DC MACHINE TRAINER

OPERATING MANUAL

ENERGY LAB-I
DEPARTMENT OF SUSTAINABLE ENGINEERING
TERI SAS
 FUNDAMENTALS OF DC MACHINE
INTRODUCTION

Fundamentals of dc machines are extremely essential for proper conduction of various

experiments on dc machine. This manual deals with basic fundamentals of dc machine like,
Construction, classification, characteristics, losses etc. which give a clear idea regarding the
theoretical behavior of dc machine. These concepts can be well utilized to test the dc machine for
its performance.

D.C. machines, which have a wide industrial field, are produced both as generators and motors.
Conversion of mechanical power to electrical power is achieved by dc generator, which basically
works on the Faraday's law of electromagnetic induction. The mechanical power for the rotation
of armature of dc generator is normally derived from a steam engine, steam turbine, internal
combustion engine or water turbine. The direction of the dynamically induced emf in armature
conductors is given by Fleming's right hand rule.

D.C. motor is converse of dc generator i.e. it converts electrical power into mechanical power.
The dc motor works on the principle that when armature conductors carrying current are
influenced by the stationary magnetic fie_ mechanical force acts on the armature, as a result
armature starts rotating in a direction decided by the-direction of current and the field and is given
by Fleming's left hand rule. The above discussion clearly shows , that dc generators and motors
are quite similar in their operation and as such should be similar in their construction also.

CONSTRUCTION

The dc machine consists of the following parts for its proper operation and satisfactory
performance.

Armature - Cylindrical body, rotating between the stationary magnetic poles and consists of
slots, teeth, core and winding in the slots. The rotating armature is subjected to alternating
flux, which gives rise to eddy current and hysteresis loss in the armature core and teeth. In order
to reduce eddy current losses, the armature is built up of 0.4 to 0.5 mm dynamo sheet steel
laminations, insulated from each other by a thin layer of varnish. Slots used in dc machines are
rectangular and as such the teeth will be tapered. Armature coils are properly held in the slots
against the centrifugal, forces, by wooden or fibre wedge inserted in the upper portion of the slot.
Simple lap and wave windings are commonly used for the armature of dc machines. Number of
parallel circuits in lap wound armature is equal to the number of poles, where as it is only two in
wave wound armatures, irrespective of the number of poles. A lap winding is preferred for high
current machines, where as wave winding is more suitable for machines with lower current rating.

Main poles - Stationary part, consisting of pole body, pole shoe and field windings (shunt and
series). These are made up of sheet steel laminations of 1.0 to. 1.2 mm thick. Flux produced by
the main pole is of constant nature and as such there are no iron losses in the pole body.
However, it has been laminated for standardization purposes. The main poles are secured to. the
Yoke by means of bolts. The pole shoes provide a proper support to the field coils placed on the
pole body and also. spread the total flux produced over a greater area.

Inter poles or commutating poles - Arranged mid way between. the main poles with inter pole
winding on them, in order to improve commutation under loaded condition of the machine. Thus
these poles ensure spark less operation of the brushes at the commutator. These are made up of
wrought iron or mild steel and are bolted to the yoke.
 Yoke - Forms a part of the magnetic circuit and also serves as mechanical support for the entire
assembly of the dc machine. Cast steel or forged steel is mainly used for the yokes of dc
machines.

Commutator - The ends ef the armature coils are connected to the commutator segments.
Commutator together with the brushes rectifies the alternating emf induced in the armature coils
and also. helps in collection of current. Commutator is built up of a number of wedge shaped
segments of high Conductivity, hard drawn copper, assembled over a steel cylinder and insulated
from each other by mica. . .

Brushes – To collect the current from the rotating commutator or to lead the current to it. Brushes
are generally made up of carbon or graphite, so that the commutator surface is not spoiled, when
these are in contact with the commutator. These are accommodated in box type brush holder and
the springs press them against the commutator with proper pressure.

Bearing – To support the rotating armature and to allow smooth motion with minimum friction.

Enclosure - To protect the dc machine from external agencies.

TYPES OF DC MACHINE

The dc machines are classified into the following group, as per the connection of field winding
with armature winding.

1. Separately excited dc machines - The field winding is connected to a separate de source

and has no direct connection with the armature winding.

. 2. DC shunt machines - The field winding is connected across the terminals of the armature
winding. The shunt field coils are wound with many turns of fine wire, as a result the resistance of
shunt field winding is appreciably high (of the order. of 150 to 250 Ω). The current in the shunt
field winding is due to. the voltage generated/applied across the armature terminals.

