9 Month Certification Program

Electrical

Unit 10

Install and Test

SINGLE-PHASE Electric Motors

ELECTRICAL
Module 10.1
DEFINE MOTOR
TYPES
 TABLE OF CONTENTS

Unit 10: Install and Test Motors

Module 10.1

Define Motor Types

TRAINEE HANDBOOK
Information Sheets 1
 INFORMATION SHEET

Enabling Objectives
Terminal Objective
10.1.1 Given diagrams and/or
Unaided, the trainee will correctly state the motors, the trainee will
basicoperating principles of dc motors. correctly define single-
phase, three-phase and dc
10.1.2 motor types.
Unaided, the trainee will correctly state the
operating principles of split-phase induction
andcapacitor start motors.

10.1.3
Unaided, the trainee will correctly identify
three-phase motors and state their advantages
anddisadvantages.

10.1.4
Unaided, the trainee will correctly classify
motortypes.

INTRODUCTION
An electric motor is a device used to change Many engines also have their
electrical power into mechanical power. Commonly, power rated in hp. A good
a motor's mechanical power rating is given in example is the automobile
engine.
horsepower (hp). 1 hp equals 746 Watts. Mechanical
power is used to drive devices such as fans, pumps,
machine tools, or portable tools.

In this unit, you will learn the operation, parts, and

functions of common electric motor types. You will
also learn how to troubleshoot motor faults.

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 INFORMATION SHEET

In this first module, you will learn the operating

principles of:

❏ dc motors
❏ single-phase motors

You will then learn how to identify three-phase

motors and the advantages and disadvantages of
different models.

This module ends by covering how to classify a

motor, and motor enclosure types from the
information given on its nameplate.

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 INFORMATION SHEET

PART I OBJECTIVE 10.1.1

State the Basic Operating Principle of DC Motors

In this part, you will learn the operating principles

Universal (dc/ac) motors
of dc motors, and the types of dc motors used at contain the same parts and
Saudi Aramco plants. operate on the same principles
as dc series motors.

A dc motor consists of a rotating part (armature)

and a fixed part (frame). There are electrical
connections to the armature via carbon brushes and
a commutator.

TYPES OF DC MOTORS

There are four main types of dc motor:

❏ separately excited
❏ shunt wound
❏ compound wound
❏ series wound

Separately Excited Motor

The armature of a motor is powered by one dc

source. The field windings are powered by a separate ARMATURE FIELD
SUPPLY SUPPLY
dc source. (See figure 1).

This dual connection allows the speed of the

ARMATURE
armature to be controlled smoothly. FIELD

Figure 1
Separately Excited Motor

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 INFORMATION SHEET

Shunt Wound Motor

FIELD REGULATOR
POWER SUPPLY
In these motors, the field winding is connected in
shunt, that is, in parallel, with the armature. (See
figure 2). Both the field and armature windings have
dc supplied from the same power source.
SHUNT FIELD
ARMATURE

This connection allows easy regulation of the

motor’s speed.

Figure 2
Shunt Wound Motor Compound Wound Motor
This type of motor has two field windings:
FIELD REGULATOR
POWER SUPPLY
❏ series field winding – carrying the armature current
❏ shunt field winding – can be connected in two
SERIES FIELD

ways (see dotted lines on figure 3):

SHUNT FIELD

U RE
AT
AR
M
i. across both armature and series winding

(ii)
ii. across the armature alone

(i)
These connections either assist, or oppose one
another. Therefore, a wide variety of motor
Figure 3
Compound Wound Motor
characteristics are available depending upon the
connections made.

Series Wound Motor

POWER SUPPLY In figure 4, the motor field winding is connected in
series with the armature to be capable of carrying a
SERIES FIELD

ARMATURE heavy current. For this reason, the field winding has
only a few turns of thick wire.

This type of motor produces a much larger torque

than shunt wound motors. These motors are in
common use for heavy mechanical loads.
Figure 4
Series Wound Motor

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 INFORMATION SHEET

OPERATION

To maintain any machine, you must first learn how

it operates. You should know the answer to the
following questions about dc motors:

❏ What makes the armature turn?

As series wound and universal
❏ What makes it turn in a forward (clockwise) or motors are the dc types most
commonly seen, the following
reverse (counterclockwise) direction? sections use their principles as
the examples.
❏ What does the commutator do?

Operating Principles

The first operating principle of a dc series (and

universal motor) is:

A current carrying conductor in a magnetic field will

move at right angles to the direction of the field.

This principle explains why the armature turns in

the magnetic flux when there is current flow in the
armature conductors, between the north and south
pole field windings.

Refer to the simple motor in

figure 5. To operate, it needs:

❏ a dc power supply
N S
❏ a two segment commutator
❏ an armature - a single coil A B

❏ a field - permanent magnet

+

Figure 5
A Simple DC Motor

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Refer to figures 5 and 6. With the commutator in

this position, current enters through the brush at
point A. It flows through the coil from A to B, and
leaves the armature through the brush at point B.

Figure 6 below shows the:

❏ current path
❏ lines of force
❏ direction the armature turns

N A
A S
B

Figure 6
Current Flows From A to B

Figure 7 shows why the armature moves in the

magnetic field:
N S
❏ When there is no current in the wire, the wire
FORCE (a)
does not move.
❏ When there is current in the wire, the
N S
magnetic field forces (a and b) make the wire
move.
FORCE (b)
Note: Figure 7 shows the wire moving up. If the direction
Figure 7 of current through this wire is reversed, the wire will move
Wire in a Magnetic Field down.

