-3.
o DC motors in your training centre or workshop.

Back to Table of Contents 49

 RESOURCE NOTES (PART ONE)
CONSTRUCTION OF A DC MOTOR

INTRODUCTION
A DC Machine is both a DC motor and a DC generator. As a motor, the machine converts electrical
energy into mechanical energy. When driven as a generator, it converts mechanical energy into
electrical energy.

We begin by first discussing the DC motor. DC motors have been used for many years to drive
machinery that requires speed control. A classic example is a locomotive, whether it is electric or
diesel-electric.

By connecting the field windings in a particular configuration, it is possible to alter the

characteristics of the motor (particularly speed versus torque) to match the requirements of the
mechanical load.

CONSTRUCTION OF A DC MOTOR
The main components are:
o The armature.
o The frame, which contains the yoke and the field windings.
o Two end shields with bearings which support the armature, and
o A set of brushes and brush-holders (brush-gear or brush-rigging).

ARMATURE
The purpose of the armature is to produce the turning effort or torque. A mechanical force
created by the armature and the field windings achieves this. When DC is fed to the armature
windings and the stator windings, magnetic poles are formed (in both) which react to produce
motion.

The armature consists of a laminated iron core. (A laminated core reduces the losses caused by
circulating or eddy currents that are produced in an iron core.) The core is pressed onto a shaft.
The armature windings comprise a number of coils of insulated copper wire. These coils are wound
in slots in the core. The armature coils are connected to a commutator, fixed to one end of the
shaft. The commutator consists of a number of copper bars or segments which are insulated from
each other and the shaft.

A set or sets of carbon brushes are positioned upon the commutator. Brushes make contact with
the commutator bars, and pass DC power into the armature coils (armature windings). A two-pole
machine has two brushes. A four-pole machine has four brushes.

The shaft assembly is supported within the stator frame upon bearings that are contained in end-
shields. The end of the shaft that is coupled to the load is called the "driving end" (DE). The
opposite end that supports a cooling fan is called the non-drive end (NDE).

Back to Table of Contents 50

STATOR OR STATIONARY PART OF THE MACHINE
The purpose of the stator is to produce a static field system consisting of pairs of poles (one north
and one south pole in 2-pole machine). The stator is composed of a laminated iron core (laminated
to reduce the electrical losses produced by eddy currents), consisting of a yoke and poles. The core
is pressed into the stator frame. Insulated copper wires (the field windings) are fitted into the core.
When DC is passed through the windings, the main magnetic field system is produced.

NOW VIEW THE VIDEO UP TO REVIEW NO. 1.

Back to Table of Contents 51

 SELF-TEST EXERCISE NO. 1

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. List the two main components of a DC motor.

_______________________________________________________

2. What is the purpose of the armature?

_______________________________________________________
_______________________________________________________

3. What is the purpose of the stator?

_______________________________________________________
_______________________________________________________
_______________________________________________________

4. What is connected to the commutator?

_______________________________________________________
_______________________________________________________
_______________________________________________________

5. What is the function of the brushes?

_______________________________________________________
_______________________________________________________

Back to Table of Contents 52

 RESOURCE NOTES (PART TWO)
BASIC OPERATING PRINCIPLE OF A DC MOTOR

INTRODUCTION
If a current carrying conductor (the armature) is placed at right angles to a magnetic field (the
stator), the inter-action between the main magnetic field and the field around the conductor will
exert a force on the conductor which results in movement.

NB: Fleming's left-hand rule applies here to assist us in

determining the direction of motion.

SIMPLE TWO BAR MAGNET

In a simple experiment using two "bar magnets", we can test this principle. (One magnet
represents the armature, and the other, the main magnetic field.) When "like" poles are brought
together, repulsion takes place and the magnets are forced apart. When "un-like" poles are
brought together, attraction takes place and the magnets are drawn to each other.

This "attraction" and "repulsion" behaviour of two magnets is what creates the motion in a DC
motor. In the following diagram (next page) two electro-magnets are attached to pole pieces that
constitute the main field (a north and a south pole). An additional electro-magnet that is free to
rotate is placed between the fixed electro-magnets (within the main magnetic field).
DC power is connected directly to the static electro-magnets (the main field). The source is also
connected, via a mechanical switching device (brushes &commutator), to the rotating electro-
magnet (the armature). At power-up, the magnets react with each other producing motion.