3. DC series machines - The series field winding is connected in series with the armature
winding. The series field coils are wound with few turns of wire of large cross-sectional area, as
such the resistance of field winding is very low. Series generators will excite only when the load
circuit is completed.

4. DC compound machines - Consisting of two field windings i.e. series winding connected in
series with the armature winding and shunt winding connected across the armature winding. Both
these windings are accommodated en the main pole, as such field magnets are excited partly by
shunt field winding and partly by series field winding.

DC MOTOR CHARACTERISTICS
Important characteristic of dc motors, which need discussion are,

(i) torque V/S armature current

(ii) speed V/S armature current

(iii) speed V/S torque. .

TORQUE-ARMATURE CURRENT CHARACTERISTICS

Based on the above discussion of variation of torque-armature current characteristics can be

drawn

DC shunt motor

Fig (3.7) shows the torque-armature current characteristic of dc shunt motor, drawn on the basis
of above discussion. In the initial portion, the characteristic is a straight line passing through the
origin, however it bends over at increased values of armature current, because of slight decrease
in flux, φ due to armature reaction.

DC series motor
Fig (3.8) show the torque-armature current characteristic of dc series motor. At light load, flux is
directly proportional to armature current, as such the torque developed is directly proportional to
the square of armature current and hence the characteristic is a parabola in the initial portion. At
increased load, flux φ tends to become constant because of saturation and thus the characteristic
merges into a straight line.

SPEED-ARMATURE CURRENT CHARACTERISTICS

The back emf for dc motor, Eb = { (P φ N Z) / 60A}

Also, Eb = V-laRa

Thus speed of the motor, N = (V - Ia Ra) { (60A) / P Z } X (1/ φ)

P, Z and A are constants for a particular motor and thus the term (60A) / P Z is represented by a
constant K.

Hence, speed of the motor, N = K (V - Ia Ra) / φ

Based on this equation, speed-armature current characteristics of two types of motor can be
drawn.

DC shunt motor

Speed, N = K1 (V - Ia Ra ), as φ is practically constant.

The equation shows clearly that the speed will fall slightly with increasing armature current as
shown in fig (3.9). The dc shunt motor is generally called a constant speed motor, because the
speed characteristic is only slightly drooping.

DC Series Motor

The speed of the dc series motor becomes quite high at-light loads, because of quite low value of
armature current and hence the flux, as shown in fig (3.10). The speed will decrease sharply as
the armature current increases. However at appreciably higher armature or load current, the
characteristic flattens out as shown in fig. (3.10) because of the saturation effect. This
characteristic clearly indicates that a dc series motor should never be started without load.

SPEED-TORQUE CHARACTERISTICS

Fig (3.11) represents the speed-torque characteristics of dc shunt and series motor, which can be
obtained from the above two characteristics.

LOSSES IN DC MACHINE

Power losses occurring in dc machines are classified into four groups, discussed below.
Copper losses - Caused by the current flow in various windings of the machine. Copper losses
are directly proportional to (i) the square of current flowing in the winding and (ii) the resistance of
the winding i.e. I2R. In case of dc machine, these losses occur in the following Winding.

1. Armature winding, Ia 2 Ra

2. Series field winding, Is 2Rse

3. Shunt field winding, Ish2 Rsh

4. Inter pole winding, Ia2 Ri

5. Compensating winding, Ia2 Rc

6. Loss due to brush contact resistance

As the current in the series field winding, inter pole winding and the compensating winding is the
same as the armature current, the total copper losses occurring in these four windings is
designated as armature circuit copper losses i.e.

Armature circuit copper losses = Ia2 (Ra + Rsc + Ri + Rc) watts

Thus the armature circuit losses are also called the variable losses, because these are directly
proportional to the square of armature current. Copper losses in the shunt field winding is a
constant loss and does not depend on the loading condition of the machine.

Iron losses - Occur in armature teeth and armature core due to changing flux in these parts. Iron
losses in pole body and yoke are zero, because the flux is of constant nature in these parts. Iron
losses are further subdivided as hysterisis and eddy current losses. .

Hysteresis Loss:

Hysteresis loss occurring in armature teeth and core depends upon the following.