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Therefore, the second operating principle is:

The direction in which the armature turns depends on:

❏ magnetic field polarity
❏ direction of current in the armature conductors

Figure 8 shows the wires in the armature. (The same

A
as A and B on the armature in figure 6.)
N S

In wire A, current moves away from the

commutator. Due to the magnetic lines of force
B
around the conductor, the wire moves up.
N S
In wire B, current moves towards the commutator.
The magnetic lines of force around the conductor
now move the wire down.
Figure 8
Direction of Movement and Current
Armature current and magnetic flux makes one side Flow in the Armature
(A) move up, and the other side (B), move down.
This turns the armature to the position shown in
figure 9.

When the commutator is as

shown in figure 9, no current
flows through the armature coil
A
conductors. This is because the
commutator segments are
N positioned at the non-
S conducting point, at the
brushes.
A B

Figure 9
Commutator Opens the Circuit. No Current Flows

When the armature moves past the position shown

in figure 9, as the commutator changes position, it
reverses the direction of armature current flow.

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 INFORMATION SHEET

Refer to figure 10. With the commutator in this

position: current enters B, flows from B to A, then
leaves the commutator through brush B.

N B

A
S
B
A
A
B

Figure 10
Current Flows From B to A

Compare the direction of current flow in the

armature conductors in figures 6 and 10. From these
examples, you can see that:

❏ The armature conductor next to the north

magnetic pole of the field always carries current
away from the commutator.
❏ The armature conductor next to the south
magnetic pole of the field always carries current
towards the commutator.

As a result, the motor turns in one direction.

Flemings rule, (commonly called the right hand
rule) states:

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“If the thumb, first, and second fingers of the right

hand are extended at right angles to one another,
with the first finger representing the direction of
magnetic lines of force and the second finger
representing the direction of current flow induced by
the wire’s motion, the thumb will be pointing in the
direction of motion of the wire”. (See figure 11).

C DIRECTION OF
CONDUCTOR

A DIRECTION OF
MAGNETIC FIELD

S N

A C

B DIRECTION OF
CURRENT FLOW

Figure 11
Right Hand Motor Rule

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 INFORMATION SHEET

The following figures show the complete circuit for

a dc series motor. In these, field coils replace the
permanent magnets. The field coil’s polarity depends
on the:

❏ direction of turns in the windings

❏ direction of current flow

Figure 12 shows that:

S N S
❏
N
Current flows from left to right.
❏ Field polarity is N-S (as shown in
figures 5–10).
❏ The motor turns in a clockwise
L R direction.

Figure 13 shows the same motor as figure

12, but in this case:
Figure 12
A DC Series Motor with N-S Field ❏ Current flows from right to left.
Poles and Clockwise Rotation
❏ Field polarity is S-N (opposite to figure 12).
❏ The motor turns in a clockwise direction.
N S N S
Compare figures 12 and 13. In figure 13,
the direction of current flow is reversed in
both the field and armature.

Notice that both motors run clockwise. The

L R third principle of operation is therefore:

If the polarity of the supply current for an

operating dc series motor is reversed, both
the polarity of the magnetic field and the
Figure 13 armature current direction is reversed. This
A DC Series Motor with S-N Field allows the motor to continue turning in the
Poles and Clockwise Rotation same direction.

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 INFORMATION SHEET

To allow the motor to turn in one direction, the This is the reason that a
direction of the current flow in the armature universal motor can operate on
either ac or dc. The figures
conductors must change each time the conductor show the motor operates in the
cuts the next set of lines of magnetic flux. The same direction, even when the
polarity of the supply current is
commutator does this as it turns on its axis. Look at reversed. This is true even if
the direction of flow shown in figures 6, 9, and 10. this reversing of current takes
place at the rate of 60 times
each second, (normal single-
❏ Figure 6 is from A to B.
phase ac supply). The motor
still continues operating in the
❏ Figure 9 is zero. If there is no current, there is same direction.
no direction.
❏ Figure 10 is from B to A.

Each time an armature coil moves from one field

pole to the next, the direction of the current in the
armature coil conductor changes due to the
commutator movement. The movement from pole
to pole also causes the armature to move in the
same direction as before.

This is the fourth principle of operation:

The commutator changes the direction of current flow

in the armature so that the motor continues to turn
in the same direction.

The figures below show how to connect the

motor to operate in the counterclockwise
direction. There are two ways to do this. S N S N

1. Figure 14 shows the current in the

armature reversed compared to figure
12. Notice the following:

❏ Field polarity is N-S (as in figure L R

12).

❏ Current flows from right to left.

Figure 14
❏ Brush connections are reversed. Motor With Current Flow in Armature Reversed

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 INFORMATION SHEET

❏ The direction of armature current is

opposite to that in figure 12.

❏ The motor turns counterclockwise.

2. Figure 15 shows the circuit with the

S polarity of the field reversed compared
N N S
to figure 9. Notice that:

❏ Field polarity is S-N (opposite to

figure 12).
❏ Brush connections keep the
current flow from left to right,
L R but reverse the field polarity.
❏ The motor turns in the
Figure 15 counterclockwise.
Motor with Field Polarity Reversed

The fifth principle of operation is therefore:

If you change the direction of current in the armature

or field, (but not both), the motor will run in the
opposite direction.