Back to Table of Contents 53

THE FUNCTION OF THE COMMUTATOR
The armature would not continue to rotate were it not for the action of the commutator and
brushes. The function of the commutator is to reverse the flow of current in the armature when
the armature poles turn through the "magnetic neutral" position. By reversing or switching the
current flow in the armature, the polarity of the field changes ensuring that the forces of attraction
and repulsion always react to sustain the motion of the armature.

Switching power in a DC circuit when a current is flowing results in an arc between the switching
contacts. In order to minimise arcing and avoid commutator damage we need to switch over the
armature circuit when minimum current is flowing. Minimum sparking occurs at the magnetic
neutral position, i.e. when the armature poles are at right angles to the main poles.

In this position the armature poles are cutting the least lines of force produced by the main
magnetic field and the current induced into the armature is at a minimum. This position is known
as the "correct point of commutation". It is possible to set the exact switching position (point of
commutation) by moving the position of the brushes relative to the commutator.

CHANGING THE DIRECTION OR ROTATION

Simply swapping the connections to the armature circuit changes the direction of rotation.

Alternatively, we can cause a direction change by reversing the current flow in the main field. This
is achieved by swapping the connections to the field windings. The preferred way is to change the
circuit connections at the armature terminals.

Back to Table of Contents 54

BACK OR COUNTER-EMF
We mentioned earlier the importance of setting the brush position so that the switching point or
"point of commutation" occurred when the armature poles lay within the "magnetic neutral"
position. This we said was necessary, to ensure that minimum current would be flowing in the
armature circuit, and thus reduce arcing on the commutator.

When a current carrying conductor moves within a magnetic circuit it will cut through lines of
magnetic flux. This action induces a voltage into that circuit which opposes the applied voltage.
This induced voltage is called a back or counter emf (Lenz's Law).

It is this counter-emf which causes the arc. However if it were not for this counter emf, the motor
would draw a very large current and ultimately burn out. The actual current, drawn by the motor,
is equal to the difference between the applied current and the current generated by the counter-
emf.

When we drive a DC Motor with another motor, it is this "counter-emf” that is collected by the
brushes, thereby changing the function of a DC Motor to a DC Generator.

The counter-emf is dependent on three things, namely:

1. Field strength produced by the main field.
2. The number of turns in the coils of the armature windings.
3. The speed of rotation of the armature, or in other words, the rate at which the armature
conductors cut the lines of magnetic force produced by the main magnetic field.

NOW VIEW THE VIDEO UP TO REVIEW NO. 2.

Back to Table of Contents 55

 SELF-TEST EXERCISE NO. 2

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. Complete the following sentence:

_____________poles attract, whilst _____________ poles repel.

2. What is the function of the commutator?

_______________________________________________________
_______________________________________________________
_______________________________________________________

3. How do we set the switching position or point of commutation?

_______________________________________________________

4. The brushes should be set to switch at a pre-determined position.

What is that position called?
_______________________________________________________

5. What will happen when a switch interrupts the current flowing in a

DC circuit?
_______________________________________________________
_______________________________________________________

6. Why is it necessary to reduce the size of the arc?

_______________________________________________________
_______________________________________________________

Back to Table of Contents 56

7. What is back or counter-emf?
_______________________________________________________
_______________________________________________________
_______________________________________________________

8. What three factors determine the magnitude of the back or

counter-emf?
a) _______________________________________________
b) _______________________________________________
c) _______________________________________________

9. How does the back emf affect the current drawn by a motor?
_______________________________________________________
_______________________________________________________

Back to Table of Contents 57

 RESOURCE NOTES (PART THREE)
TYPES OF DC MOTORS

INTRODUCTION
DC motors differ according to their purpose or application. The main difference is found in the
construction of the field coils and in the manner in which the field coils and armature are
connected.

1. SERIES WOUND MOTOR

o Contains field coils consisting of a few turns of heavy gauge insulated copper wire
connected in series with the armature. The current in the series field is controlled by
the back-emf in the armature, but the back-emf of a series motor is never enough to
limit the speed, therefore the motor does not have good speed regulation.
o The motor has a high starting torque and is popular for high torque loads and
traction applications e.g. cranes, winches, and starter motors.
o Without a load or if the load is suddenly removed, the motor will overspeed and
may self-destruct.

CONNECTING A DC SERIES MOTOR

o Series motor - the field coils are connected in series with the armature.