(i) The frequency of magnetic flux reversal ,f (f = PN/120)

(ii) The flux density at which the material is being worked, Bmax

(iii) Volume of the core, V

(iv) Quality of material used for armature core

Thus, hysteresis loss = η V f (Bmax)n

where, η is a constant, commonly known as Steinmetz's or hysteresis coefficient, and the
exponential quantity varies from 1.6 to 2.1 depending upon the quality of material used for
armature core. Hysteresis losses are reduced by selecting the material for the armature core with
low hysteresis coefficient such as alloy steel.

Eddy current loss:

Eddy current losses occurring in armature teeth and core arc basically due to the eddy currents
circulating in the armature structure, caused by small induced emf in the armature core body.
These losses depend upon the following factors.
(i) Frequency of magnetic flux reversal, f
(ii) Maximum value of operating flux density, Bmax (iii) Volume of the core, V .
(iv) Thickness of armature lamination, t
(v) Quality of material used for armature core.
Thus, eddy current losses = K Bmax f2 V t 2 watts
Eddy current losses are reduced by laminating the armature core and decreasing the thickness of
lamination. These are further reduced by adding 3 to 4 percent silicon to the steel used for
armature core.

Mechanical Losses - Caused by the rotation of armature and occur as (i) bearing friction (ii)
brush friction (iij) air friction (windage). These are normally called as friction. and windage losses.
All the three components of mechanical losses depend upon the peripheral speed of the
armature. As such these are practically constant, provided the speed is maintained constant
during the loading of machine.

Stray load losses - include (i) increase in copper losses due to eddy currents flowing in armature
conductors (ii) slight increase in iron losses under loaded condition and (iii) additional losses
caused by short circuit currents in the armature coils undergoing commutation.

These losses can be neglected for smaller machines, however these should be considered for
fairly large machines. These losses can. be taken approximately one percent of the rating of the
dc machine.

EFFICIENCY
The efficiency of a dc machine is defined as the ratio of output power to its input power i.e.

Efficiency η = Output power / Input power

Input to the machine = output power + total losses

Total losses in dc machines = constant losses + variables fosses.

η= Output power / (Output power + constant losses + variable losses)

The efficiency of dc machine will be maximum, when copper losses in the armature circuit are
equal to the constant losses of the machine.

The efficiency for smaller dc machines, is approximately 84 to 86 percent, where as for

comparatively large machines, it may range from 87 to 92 percent.
SPECIFICATIONS OF DC MOTOR AND GENERATOR

Normally the nameplate of a dc machine indicates all the important informations such as power
output, rated voltage, rated current speed etc regarding a particular machine. The knowledge of
these informations is most essential for proper operation of the machine and also for deciding the
range of various instruments needed for experimentation on his machine.

SYMBOLIC REPRESENTATION OF DC MACHINE

A dc machine basically consists of the following windings for its satisfactory operation under
loaded conditions.

(i) Armature winding – accommodated on the rotating member (armature) of the

machine and is represented by a circle with brushes on either side of the circle.
The winding is designated by the symbols A, AA.

(ii) Shunt field winding – accommodated on the stationary member of the machine,
represented by a coil and designated by the symbols, Z,ZZ.

(iii) Series field winding – accommodated on the stationary member, represented by

a coil and designated by the symbols Y, YY.

(iv) Interpole winding – provided to improve the communication, connected in series

with the armature winding, represented by a coil and designated by the symbols,
H, HH.

Fig. 4.1 shows the symbolic representation of a compound dc machine along with
interpole winding.

INSTRUMENTS USED AND SELECTION OF THEIR RANGE

The instruments commonly required for conducting various experiments on dc machine are as
follows:
1. Ammeter – MC type, for measuring the current in the armature circuit and field circuit
2. Voltmeters – MC type, for measuring the voltage (i) across the armature (ii) across the
load (iii) across the field circuit.
3. Rheostats –
(i) used as variable resistance in the field circuit of the motor to adjust the speed
to rated value or to control the speed.

(ii) used as potential divider in the field circuit of the generator to vary the field
current.

(iii) used as variable resistance in the armature circuit of the motor to limit
the starting current to a safe value and also to vary the voltage applied
to the armature circuit.
 4. Tachometer – used to measure the speed of the motor.

MODES OF OPERATION OF DC MACHINE

The dc machine working as a motor or a generator is mainly required to operate under the two
different conditions for conducting various experiments.

(i) No load operation – under this condition, motor draws power from the line for the no
load losses only, which are mainly the constant losses. As such, current drawn by the
motor is very small, hardly of the order of 5 to 10 percent of the full load current of the
motor. The voltage applied to the armature and the field circuit is of rated value.