If ac is connected to a dc series motor, the motor

will run, but not efficiently. When ac is connected
to it, a dc series motor has a lower power factor.
This is caused by the following:

❏ inductive reactance in the windings

❏ power loss in solid iron cores
❏ sparking at the brushes

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 INFORMATION SHEET

UNIVERSAL MOTOR

As you know, the universal motor has the same parts Universal motors are commonly
and operates the same as a dc series motor. used in small portable electric
tools such as grinders, sanders,
However, because either dc or ac can power and drills.
universal motors, these motors have some minor
differences. When powered by single-phase ac, to
increase efficiency (improve their power factor), these
motors include the following changes from a basic
dc series machine:

❏ laminated core for field

❏ fewer turns in the field winding
❏ larger area of field poles
❏ laminated core for armature
❏ more copper in armature winding
❏ more coils with fewer turns in the armature
❏ more segments in the commutator

SUMMARY

In this part, you have learned the operating

principles for series dc motors and that there are
four main types of dc motor in use. You have also
learned that dc motors can run on ac, but not
efficiently. Finally, you learned what must be added
to make a universal motor operate efficiently as a
single-phase ac motor.

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 INFORMATION SHEET

EXERCISE A
Directions: Write the correct answers in the spaces
provided.

1. What type of dc motor has its field and

armature windings connected in parallel?

2. What type of dc motor has two field windings

that can be connected in either series or
parallel?

3. What would happen to the rotation if the

supply leads to a dc series motor were reversed?

4. What must you do to reverse the direction of

rotation?

5. Why do universal motors have fewer armature

turns and more segments in the commutator
than a basic dc series motor?

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 INFORMATION SHEET

PART II OBJECTIVE 10.1.2

State the Operating Principles of Split-Phase

Induction and Capacitor Start Motors

In the previous part, you learned about dc motors There are many different types
and a single-phase motor that can also be dc of single-phase motors. This part
covers the two most commonly
powered - the universal motor. In this part, you will used in Saudi Aramco.
learn about two common single-phase motors: split-
phase induction, and capacitor start.

SPLIT-PHASE INDUCTION MOTORS

Split-phase induction motors are commonly used to

drive machine tools and large grinders.

❏ Motor starting - start and run

Operating Principles windings both energized to
start motor rotating.
Like all electric motors, split-phase induction motors
❏ Motor running - start windings
operate because of electromagnetic induction. They disconnect when motor
have the name split-phase induction motors because reaches running speed.

they convert a single-phase power supply into two

separate electrical phases, almost 90 electrical degrees
apart.
ROTOR STATOR COILS

Induction causes the rotor to turn because of voltage

and current induced in it by the stator’s rotating
magnetic fields. Refer to figure 16 for the rotor and
stator coils arrangement and a graphical indication RUN
WINDINGS
of how the two electrical phases are almost 90 N
START
START
WINDINGS
electrical degrees apart. WINDINGS
S 90 0
N

RUN
When voltage is applied to the stator coils, ac flows S
WINDINGS

through them, creating a magnetic field around each

coil. Because of the position of the coils in the Figure 16
a. Simple Arrangement of Stator
stator, and the fact that current is strongest in one Coils Around the Rotor
b. Position of Stator Windings

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ONE CYCLE OF AC COIL coil pair at a different time than it is in the other,
the magnetic field seems to rotate around the inside
N
of the stator. This stator field induces a voltage in
the rotor. As a result, current flows in the rotor
creating another magnetic field. It is the reaction
A
between the two magnetic fields that makes the
S
rotor turn.

When ac current flows through the coils, the magnetic

fields around the coils change. (See figure 17).
B

S In A, current builds to a maximum. The coil

magnetic field follows the growth of the current,
therefore, producing maximum field strength.

C
N In B, as the current reduces to zero, the coil’s
magnetic field strength also reduces to zero.

In C, the current reverses for the second half of its

cycle. Again, the induced magnetic field builds up
D
to a maximum to match the current flow.

Figure 17 Note: The poles are now reversed.

Magnetic Fields Produced by AC

In D, the current flow again returns to zero. A at

this point the coil again has no magnetic field.

Important Points to Remember:

❏ Current flowing through a winding coil
produces a magnetic field.

If the supply frequency is 60Hz, ❏ Ac produces and destroys magnetic fields at the
the magnetic fields, shown in frequency of the supply current.
figure 17, are induced in the
coil 60 times every second. ❏ The direction of the current flow and the way
the coil is wound set the position of the
magnetic field poles.

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 INFORMATION SHEET

Refer to the clockwise magnetic field rotation shown START WINDING

by figures 18 through 20. In these, the arrows

indicate the direction of magnetic lines of flux. N
Because of the phase shift, current flows through the
start winding coil pair first. Current flow produces a RUN
WINDING
magnetic north pole at the top, and south pole at S
the bottom of the inside of the stator. (See figure
18).
Figure 18
Note: The actual position of the poles depends on the Start Winding Receives Current
direction of current flow, and the way the coil is wound.

START WINDING
Refer to figure 19. As the magnetic field decreases
around each start-winding coil, the run winding’s
N
magnetic field begins to build. The overall effect is
that the stator’s magnetic field starts to turn S N
RUN
clockwise. WINDING
S
Refer to figure 20. With maximum run winding
current, the stator’s magnetic field continues to turn.
This sequence is repeated through many complete Figure 19
Current Build-up in Run Winding
revolutions around the inside of the stator every
second. The effect is a rotating magnetic field in the
stator. This causes the rotor to turn. START WINDING

Inductive Reactance Operating Principles

❏ Start windings are resistive, while run windings S N
are inductive. RUN
WINDING

❏ In the stator, windings coils are placed 90

electrical degrees apart.
❏ Start winding current is nearly in phase with Figure 20
the voltage. Run winding current is almost 90 Maximum Current in Run Winding

electrical degrees behind the current to the start

windings.
❏ The two currents (split from the single-phase)
pass through the winding with a time lag that
shows at 90° on the current cycle. This creates
two separate rotating magnetic fields.
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 INFORMATION SHEET

❏ This series of rotating magnetic force fields turn

the motor by magnetic attraction. This attraction
is induced in the rotor’s squirrel-cage windings.