2. SHUNT WOUND MOTOR

o A shunt motor has a field winding made with many turns of fine wire.
o The field windings and armature are both connected across the supply.
o The strength of the shunt field, once set, cannot vary with load, and does not
provide extra field strength when the load is increased.
o The shunt motor is not suitable for varying loads but it does provide a fairly constant
speed characteristic (10-15%) -suitable for loads that require a steady speed e.g. fan.

CONNECTING A DC SHUNT WOUND MOTOR

o Shunt wound motor - the field and the armature are connected in parallel.

Back to Table of Contents 58

3. COMPOUND WOUND MOTOR
o The "compound motor" has both a series and shunt winding.
o The shunt field provides for good speed regulation, whilst the series field gives the
motor a good starting torque and the ability to handle overloads.

Types of compound connection are:

The windings can be cumulatively connected, where both fields add to the overall
field strength, or differentially connected where the series and shunt fields oppose
each other.

These different combinations affect the overall output characteristic of the machine and
enable the user to set the characteristics of the machine to the requirements of the load.

Back to Table of Contents 59

 BASIC CONNECTION OF A DC MOTOR

THE OVERSPEED OR TORQUE CONTROL (SHUNT FIELD REGULATOR)

o A decrease in field strength is followed by a reduction in back emf. This in turn
causes the applied current to the motor to increase accompanied by an increase in
motor speed until motor current stabilises.
o Hence the shunt field regulator is called an "overspeed" or "torque control".

THE UNDER-SPEED OR HORSEPOWER CONTROL (SERIES FIELD REGULATOR)

o A controller can be placed in series with the armature circuit to control the
armature voltage -this will decrease the speed of the motor.
o "Sack emf "decreases allowing more current to flow in the armature thereby
increasing the torque until the speed is stabilised.
o When the armature speed slows, as a result of increased load, the "back emf' will
decrease. When "back emf' decreases current flow to the armature increases. This
results in an increase in torque to the armature shaft until the speed stabilises.

REVERSING THE THREE MOTOR TYPES

o Swap either the field or armature connections, but not both.
o It is usual procedure to reverse the current through the armature.

AN OVERVIEW OF DC GENERATORS
We have seen how the characteristics of a DC motor can be altered by changing the connections of
the field windings. Since a DC Generator is a "driven" DC motor, the same procedures of
"matching" the generator output to the load apply, i.e. by the way in which the field windings are
arranged.

Back to Table of Contents 60

BASIC PRINCIPLE OF OPERATION
When a conductor is moved at right angles to the lines of force in a magnetic field, a voltage is
induced in the conductors. The magnitude of the voltage generated is represented by:
a) The sum of the voltages generated in each conductor.
b) The strength of the magnetic field.
c) and the speed with which the conductors cut the field.

The magnetic field (lines of force) is produced by either:

a) Permanent magnets.
b) Excitation of the generator field coils from an external DC source (external excitation).
c) Excitation of the field coils by the current from the armature (self-excitation).

GENERATOR TYPES
SERIES GENERATOR (CONSTANT CURRENT GENERATOR)
o Rare these days -only used in locomotives.
o Output is only possible once the load has been connected.
o The voltage generated is proportional to the load.
o If a small load is connected, a small current will be generated. If the load is increased, a
greater current will flow and the field will strengthen producing a higher voltage.
o Further increase in load will cause a further increase Load in the volt drop across armature
and output voltage falls (due to copper and iron losses).

SHUNT GENERATOR (CONSTANT VOLTAGE GENERATOR)

o The field coils are connected across the armature and, as a result, the field strength is
practically constant regardless of load.
o As the load is increased, the output voltage decreases because of the increased volt drop in
the armature.
o The shunt generator produces a maximum output at no load which reduces slightly as the
load is increased.

Back to Table of Contents 61

COMPOUND GENERATOR (CONSTANT VOLTAGE UNDER VARYING LOAD CONDITIONS)
o Most common is the "short-shunt cumulative compound-connected generator".
o Current flow in the shunt field is in the same direction as in the series field (field strengths
add = cumulative effect).
o The generator supplies near constant voltage as load is increased.

o Increasing or decreasing the number of turns on the series field, or using a bypass resistor
(diverter) connected across the series field can modify regulation.
o By changing the number of turns on the series field winding, the generator will behave as
"level compounded", "over-compounded", or "under-compounded".
o A shunt field regulator (field rheostat) is used to vary the strength of the magnetic field and
hence the output voltage of the generator.