(ii) Loaded operation – Load on the motor or the generator is varied in steps to examine its
behavior under different conditions of loading till the full load rated current. The voltage
applied or generated by the generator is of a rated value.

SELECTION OF RANGE

(a) Instruments in armature circuit: At the instant of starting of dc motor, its back emf is
zero, hence it draws a large a large current from the supply (I a = V/Ra). To limit the
starting current to a safe value, a variable resistance either in the form of a starter or
rheostat must be inserted in the armature circuit. The resistance of the rheostat
should be such that the starting current is 4 to 5 A for low rating motors used for
laboratory purposes. The range of ammeter is decided on the loading condition and
the specification of the machine. Based on this discussion the ranges of various
instruments for the machine with given specification are as follows.
(i) Rheostat – 45 Ω, 5 A, or equivalent
(ii) Ammeter for no load test : 0-5 A
(iii) Ammeter for load test : 0-25 A (higher than full load current)
(iv) Voltmeter for both no load and loaded operation : 0-300 V (higher than the
rated voltage)

(b) Instruments in field circuit : The resistance of shunt field circuit is quite high (200 to
250 ohms) and the voltage across the shunt field is of rated value. As such the shunt
field current is quite low normally 0.8 to 1.2 A for low rating machines used for
laboratory purposes. Based on this, range of instruments in the field circuit are as
follows.

(i) Rheostat – for both motor and generator ; 272 Ω, 1.7 A or equivalent
(ii) Ammeter ; 0-2 A
(iii) Voltmeter ; 0-300 V

STARTING OF DC MOTOR

In case of dc motors, the back emf developed in the armature winding is directly proportional to
the speed of rotation (EB = P Ф NZ/60A). When the motor is just connected to the dc supply
system, its back emf is zero, because the motor has not yet started rotating. Hence the applied
voltage, V directly appears across the armature terminals, causing an extremely large current
through the armature winding. Theoretically, the maximum starting current is V/R a (Ia = V – 0/Ra),
where Ra is the resistance of the armature winding, which is quite low (0.5 to 1.0 ohm). The
starting current drawn by the motor can be limited to safe value either by using a starter or by
inserting a rheostat as a variable resistance in the armature circuit.
 (a) STARTING OF MOTOR USING A STARTER

DC Motor starter basically consists of properly graded starting resistances, connected in series
with the armature circuit and the two protective devices i.e. no volt and over load release as
shown in fig. (4.2). The shunt field winding of the motor is connected to a segment, s and thus full
voltage appears across this winding. The no volt release consists of an electromagnet with a
proper winding connected in series with the field winding and protects the motor from the
following hazards

(i) Power failure : In the event of sudden power failure electromagnet gets demagnetized
and releases the starter arm, which flls back to the position by the action of spiral spring,
thus stopping the motor.
(ii) Opening of the field circuit : In case the field circuit gets opened accidently, the motor
would tend to operate at a dangerously high speed. No volt release safe gaurds the
motor from this hazard also. It gets demagnetized under this condition and releases the
starter arm to off position.

Over load release also consists of an electromagnet with proper winding and connected in series
with the armature circuit, so that the current flowing in the electromagnet winding is equal to the
armature current. It protects the motor from over loading conditions. Under overloading, motor
drwas an excessive current and the electromagnet ges more magnetized, as a result it attracts
the iron part ‘C”, thus short circuiting the coil of no volt release which gets demagnetized and
release the starter arm to return to its ‘off” position.

While starting the dc motor, the starter arm is shifted onto the first stud, which includes the
complete resistance of all the steps in the armature circuit, thereby reducing the starting current
to a safe value. When the motor has gained appreciable speed, the starter arm should be moved
slowly on to the studs, 2, 3, 4 etc., finally cutting out all the resistance steps and then iron keeper
provided on the starter arm will rest firmly against the iron poles of the holding electromagnet (no
volt release), which exerts greater force than the spiral spring.

Generally three terminals of the starter, L, Z and A are brought out, which are connected
respectively to the positive line terminal, shunt field terminal and the armature terminal of the
motor. The symbolic representation of the starter is shown by a rectangle with the above three
points as shown dotted in fig. (4.2). It may be noted clearly that,
(i) Between the points L and A of the starter, starting resistances are included in
series with the armature circuit.
(ii) Between the points L and Z, no starting resistances are in the circuit, but
connection is through the segments.

Referring fig. (4.2), the other terminals of the armature and shunt field winding are connected to
the negative of the line. A rheostat has been added in the field circuit to vary the speed of the
motor.