Windings

Start windings use thinner size

With current flow, the start and run windings make
wire than the run windings. The north and south poles. With no current flow, the
thinner wire has a higher poles disappear. The poles are electromagnets. They
resistance and gives the start
windings a low inductive only exist when current flows. Their magnetic
reactance. strength increases and decreases depending on the
Run windings use thicker wire amount of current flowing through them.
with less resistance than the
start winding wire. The run
windings have a high inductive There is a switch in the start winding circuit. Called
reactance and run the motor at
speeds above 75% of the
a centrifugal switch, it is mounted on the rotor
rating. shaft. When the rotor shaft reaches about 75% of
the motor’s rotating speed, the centrifugal switch
opens. By opening, it breaks the start winding’s
circuit and leaves the run windings to drive the
motor. If the operating speed of the motor falls
below 75% of it’s rated speed, the centrifugal switch
closes and the start windings again operate. Figure
21 shows a diagram of the centrifugal switch in the
start winding circuit.

Note: Because the start windings have a high resistance,

they will heat up as the motor runs. If the start windings are
energized too long, they can overheat and damage the motor.

RUN WINDING START WINDING

LINE ROTOR

CENTRIFUGAL SWITCH

Figure 21
Centrifugal Switch in a Split-phase Motor Diagram

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 INFORMATION SHEET

CAPACITOR-START MOTORS

Capacitor-start motors are the most common types Some common uses of the
of single-phase induction motor. They have: capacitor-start motor are to drive
machines like small air
compressors, pumps, and small
❏ a main winding arranged for direct connection air conditioners.
to the power source
❏ an auxiliary winding connected in series with a
The auxiliary winding with the
capacitor capacitor is in the circuit only
during starting.

Figure 22
Capacitor-start Motor

You can easily identify these motors by their

capacitor housing. The capacitor, located inside the
capacitor housing, will be mounted on either the top
or side of the motor body.

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 INFORMATION SHEET

Operating Principles

Remember, a capacitor is an A capacitor-start motor is similar to the split-phase

electrical device that allows an induction motor with two exceptions:
electrical charge to be stored,
and then discharged, when
required. ❏ a capacitor connected in series with the start
windings

In comparison to a split-phase ❏ the start windings, with the capacitor in series,

induction motor, these convert the single-phase supply into two separate
differences give the capacitor-
start motor more starting electrical phases, nearly 90 degrees apart
power, a better starting torque,
and lower starting current. Figure 23 shows the windings and capacitor in a
capacitor-start motor.

CAPACITOR

CENTRIFUGAL
SWITCH

AC POWER
SUPPLY RUN START
TERMINALS WINDING WINDING

SQUIRREL-CAGE
ROTOR

Figure 23
Capacitor-start Motor Circuit

In a split-phase motor, it is the currents of the start

windings leading the run winding by 90° that cause
the rotating magnetic field. In a capacitor-start
motor, the phase-split is obtained by use of a
capacitor. (See figure 24).

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 INFORMATION SHEET

+1 IR

IS
TIME
0

-1
IS - START WINDINGS
IR - RUN WINDINGS

Figure 24
Capacitor Affects Current

To start up, the capacitor-start motor uses:

❏ the current flow in both windings

❏ the capacitor to cause start winding current to
lead run winding current (see figure 24)

This creates a two-phase revolving magnetic field in

the stator, and the motor to increase rotation to its
rated speed.

When running at 75–80% of its rated speed, the

capacitor-start motor operates just like a split-phase
induction motor.

❏ A centrifugal switch opens, shutting off the

capacitor and start windings.
❏ The run windings keep the motor operating at
its rated speed.
❏ The centrifugal switch closes when the motor
stops, making the motor ready to use the start
windings/capacitor circuit to start operating,
when it is energized.

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 INFORMATION SHEET

SUMMARY

In this part, you have learned the operating

principles of split-phase induction and capacitance-
start, single-phase motors. You now know the
similarities and differences in their operating
principles.

In the next part, you will learn the advantages three-

phase motors have over single phase, and why they
are more often used in industrial sites.

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 INFORMATION SHEET

EXERCISE B
Directions: Write the correct answers in the spaces
provided.

1. What is the relationship between current in the

run and start windings in a split-phase motor?

2. In a split-phase motor, which windings are

inductive and which resistive?

3. In a capacitor-start motor, how is the capacitor

connected?

4. What are three advantages a capacitor-start

motor has over a split-phase motor?

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 INFORMATION SHEET

PART III OBJECTIVE 10.1.3

Identify Three-Phase Motors and State their

Advantages and Disadvantages

There are three types of three-phase motors. This

part of the module will identify the types of motors
their advantages, disadvantages, and applications.

As you learned in an earlier module, three-phase

equipment has advantages over single-phase
equipment. This is as true for motors as for any
other machines. Generally, motors using three-phase
supply have a more constant level of power,
therefore, run smoother and more efficiently. Use of
three-phase power also allows production of smaller,
more efficient motors.