A "differentially-connected" generator will cause the output to fall rapidly as the load is increased
due to the field systems opposing each other (field weakening =reduction in generated voltage).

Back to Table of Contents 62

NOW VIEW THE VIDEO UP TO REVIEW NO. 3.

Back to Table of Contents 63

 SELF-TEST EXERCISE NO. 3

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. Name one useful characteristic of a series connected DC motor.

_______________________________________________________

2. What is the series motor used for?

_______________________________________________________
_______________________________________________________

3. What happens to a series wound motor when the load is suddenly

removed?
_______________________________________________________

4. Describe the characteristics of a shunt winding.

_______________________________________________________
_______________________________________________________

5. How is the field winding connected in a shunt motor?

_______________________________________________________
_______________________________________________________

6. Name an important characteristic of a shunt machine.

_______________________________________________________

7. Name the two windings of a compound motor.

_______________________________________________________

Back to Table of Contents 64

8. Name two characteristics of a compound motor.
_______________________________________________________
_______________________________________________________

9. How can a DC motor be made to over-speed (electrically)?

_______________________________________________________
_______________________________________________________
_______________________________________________________

10. How can a DC motor be made to run under-speed (electrically)?

_______________________________________________________
_______________________________________________________

11. How would you reverse the direction of rotation in a DC motor?

_______________________________________________________

12. Name the output characteristics of a series, shunt and compound

generator.
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________

Back to Table of Contents 65

 RESOURCE NOTES (PART FOUR)
ELECTRICAL TEST PROCEDURES

INTRODUCTION
In this section we will discuss basic electrical test procedures that should be performed after a
motor has been serviced, repaired, or is simply being tested for integrity, namely:
1. Continuity of windings.
2. Insulation resistance between windings.
3. Insulation resistance between windings and earth (frame).

SAFETY REQUIREMENTS
Before commencing any electrical tests:
1. Ensure that the motor is completely isolated from the main supply, and
2. Adhere to the safety procedures specified by your Company and the relevant code of
practice.

TERMINAL BOX & TERMINAL BLOCK

Access to all electrical connections is made in the motor's terminal box. The windings are
connected inside the box to a terminal block. A wiring diagram is usually affixed to the inside of the
lid indicating how the motor windings should be connected to achieve a particular direction of
rotation.

PREPARING THE MULTI-METER TO MEASURE RESISTANCE

o Use a good quality analogue or digital multi-meter to check the resistance of the windings.
o Remember to adjust the meter to read zero ohms when the test leads are shorted together.
o A digital meter will read approximately 0,3 ohms when the test leads are shorted together.
This value represents the resistance of the test leads.
o To calculate the true resistance of the windings, subtract the resistance of the test leads
from the meter reading, alternatively, refer to the manufacturer's instructions as to the
zero reference procedure.

ELECTRICAL CHECK LIST

We suggest that you make / obtain a checklist to record all measurements and comments as the
tests are carried out. A sketch of the terminal block will help you to create a picture of all the
electrical circuits in the motor.

PREPARATION
Before commencing the tests, ensure that all bridge pieces (brass links) are removed. Failure to do
this will affect the resistance readings.

Back to Table of Contents 66

1. CONTINUITY TESTING
o The purpose of this test is to identify each winding, and determine its resistance.
o Clip one of the test leads to the top left hand post.
o Probe all the remaining posts until a reading is obtained.
o Note the position and the resistance reading and record this information on the
checklist.
o Move the test lead to the next post along, and repeat the procedure until all the
posts have been mapped.

As a rule, the series winding will produce the lowest value of resistance, the armature
circuit will measure slightly higher, and the shunt field winding will show the highest value
of resistance.

INSULATION RESISTANCE TESTING

Continuity tests tell us that the windings are continuous (no breaks or shorts), but
sometimes due to overheating or moisture, the insulation breaks down between the
windings causing a high current to flow, and consequent overheating or burnout.

To test for an insulation breakdown, we must apply at least twice the normal operating
voltage across the windings and check the resistance (a leakage path) between the
windings.

We use an insulation resistance tester (sometimes referred to as a megger) since this

instrument generates a high voltage (typically 500-volt output) which we apply across the
windings. The meter on the unit displays the resistance measured in meg-ohms. At this
level of potential difference, a weakness or fault in the insulation is highly likely to show a
low resistance reading to earth.