(b) STARTING OF DC MOTOR USING A RHEOSTAT

The starting current drawn by the dc motor can be reduced to a safe value by adding a rheostat
of proper range in the armature circuit. The resistance is fully inserted in the circuit, when the
motor is to be started. Once the motor has picked up the speed, the resistance is cut out from the
armature circuit. This concept of reducing the starting current does not provide any protection to
the motor, whereas the use of starter protects the motor against failure of supply, accidently
opening of field circuit and the over load on the motor in addition to reduction of starting current.

Fig. (4.3) shows the circuit diagram for starting a dc motor based on the above concept, where a
rheostat of 45 Ω, 5 A has been connected in series with the armature circuit to reduce the starting
current and a rheostat of 272 Ω, 1.7 A is included in the field circuit to vary the speed of the
motor.

Important precautions to be observed before starting the dc motor are as follows

(i) Resistance in the armature circuit should be fully inserted at the time of starting the dc motor.

(ii) External resistance in the field circuit should be zero at the instant of starting the dc motor.
This would ensure the lower speed initially and also high starting torque, because speed is
inversely proportional to the flux and the torque is directly proportional to the flux.
 About the Trainer

The DC Machine Trainer is designed in such a manner that all types of experimentation related to
the DC Machines can be carried out using DC Machine Trainer

Panel view
The entire system is divided into two parts one is the metering and controlling section and other is
testing and circuit layout section

The metering and controlling part consist of 3 point DC startor which is used for starting the DC
Machine and list of meters as follows

1) 5A MC DC panel meter - 2 Nos.

2) 2A MC DC panel meter - 2 Nos.
3) 600 V MC DC Panel Meter – 1 Nos.
4) 300 V MC DC Panel Meter – 2 Nos.

the circuit layout section consist of the diagrammatical representation of circuit which is to be
made for various experiments
As on this trainer we can conduct test on single motor , motor generator set and motor generator
with motor set (for Ward Leonard method )

We can further can subdivide this board in two parts

The red marked portion is used while working with Motor Generator Set (ie. For Hopkinsons test ,
load test on generator etc )

And below can be seen the diagram with blue lining this marked section is used for testing of
alone DC motor (Load Test , speed control etc.)

And the entire system can be used for speed control of DC motor using ward Leonard method
Now as we can see on the above diagram there is one input MCB which is directly connected to
the startor from inside and we would get outputs from strtor at terminals marked L, F and A
respectively . Here L stands for Line , F stands for Field Supply, and A stands for armature supply
to the DC shunt Motor,

As soon as we start the DC input supply to the through DC Input MCB the startor gets it supply at
line terminals and as soon we move the slider on metallic contacts the motor armature and field
finding start get there supplies

For running the DC motor alone one can use patch cords from field and armature terminals

For excitation of DC shunt generator MCB is given which is to be kept on before running the
generator
 Experiment No. 1
SPEED CONTROL OF DC MOTOR
(a) To study the speed control of DC motor below the normal range by armature
resistances control and to plot speed Vs armature voltage, characteristic.

(b) To study speed control of dc motor above the normal range by field control and to plot
speed Vs field current, characteristic.

INSTRUMENTS

S. No. Name Type Range Quantity

1. DC Machine trainer 1
2. Voltmeter MC 0-300V 1
3. Ammeter MC 0-2 A and 0-5A 1 each
4. Rheostat Single tube 270 Ω, 1.7 A 1
5. Tachometer Digital 0-2000 rpm 1

THEORY

The back emf for a dc motor is given by,

Back emf, EB = PФ NZ/ 60A

The number of poles, P the armature conductors, Z and the number of parallel paths, A are
constant for a particular machine. Thus the speed of dc motor is given by,

Speed of the motor, N = KEB/Ф = K V-IB RB / Ф

The equation for the speed of the motor clearly indicates the following
(i) Speed of the dc motor can be controlled below the normal range of speed by varying
the resistance in the armature circuit included in the form of a rheostat as a variable
resistance (armature control).
(ii) Speed of the dc motor can be controlled above the normal range of speed by
decreasing the flux Ф i.e. by decreasing the current in the field circuit by including an
external resistance in the form of a rheostat as variable resistance (field control).

ARMATURE CONTROL
Let the external resistance in the armature circuit of dc shunt motor be R ohms, then the speed
equation modifies to,
N = k V-IB (Ra + R)/ Ф rpm
Hence the speed of the motor decreases with an increase in the value of external resistance R.
Thus reduced speeds lower than the no load speed can be obtained by this method. However,
there is an excessive wastage of power in the additional resistance, which lowers the efficiency of
the motor considerably.