Each of these motor types has The three types of three-phase motors are:
its own special advantages,
disadvantages, and particular ❏ squirrel-cage induction motors
applications.
❏ wound-rotor induction motors
❏ synchronous motors

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 INFORMATION SHEET

SQUIRREL-CAGE INDUCTION MOTOR

Figure 25 shows a totally enclosed, three-phase,

squirrel-cage induction motor. This uses a fan to
blow air over the frame to keep the motor cool.

FRAME STATOR
ROTOR
SQUIRREL-CAGE
FAN
BLADES ROTATING
BEARING SEAL

STATOR BEARING
WINDING
DRIVE SHAFT

FRAME END SHIELD

(RIBBED)

DRAIN PLUG
CONNECTION BOX (TO REMOVE CONDENSATION)

Figure 25
Three-Phase Squirrel-cage Induction Motor

The three-phase/squirrel-cage induction motor is

widely used in industry. It is dependable. If properly
maintained, the motor gives many hours of trouble-
free operation.

Advantages
❏ Compared with other types of motors, the 3-
phase squirrel-cage induction motor is relatively
small for its hp rating.
❏ It has no commutators/slip rings to service, nor
brushes to replace.

Disadvantages
❏ Speed control is difficult.
❏ The power factor is poor at no-load and low-
load conditions.
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 INFORMATION SHEET

Applications

Figure 26 shows a common industrial application for

squirrel-cage motors.

MOTORS

Figure 26
Industrial Application of Squirrel-cage Motors

Because these motors are relatively trouble-free, they

are commonly used in industry. For example:

❏ blowers
❏ centrifugal pumps
❏ motor-generator sets
❏ various machine tools

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 INFORMATION SHEET

WOUND-ROTOR BRUSH SLIP BRUSH HOLDER STATOR

HOLDER STATOR
INDUCTION MOTORS YOKE
RINGS AND BRUSH IRON WINDING

GREASE
Figure 27 shows the three-phase FITTING

wound-rotor induction motor.

Advantages

The primary advantage of a

wound-rotor motor over a
squirrel-cage motor is the ability M1 M2 M3

to control its speed. Run Speed T1 T2 T3

can be controlled manually or

automatically using:
Figure 27
Three-Phase Wound-Rotor Induction Motor
❏ timing relays
❏ contactors
❏ reactors

Other advantages of three-phase wound-rotor motors

The torque of a motor is the
are: force that produces rotation.

❏ high starting power (torque)

❏ smooth acceleration under heavy loads
❏ no excessive heating of the windings during
starting
❏ can be stopped and started frequently

Disadvantages
❏ The initial cost is higher than a squirrel-cage
motor.
❏ The maintenance costs are higher because it
regularly needs new slip rings and brushes.

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 INFORMATION SHEET

Applications

These motors are used where the driven machine

starts slowly and needs high starting power, or
torque. Some common examples are:

❏ variable-speed centrifugal pumps

❏ refrigeration compressors
❏ any equipment requiring frequent starts

SYNCHRONOUS MOTOR

Figure 28 shows a synchronous motor.

EXCITER
SECTION

Figure 28
Synchronous Motor

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 INFORMATION SHEET

The synchronous motor is used in many industrial

applications. However, it is most commonly used
when a motor with constant speed from no-load to
full-load is needed.

Advantages

Synchronous motors have several advantages over

induction motors, as described below:

❏ Load variations do not change the operating

speed.
❏ They are more efficient than an induction
motor with the same power rating.
❏ The rotor always runs at the synchronous speed
of the stator winding.

Disadvantages
❏ Their starting system is more complicated than
squirrel-cage motors.
❏ They have a low starting torque.
❏ They overheat if frequently stopped and started.

Applications

Synchronous motors are used to drive loads needing

a constant speed. Typical loads are:

❏ reciprocating compressors
❏ line-shaft drives on machinery
❏ constant speed blowers
❏ constant transfer pumps and other constant
speed machinery

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 INFORMATION SHEET

Power Factor Correction

Synchronous motors are also used to correct the

power factor of an industrial power system. Because
they can be adjusted to create a leading power
factor, they can correct an industrial feeder power
factor to near unity (1) or 100%.

SUMMARY

In this part, you have learned that there are

advantages to using three-phase motors in place of
dc or single-phase motors. You also learned that
there are three types of three-phase motor, their
applications, and the advantages and disadvantages
between them.

30
 INFORMATION SHEET

EXERCISE C
Directions: Write the correct answers in the spaces
provided.

1. What are two advantages of three-phase motors?

2. What type of three-phase motor can be used to

correct the power factor of a power system?

3. What type of three-phase motor is used on

equipment that starts and stops frequently?

31
 INFORMATION SHEET

PART IV OBJECTIVE 10.1.4

Classify Motor Types

Always turn off the Though motors come in many types and models,
power supply before
they are relatively easy to classify from the
trying to locate the
motor’s nameplate. information they list on their nameplates.

NEMA sets the standards Refer to figure 29. This shows a typical nameplate
for manufacturing electrical for a single-phase electric motor.
equipment.

Note: The information shown on the figure nameplate is, in

A three-phase motor’s general, the minimum information which you will see on a
nameplate would normally motor nameplate.
provide more information.

32
 INFORMATION SHEET

15

AC MOTOR

1 Style 34-3-1601 NEMAL 13

2 Frame 48 EXPLOSION-PROOF 14
3 HP 1 Ph 1 4
5 RPM 1725

6 Cycles 60 KVA CODE C 12

7 Volts 115

8 Amps 10 INS. CL F 11
40oC AMB Hours Cont. 10
9
Westinghouse Electric Corp.
108P156GWIT Made in USA

Figure 29
Motor Nameplate

33
 INFORMATION SHEET

1. Style – The manufacturer’s specification code.

Each manufacturer uses its own numbering
system for these codes.