2. PROCEDURE FOR TESTING THE INSULATION RESISTANCE BETWEEN WINDINGS

SAFETY TIP: Remember to keep hands clear of the probes when measuring! (500 volts
across the probe tips will give you a nasty shock!).
o A typical test sequence is illustrated: In each case, the resistance measurement must
be greater than 1 megohm.

Back to Table of Contents 67

 TEST POINTS RESISTANCE
C–F >1Ω
C – FF >1Ω
CC – F >1Ω
CC - CC >1Ω

In each case, the resistance measurement must be greater than 1 megohm.

3. INSULATION RESISTANCE BETWEEN WINDINGS & EARTH (FRAME)

The purpose of this test is to ensure that all windings are clear from earth (motor
frame).
To test for this condition, we once again use an insulation tester and apply the high
voltage between the electrical part and earth. A resistance less than 0,5 megohm
indicates a possible leakage path from the winding or component to earth.

The measurement procedure is as follows:

o Connect one end of the insulation tester to a good earth point (free from paint /
grease) on the frame.
o Probe the ends of each winding and confirm that the resistance measured in each
case is greater than 0,5 megohm.

THE ARMATURE CIRCUIT

When performing continuity checks on our motor, we said that, as a rule of thumb, the
armature circuit has a resistance slightly higher than the series field.

If when measuring the resistance of the armature circuit you find that it is reading
zero (very low) or infinity (very high), it is likely that there is a fault in the armature
windings.

Let's examine the armature circuit in more detail. Although constructed as separate
parts, the armature circuit includes the armature, the inter-poles and the brush

Back to Table of Contents 68

rigging, which are all connected in series. The brushes provide the electrical connection
between the armature (which includes the inter-pole windings) and the terminal posts.
Brushes therefore must be considered as part of the armature circuit when testing or fault-
finding.

CONTINUITY CHECKS
We begin with the armature. All the individual coils of the armature circuit must be tested.
The resistance of each coil must be determined. Measuring between each adjoining pair of
commutator bars makes this reading. The resistance reading of each coil should be
approximately the same (within 5%). A zero ohm reading suggests that a coil is "short
circuited", whilst a reading approaching infinity means a possible open circuit coil.

INSULATION RESISTANCE TEST BETWEEN ARMATURE WINDINGS AND EARTH

We continue by testing the resistance between each coil end and earth (the armature
shaft). The insulation resistance tester (megger) is suitable since it give us the high voltage
(500V) necessary to induce a breakdown in the resistance should there be a weakness
somewhere in an electrical circuit. A measurement must be made between every
commutator bar and earth. In each case the resistance must be greater than 0,5 meg-ohm
to be acceptable.

NB: The test does not isolate the commutator bars that could be shorting.

THE BRUSH RIGGING (BRUSH-GEAR) CHECKS

It is possible that the brush rigging may be shorting to earth. We should therefore
isolate and test the brush holders. Isolate the brush-gear by lifting the brushes away
from the commutator. Once clear of the commutator bars, the insulation resistance
can be tested by measuring between each brush holder and earth.

NB: The armature circuit must not be connected to any other circuit (at the
terminal box).

Back to Table of Contents 69

THE INTERPOLE WINDING CHECKS
Once the brush rigging has been tested and is known to be clear of earth, we can test the
state of the interpole windings. These windings are connected in series with the armature,
so if we place a shorting link cross the armature, we effectively isolate the windings.
Alternatively, lifting the brushes away from the commutator will isolate the interpole
circuit.

Measure the ohmic resistance between the armature terminals (terminal block). As a
rule, the interpole winding resistance should be a little lower than the series field
resistance.

INSULATION RESISTANCE BETWEEN THE INTERPOLE WINDING TO EARTH

The routine is as previously discussed, and the reading between each end of the winding
and earth (frame) must be greater than 0,5 meg-ohm.

NOW VIEW THE VIDEO UP TO REVIEW NO. 4.

Back to Table of Contents 70

 SELF-TEST EXERCISE NO. 4

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below, and perform the
practical exercise suggested.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. Tick the correct statement.

a) Motors should be tested as a routine part of a good
maintenance schedule.
b) Motors should be tested in order to find out when they will fail.
c) Motors should be tested to improve their performance and save
on electricity.