FIELD CONTROL
The speed of the dc motor can be increased beyond the no load speed by inserting an external
resistance in the shunt field circuit. The current resistance is very low, hence the losses occurring
in the additional resistance is quite small.
CIRCUIT DIAGRAM
Fig. (4.5) shows the circuit diagram for speed control of dc motor. Instruments used in the circuit
serve function mentioned against each.

Voltmeter – to measure the applied voltage across the armature winding.

Rheostat ( 270 Ω, 1.7 A ) – to vary the field current of dc motor.

 Ammeter – to measure the field current.

PROCEDURE
1. Connect the dc motor as per the circuit diagram shown in fig. (4.5)
2. Loose the belt of motor in order to run it on no load
3. Ensure that the external resistance in the field circuit is minimum
4. After ensuring step 2 and 3, switch on the dc supply,
5. Cut out the external resistance in the armature circuit and adjust the field
current, so that the speed of the motor becomes rated speed.
6. Keep the applied voltage to the armature constant at its rated value. Vary
the speed of the motor by inserting external resistance in the field circuit. Record the field
current and the corresponding speed of the motor.
7. Repeat step 6 for various values to the field current, till the speed of the
motor is about 1.2 times the rated speed of the motor. It is not advisable to increase the
speed beyond 1.2 times the rated speed, otherwise mechanical stresses will be high, which
may damage the motor. Hence, the field current should not be decreased to very low value.
8. Switch off the main supply to stop the motor.

READINGS

S. No. ARMATURE CONTROL FIELD CONTROL

Voltage across Armature Current Speed Field Current Speed
Motor
1
2
 Experiment No. 2

HOPKINSONSON’S TEST
(a) To perform Hopkinson’s test on two identical dc machines.

INSTRUMENTS
S. No. Name Type Range Qty.

1. Ammeter MC 0-5 A 2

2. Ammeter MC 0-2 A 2

3. Voltmeter MC 0-300 V 1

4. Voltmeter MC 0-600 V 1

5. Rheostat Single tube 270 Ω, 1.4 A 2

6. Tachometer Digital 0-2000 rpm 1

THEORY

The efficiency of the dc machine can be accurately determined by the regenerative method,
normally known as Hopkinson’s test. This test overcomes the drawback of Swinburne’s test,
which does not take any account of the stray load losses occurring in dc machines under loaded
conditions. As such the efficiency, calculated by Swinburne’s test is comparatively higher than the
actual one. Hopkinson’s test needs two identical dc machines coupled mechanically and
connected electrically as shown in fig. (4.13). One of the machine is operated as motor, driving
the other machine as generator. The output power of the generator is fed to the motor. Thus the
power drawn from the supply is only to overcome the losses of both the machines. By varying the
field currents of generator and motor i.e. I4 and I3, any desired load can be adjusted on these two
machines.
Referring the circuit diagram of fig. (4.13), following expressions can be established for this case.
Armature copper losses in the generator = I22 rg
Armature circuit copper losses in the motor = (I1 + I2 )2 rm
Total power drawn by the armature circuit of the motor = V x I1 watts
Let the sum of iron losses and mechanical losses of each machine be Wc2 then
V x I1 = 2 We + I22 rg + (I1 + I2 )2 rm
Thus, We = ½ [V x I1 - I22 rg - (I1 + I2 )2 rm ]
Efficiency of Motor
Shunt field copper losses of the motor = V x I3
Hence, total losses of the motor = We + (I1 + I2 )2 rm +V x I3
Total power input to the motor, P1=V x (I1 + I2 + I3)
Thus, efficiency of the motor, ηm= V (I1 + I2 + I3) – [(We + (I1 + I2 )2 rm +V x I3 / V (I1 + I2 + I3) x 100
percent

Efficiency of generator
Shunt field copper losses of generator = V x I4
Total losses of the generator = We + I22 rg + V I4
Total power output of the generator = V x I2
Thus, efficiency of generator, ηG = V I2 / V I2 + (We + I22 rg + V I4) x 100 percent
Hence, the efficiency of the motor and the generator at various loads can be worked out,
recording the various currents and voltage during the experiment and measuring the resistance of
armature of both the machines.

The major advantages of this test are as follows:

1. Power drawn from the supply is low.

2. Both the dc machines are operating under loaded conditions, as such stray load losses are
taken into account. Moreover, final temperature rise of the machines can be checked.