2. Frame – refers to the National Electrical

Manufacturer’s Association (NEMA)
classification of the framesize. Figure 30 shows
part of a table from the NEMA standards. All
frame numbers with the number 145T have
the same dimensions as shown in the table.
However, not all 145T motors are
interchangeable. For example, according to
NEMA standard tables, a particular class of
motors ranging from 3/4 horsepower at 900 rpm
to 2 horsepower at 3600 rpm has the framesize
designation 145T.

34
 INFORMATION SHEET

N
W
N-W XC
V XD
XE

A
D U
SECTION
THROUGH
SHAFT
F F BA E E
H DIA.
B A
4 HOLES

Frame
Number A B D E F BA H N-W U V min. XC XD XE
145T 7 in. 6 31/2 2 3/4 21/2 21/4 11/32 2 1/4 7/8 2 3/16 3/16 1 3/8
184T 9 71/2 41/2 3 3/4 2 3/4 2 3/4 13/32 2 3/4 11/8 21/2 1/4 1/4 13/4
213T 10 1/2 71/2 5 1/4 4 1/4 2 3/4 31/2 13/32 3 3/8 1 3/8 3 1/8 5/16 5/16 2 3/8

The drawing and table identify the following dimensions by letter. Three examples
are listed with all dimensions specified.

A = Maximum width of base

B = Maximum length of base
D = Height of Shaft center above lower bottom of base
E = Radial distance of center of mounting hole from centerline shaft
F = Axial distance of center of mounting hole from front surface of collar
BA = Axial distance of center of mounting hole from front of collar
H = Diameter of holes in mounting base
N = Overall length of exposed shaft
W = Thickness of shaft collar
N-W = Overall length of exposed shaft, minus thickness of collar
U = Diameter of shaft
V = Maximum width of mounting a pulley or sprocket
XC = Width of keyway
XD = Depth of keyway
XE = Length of keyway

Figure 30
NEMA Motor Dimensioned Drawing and Table

35
 INFORMATION SHEET

3. HP – the output power of the motor at the

rated speed, measured in horsepower. You will
also see output power marked in watts or
kilowatts.

4. PH or Phase – the type of electrical current the

motor needs. AC motors are either single-
phase or three-phase.

5. RPM – the motor speed, measured in

revolutions per minute, when running at its
rated power, voltage, and frequency.

6. Cycles (CPS) or Hertz (Hz) – the frequency of

the ac at which the motor can be operated.

7. Volts – voltage at which the motor may be

operated.

8. Amps – amount of current in amperes which

the motor draws at full load.

9. 40°C AMB – the maximum ambient

temperature for which the motor is designed.

10. Hours – the time the motor may be operated

without overheating.

11. INS. CL. F – insulation class F.

Note: NEMA has four classes of insulation: A, B, F, H.

The classes indicate the maximum temperatures the
insulation can withstand: A — 105°C, B — 130°C, F —
155°C, H — 180°C

12. KVA Code – NEMA letter code showing the

locked rotor power input or horsepower of
output.
36
 INFORMATION SHEET

13. Explosion-Proof – the type of motor enclosure.

NEMA generally classifies motors as either
totally enclosed, or open.

Totally enclosed motors are enclosed tightly enough

to prevent air from entering the enclosure. However,
the motors are not considered airtight. Some totally
enclosed motor classifications:

❏ Totally enclosed non-ventilated motor –

Cooled by surrounding air.
❏ Totally enclosed fan-cooled motor – A fan
on one end of the shaft cools by forcing
air over the motor when running.
❏ Explosion-proof motor – For use in areas
Explosion-proof motors are
where flammable vapors are present. These found in many Aramco plants.
motors will contain an explosion inside the
enclosure and will not cause an explosion by
any sparks or flashes from inside the motor.
❏ Dust-ignition proof motor – For use where
flammable dust is present. Its internal parts
are designed to prevent sparking that could
ignite vapors.
❏ Waterproof motor – Designed to keep out
Waterproof motors are not
water in the form of a stream from a hose. designed to operate under
water.
❏ Totally enclosed pipe-ventilated motor –
Cooled by air forced through a pipe or duct.
❏ Totally enclosed water cooled motor – Has
a special cover containing cooling ducts.
Water flows through the cover to cool the
motor.

Open motors have open slats or grills to allow air to

pass through and cool the windings. The openings
are usually in the end plates. Some classifications are:

37
 INFORMATION SHEET

150 150
❏ Dripproof motor – Openings constructed
to prevent drops of liquid or solid
particles from interfering with the
operation when they strike or enter the
enclosure at any angle from 0° to 15°
downward from the vertical.

❏ Splashproof motor – Openings constructed

to prevent drops of liquid or solid
particles from interfering with the
DRIPPROOF operation when they strike or enter the
enclosure at any angle from 0° to 100°
downward from the vertical.

100% 100%
❏ Guarded motor – Has screens or grills
over openings to prevent accidental
contact with hazardous parts.

❏ Open externally ventilated motor –

Cooled by outside air coming from a
separate motor- driven blower.

SPLASHPROOF ❏ Open pipe-ventilated motor – Has pipes

or ducts connected to the openings for the
Figure 31
Dripproof and Splashproof Motor
air supply.
Enclosures
❏ Weather-protected motor – Has ventilating
openings designed to minimize the
entrance of rain, snow, and dust.