2. Name the type of measuring instrument used to measure the

resistance of the windings.
_______________________________________________________
_______________________________________________________

3. When using an analogue multi-meter what must you do before

making any resistance measurements?
_______________________________________________________
_______________________________________________________
_______________________________________________________

4. When the test leads of a digital multi-meter are shorted together,

the resistance reading is greater than zero ohms. Why is this is so?
_______________________________________________________
_______________________________________________________

5. When measuring the insulation resistance between windings, what

is the minimum acceptable resistance value?
_______________________________________________________
_______________________________________________________

Back to Table of Contents 71

6. What is the minimum resistance value when testing between a
winding and earth?
_______________________________________________________
_______________________________________________________

PERFORM AN ELECTRICAL TEST AND REPORT ON A MOTOR IN YOUR WORKSHOP.

Back to Table of Contents 72

 RESOURCE NOTES (PART FIVE)
MECHANICAL & ELECTRO-MECHANICAL CHECKS

INTRODUCTION
Mechanical checks are necessary to ensure that the motor is operating at its maximum level of
efficiency and safety. Here is a list of checks that should be performed after a motor has been
serviced repaired or is simply being tested for integrity.

BEARINGS
The condition of bearings will provide clues to many mechanical problems. Rotate the shaft and
listen carefully for any abnormal noise that may indicate worn or damaged bearing surfaces.

Test for excessive lateral play by moving the shaft from side to side, and for excessive float by
moving the shaft in and out. There should be no appreciable movement if the bearing is in good
order.

SHAFT AND KEY WAY

A visual inspection of the key and keyway will indicate excessive wear or damage to the surfaces.
The key should fit snugly into the keyway.

MOTOR SHAFT
Using a dial gauge indicator, test the alignment of the shaft. Under normal circumstances, there
should be no deflection beyond approximately 0,02 mm.

STATOR FRAME AND END-SHIELDS

Check these parts for cracks, breaks or missing through-bolts or fixings.

FAN
The fan prevents the motor from overheating and broken or damaged blades will affect the airflow
over the stator frame. Check the fan carefully for damaged or broken blades.

TERMINAL BOX
It is important that the terminal box is sealed from the ingress of dust, dirt and moisture. Check the
terminal box for cracks, breaks or missing parts especially the gasket which seals between the box
and its cover.

NAMEPLATE
The motor nameplate is like a character reference. It records all the important information that the
user requires to safely operate the motor. Check that the nameplate is firmly secured to the stator
frame and that all the information contained on the plate is legible.

Back to Table of Contents 73

ELECTRO-MECHANICAL CHECKS
Unlike the cage induction motor, the DC motor has a more complex electrical system involving
brush rigging and a commutator. Since these components connect DC power to the armature, they
must be in good condition and correctly adjusted, for the motor to achieve maximum speed.

COMMUTATOR CHECKS
The surface of the commutator must not show signs of uneven wear (grooved, burnt or out-of
true). The surface must be clean and free from grease, oil or grit.

BRUSH RIGGING CHECKS

o Pigtails on the brushes must not be loose or damaged.
o Brush length must be checked to ensure that brushes are not worn beyond the specified
limits (>20% worn off = replace).
o Brush holders must be clean and the brushes must be able to move freely inside the holder.
o Brush spring pressure must be checked since faulty or weak springs will produce brush
bounce, resulting in poor electrical contact between brush and commutator.
o Brush tips must be examined. A properly shaped tip (correctly bedded in) will ensure
maximum electrical contact, resulting in the desired low electrical resistance path between
the supply and the armature.
o Brushes must be correctly aligned, and run centrally on the commutator.

NOW VIEW THE VIDEO UP TO THE END.

Back to Table of Contents 74

 SELF-TEST EXERCISE NO. 5

INSTRUCTIONS
o Without reference to your notes or the video answer the questions below.
o When you have finished, check your answers by referring to any of the resources.

QUESTIONS YES NO

1. Name six key components that must be checked, stating briefly

what you would be on the lookout for.
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________
_______________________________________________________

2. What should you look for when checking the surface of the
commutator?
_______________________________________________________
_______________________________________________________

3. What important check must be made when examining the brushes?

_______________________________________________________
_______________________________________________________

4. When examining the brush holder, what should you look for?
_______________________________________________________
_______________________________________________________

Back to Table of Contents 75