CIRCUIT DIAGRAM

Fig. (4.13) shows the circuit diagram, in which two identical dc machines are connected in such a
way that one of them is acting as a motor and another as a generator. The following instruments
connected in the circuit serve the function indicated against each.

1. Ammeters A1, A2 – to measure the current drawn from the supply and the generator
current respectively.
2. Ammeters A3, A4 – to measure field current of motor and generator respectively.
3. Voltmeter, V – to measure applied voltage.
4. Voltmeter, V1 – to check the condition for closing the switch, S.
5. Rheostats – to vary field current of motor and generator respectively.

PROCEDURE
1. Connect the two dc machines, coupled mechanically as per the circuit
diagram shown in fig. (4.13).
2. Ensure that the switch, S is in the open position.
3. Adjust the rheostat, so that the field current of the motor is maximum.
4. Adjust the rheostat, so that the field current of the generator is minimum.
5. Switch on the dc supply and start the dc motor using the starter properly.
6. Adjust the speed of the motor to rated value by varying the rheostat provided
in its field circuit.
7. Adjust rheostat in the field circuit of generator, so that the generated voltage of
the generator is equal to the supply voltage.
8. Check the voltage across the switch, S In case of wrong polarity, the voltmeter
will record twice the supply voltage. In such a case, switch off the mains and reverse the
armature terminals of the generator. Repeat steps 5, 6 and 7. Now the voltmeter will indicates
zero voltage. Close the switch, S after ensuring that the voltmeter V 1, reads zero. Under this
condition, the machine working as a generator is just floating i.e. neither drawing any current
from nor giving into the items.
9. Increase the field current of the generator or decreases the field current of the
motor or by doing both adjustments, any desired load can be put on the generator. Presently,
adjust the field currents of motor and generator, so that load on the generator is
approximately 10 percent of its load value. Record the readings of all the meters connected in
the circuit.
10. Repeat step 9 for various values of load current, till the full load current of the
generator.
11. Reduce the load on the generator and motor by varying their field currents.
12. Switch off the dc supply
13. Measure the resistance of the armature circuit of motor and generator.

READINGS

S.No. V I1 I2 I3 I4 WC ηm ηG
 Experiment No.3
SPEED CONTROL USING WARD LEONARD METHOD
(a) To study the speed control of dc motor Using Ward Leonard Method

INSTRUMENTS
S. No. Name Type Range Quantity
1. Voltmeter MC 0-300V 1
2. Ammeter MC 0-2 A and 0-5A 1 each
3. Rheostat Single tube 272 Ω, 1.7 A 1
4. Tachometer Digital 0-2000 rpm 1

THEORY

The back emf for a dc motor is given by,

Back emf, EB = PФ NZ/ 60A
The number of poles, P the armature conductors, Z and the number of parallel paths, A are
constant for a particular machine. Thus the speed of dc motor is given by,
Speed of the motor, N = KEB/Ф = K V-IB RB / Ф
The equation for the speed of the motor clearly indicates the following
(iii) Speed of the dc motor can be controlled below the normal range of speed by varying
the resistance in the armature circuit included in the form of a rheostat as a variable
resistance (armature control).
(iv) Speed of the dc motor can be controlled above the normal range of speed by
decreasing the flux Ф i.e. by decreasing the current in the field circuit by including an
external resistance in the form of a rheostat as variable resistance (field control).

ARMATURE CONTROL
Let the external resistance in the armature circuit of dc shunt motor be R ohms, then the speed
equation modifies to,
N = k V-IB (Ra + R)/ Ф rpm
Hence the speed of the motor decreases with an increase in the value of external resistance R.
Thus reduced speeds lower than the no load speed can be obtained by this method. However,
there is an excessive wastage of power in the additional resistance, which lowers the efficiency of
the motor considerably.

FIELD CONTROL
The speed of the dc motor can be increased beyond the no load speed by inserting an external
resistance in the shunt field circuit. The current resistance is very low, hence the losses occurring
in the additional resistance is quite small.
 WARD LEONARD CONTROL
A DC shunt Generator is moved by a prime mover which can be a DC shunt Motor or AC
induction motor , the purpose of prime mover is only providing necessary torque to armature shaft
of DC shunt Generator so it can produce DC Voltages now the generated voltages are directly
fed to armature of DC shunt motor and field circuit of the motor under control is fed externally
As we know that voltage generated in DC shunt generator depends on the field current of the
generator if we introduce a rheostat in the field circuit of the generator we can control the output
voltage of the generator, the armature of motor under control is directly fed by the output voltage
supply of generator . if we change the generator output voltage using rheostat the armature
current of motor also changes and thus speed of the motor also changes

CIRCUIT DIAGRAM
Fig. (4.5) shows the circuit diagram for speed control of dc motor. Instruments used in the circuit
serve function mentioned against each.
Rheostat (270 ohm 1.7 Amp ) – to vary the voltage applied to the field winding of dc shunt
Generator.
Voltmeter – to measure the applied voltage across the armature winding of DC shunt generator.
Ammeters – to measure the field and armature current.