14. Westinghouse – manufacturer’s name.

SUMMARY

In this module, you have learned the theory of

operation and common applications for dc, single-
phase, and three-phase motors. You also learned why
different types of motors are used, and how to use
their nameplates to identify the motor type and
specifications.

38
 INFORMATION SHEET

EXERCISE D

Part 1
Directions: Write the correct answers in the spaces
provided.

1. If a motor is waterproof, can it be operated

under water?

2. If two motors have the same NEMA frame

code, what does this tell you? Are they
interchangeable?

Part 2
Directions: Refer to the motor nameplate shown in figure PHASE 1
32. Identify the correct answer and write it in the spaces H.P. 1 1/2
provided. VOLTS 115
AMP 20.8
1. What company manufactured this motor? RPM 1725
400C MAX. AMB. TIME RATING
CONT.
145T FRAME NEMAL
STYLE: 5KC145BL2010

Figure 32
2. What power is available from this motor?

3. How many hours can the motor operate

without overheating?

39
40
ELECTRICAL
Module 10.2
INSTALL AND TEST A
DC MOTOR
 TABLE OF CONTENTS

Unit 10: Install and Test Motors

Module 10.2

Install and Test a DC Motor

TRAINEE HANDBOOK
Information Sheets 1
 INFORMATION SHEET

Enabling Objectives Terminal Objective

10.2.1 Given, diagrams, vendor
Unaided, the trainee will correctly state the manuals, tools, equipment
causeand effect of common dc motor faults. and material, the trainee
will state how to install and
10.2.2 test a dc motor.
Unaided, the trainee will correctly state
commutatorcleaning, inspection and set-up
requirements.

INTRODUCTION

At the start of this unit, you learned about the

different types of dc motors and how they operate.
In the last module, you learned to identify a
universal motor’s parts and the function they
perform. You also learned that dc motors contain
the same parts as universal motors, though they are
sometimes called a different name.

Motor parts and their functions have already been

covered for the universal motor. This module
concentrates on dc motor tests and inspections that
allow you to identify and rectify common faults.
Because the commutator and brush rigging are the
cause of most dc motor faults, this module outlines
common commutator and brushgear faults, symptoms
and their remedies.

1
 INFORMATION SHEET

PART I OBJECTIVE 10.2.1

State the Cause and Effect of Common DC Motor

Faults

Electrically, with the exception of universal motors,

dc machines have problems not commonly found in
ac motors because dc machines contain brushes and
commutators.

Maintaining the commutator and brushgear is

important for efficient motor operation because poor
commutation causes:

Any of these faults can damage ❏ electrical sparking (which also cause electrical
the armature windings. interference)
❏ burning and accelerated wear of the brushes
❏ burning and damage to the commutator

COMMUTATOR PROBLEMS

During operation, oxide builds up on the surface of

a commutator. This film is good as it helps reduce
friction between the commutator and brushes. The
film should be a light brown/chocolate color and
highly polished. When the film looks different, it is
often a sign of a problem.

Three common commutator problems are:

❏ streaking
❏ threading
❏ grooving

2
 INFORMATION SHEET

Streaking

Bright bands on the surface of the

commutator segments indicate streaking.
(See Figure 1.) The common cause of this
is low brush pressure that causes a high
resistance at the point of contact. This high
resistance causes overheating, allowing
copper to transfer to the brushes.

Note: Other causes of streaking are: chemicals

in the air, abrasive dust, or an abrasive or
porous brush.

Figure 1
Correction

To correct streaking you must clean the commutator

and replace the brushes.

If not corrected, streaking causes a more serious

condition called threading.

Threading

Threading is a name given to fine lines cut

into the surface of the commutator. These
“threads” cause arcing and sudden changes
in motor speed. The cause of threading is
copper transferring from one segment to
another. This leads to short circuits
between segments.

Correction

Threading can not be corrected on plant.

Specially trained personnel must Figure 2
recondition the commutator after it has been
removed from the motor.

3
 INFORMATION SHEET

Grooving

Grooving develops when brushes cause

heavy wear on the commutator. The
common causes are too high brush pressure
or incorrect brush material. Grooves are
produced in the commutator by abrasive
dust or an abrasive brush.

Correction

As with threading, the commutator must

be reconditioned by specially trained
Figure 3
personnel.

If not corrected, serious damage to windings and

insulation will occur.

ADDITIONAL COMMUTATOR FAULTS

Here are three additional, but less common

commutator faults:

❏ Pitch-bar marking – low or burned spots on

the commutators surface. The number of marks
will equal half or all the number of poles on
the machine.
Causes: light brush pressure, abrasive brush,
vibration, faulty armature connection, or
unbalanced shunt field.
❏ Copper drag – usually forms at the trailing
edge of the bars (segments). It is an abnormal
build-up of commutator material that, if not
corrected, can cause flashover (arcing).
Causes: light brush pressure, abrasive brush, gas
contamination, or vibration.

4
 INFORMATION SHEET

❏ Heavy slot-bar marking – when the trailing

edge of the commutator bar is etched
(removed) rather than built-up. The pattern is
related to the number of conductors per slot.
Causes: gas contamination, electrical overload,
or poor electrical adjustment.

COMMUTATOR CHECKS AND TESTS

If you suspect or see a commutator problem, a

detailed check is needed. Before doing a detailed
check, you must first deenergize, lockout and hold
tag the motor. You can then remove the guards and
turn the machine by hand (using a strap wrench).
Turning allows you to inspect the whole surface.

High Mica Test

Mica is the insulating material used to separate the

commutator segments. As segments wear, the brushes
start to make contact with the mica. This condition
is called high mica. If not corrected, high mica
causes the brushes to wear quickly.