PROCEDURE
1. Connect the dc motor as per the circuit diagram shown in fig. (4.5)
2. Ensure that the external resistance in the field circuit of Generator is maximum
3. Ensure that the external resistance in the field circuit of DC motor working as prime mover is
minimum
4. After ensuring step 2 and 3, switch on the dc supply, as a result motor will start running at a
low speed and generator start building EMF’s.
5. Check the output of Voltmeter across armature of the generator and switch on the switch S to
transfer load to the motor . motor will start running with low speed now change the field
rheostat of the generator in such a manner that field current of the generator increases , with
every increase in generator field current the speed of motor under control increases
6. The instantaneous speed of the motor can be observed using Tachometer.

READINGS

S.No. Armature current of motor Generator Field Current Speed of Motor

 Experiment No. 4

Load Characteristics of DC shunt Motor

(a) To Obtain Load Characteristics of DC shunt Motor

INSTRUMENTS
S. No. Name Type Range Quantity
1. Voltmeter MC 0-300V 1
2. Ammeter MC 0-5A 1 each
3. Rheostat Single tube 272 Ω, 1.7 A 1
4. Tachometer Digital 0-2000 rpm 1

Theory-

The load test on a dc motor is performed to obtain its various performance characteristics
including efficiency. The motor can be loaded by a belt and pulley arrangement as shown in fig.
(4.10).if w and w be the tensions in kg indicated by the two spring balances provided on the Wo
sides of the belt, then the load torque on the motor is given by,

Load torque, T =(W1-W2)*r kg-m

Then the mechanical power output of the motor ,Pm =2Πnt/60*0.102 watts

Power input to the motor, P1= V*I watts

Hence efficiency of the motor, = Pm/Pi*100percent

Where, r=radius of the pulley in meter

N=speed of the motor in rpm
V=voltage applied to the motor.
I=input current drawn by the motor

The speed of the dc motor is given by the following expression,

Speed of rotation, N=k*V-IaRa/

Where,the applied voltage v is constant,more over the flux is nearly constant for shunt motor.thus
the speed of the dc shunt motor will decrease as the load on the motor increase , because of the
increase in the armature voltage drop, IaRa. The drop in speed from no load to full load operation
is hardly 4 to 5 percent of the rated speed,as such dc shunt motor is regarded as constant speed
motor for all practical purpose.
CIRCUIT DIAGRAM
fig.(4.10) shows the circuit diagram,with the following instruments connected properly to serve the
function indicated against each.
1. Starter – to limit the starting current to safe value and to protect the motor against (i)
sudden failure of supply (ii) over load.
2. Ammeter—to measure the line current drawn by the motor.
3. Voltmeter—to record the voltage applied to the motor.
4. Rheostat-- to adjust the speed of the motor to rated value.
5. Tachometer—to measure the speed of the motor.
6. Mechanical load—in the form of belt and pulley arrangement to vary the load on he motor
in steps.

PROCEDURE

1. Connect the circuit as per fig.(4.10).

2. Ensure that there is no load on the motor.
3. Adjust the field rheostat, so that the field current is maximum at the instant of staring the
motor.
4. Switch-on the dc mains and start the motor using the starter properly.
5. Adjust the speed of the motor to rated value by varying in the field circuit.
6. Record the reading of all the meters at no load.
7. Load the motor by tightening the belt on the pulley and record the reading of the meters
speed and the reading of both the spring balance.
8. Repeat step 7by increasing the load on the motor in steps till the rated current of the
motor.
9. Remove the load gradually and than stop the motor by switching off the supply.
10. Measure the diameter of the pulley.

OBSERVATIONS may be tabulated as follows.

S. no V I N W1 W2 W

CALCULATIONS; may be tabulated as follows.

S. no. torque Mech. power Input power Efficiency

Output

SUGGESTION ; in a similar way, load test can be performed on series motor and
compound motor.