Correction

High mica levels can be lowered using

special files, or, if unavailable, a piece of PROPER MICA SEGMENT HIGH MICA
LEVEL
hacksaw blade. Draw the blade carefully
between the segments in a back and forth
motion.

Loose Commutator Segments

On small motors, clamping rings hold

commutator segments (bars) tightly in Figure 4
place. When not secure, a bar moves
relative to the bars on either side of it.

5
 INFORMATION SHEET

You can test for a loose bar by applying

pressure to the segment risers and the ends
of the segments. (See figure 5).
RISER

COMMUTATOR SEGMENT CAUTION

Do not touch the brush running surface of
the commutator with a bare hand.

Figure 5

The visual signs of loose segments are sparking and

localized pitting (burning).

Correction
DIAL INDICATOR
Sometimes, you can secure a
FIXED PART
loose bar by tightening the
OF MACHINE
threaded clamping ring. On
large motors each bar has a
SEGMENT securing bolt.
COMMUTATOR

INSULATION Commutator Runout Test

Sometimes, a commutator
SHAFT
runout test is needed. This test
checks that the commutator is
round, and that its segments
are all at the same height.

You do this using a dial

indicator set up as shown in
Figure 6 figure 6.
Runout Check

A high segment can cause

rapid brush wear and arcing. A
low segment can also cause
arcing because the brush may
not be in correct contact with
the segment.

6
 INFORMATION SHEET

PART II OBJECTIVE 10.2.2

State Commutator Cleaning, Inspection and

Set-Up Requirements

To be able to inspect a motor, you must be able to

see exactly what you are looking at. Therefore, the
motor must first be thoroughly cleaned. When the
motor is free of dirt, you can inspect for chips or
cracks in insulation. When you find minor damage,
such as chips or cracks, you can then repair them
quickly with a coating of electrical varnish.

CLEANING AND INSPECTING

CAUTION
If you use compressed air, make sure you know, and
follow all necessary safety precautions.
Most solvents are flammable. Use the correct safety
precautions when handling them.

Inside a motor, carbon dust and dirt can build up.

An effective way to remove this is to use a vacuum
cleaner on the motors internal parts. Another
method of removing loose dust is to blow it off
using clean, dry, low-pressure air.

Grease and oily dirt can be removed with an

approved solvent. However, you must make sure to
choose the best solvent for the job. Also, you must
remember to take special care cleaning insulating
materials with rags and solvent. Dirt and carbon
dust can easily provide a ground from the rigging to
the metal casing.

When preparing to inspect and replace carbon

brushes, it is normal procedure to first clean, then
inspect the brush rigging.

13
 INFORMATION SHEET

REMOVING BRUSH RIGGING FOR

INSPECTION AND REPAIR

To prepare a commutator for inspection and repair,

the brush rigging is usually removed. Though rigging
designs differ, their attachments and components are
similar. A typical assembly is shown in figure 9.

FRAME LEAD BRUSH HOLDERS

SPACER

NUT ROD

SLEEVE

Figure 9
Typical Brush Rigging

The brush rigging is attached to the machine by a

rod. Also attached to the rod is a power lead. This is
insulated from the frame by sleeves and spacers.

Note: On replacement, riggings must be replaced in their

original positions.

SERVICING BRUSH RIGGING

After removing the brush rigging, you must clean it

with solvent. Then use a smooth file to remove any
rough edges on the brush holders. Removing these
edges ensures that the brushes can slide easily into
their holders. With edges smooth, you then check
that the springs and adjustment levers are not
broken, and that they move freely.

14
 INFORMATION SHEET

BRUSH REPLACEMENT AND FORMING Remember, it is important to

install the correct grade of
Brushes must be checked for uneven wear. If brush. Always refer to the
manufacturer’s manual.
replacement is needed, the brushes must be changed
as a set, never individually.
BEFORE SEATING
Before fitting new brushes, you must shape them to
fit the commutator curvature. This is called forming
or seating. When formed/seated correctly, they
provide a better electrical contact and minimize
arcing until the brushes become bedded-in.

BRUSH
Setting Clearance
FLEXIBLE OR
BRAIDED
CONNECTOR
Obtain a piece of material of a thickness equal to
the correct gap between the holder and the AFTER SEATING

commutator. Place it between the commutator and

the brush holder. (See figure 11). Figure 10
Brush Seating/Forming

MATERIAL
STRIP
SET GAP
HERE BRUSH
BRUSH SPRING
MATERIAL FOR HOLDER
CHECKING GAP
REQUIRED
SET GAP GAP
HERE

COMMUTATOR
SET GAP
HERE

SET GAP
HERE

Figure 11

Loosen the bolts holding the brush holders on the

rod and adjust until they just touch the material. At
this point, tighten the brush holder bolts on the
rod. Then you can remove the material and replace
the machine guards.

15
 INFORMATION SHEET

SUMMARY

In this module, you have learned about the most

common faults found on dc motors. You now know
where to look for problems, how to identify
different problems and, importantly, what you can
do to rectify problems.

In the task aid, you will put this knowledge into

practice by installing, inspecting, setting up and
testing a dc motor.

Your instructor will now show you how to perform

inspections and remove/refit parts correctly. After his
demonstrations, complete exercises C and D.

16
 INFORMATION SHEET

EXERCISE C
Directions: Write the correct answers in the spaces
provided.

1. What two methods can you use to remove

loose dirt and dust from the area around the
commutator?

2. Why must you remove dirt and carbon dust?

3. How do you determine the correct grade of

brush to install?

4. Why must new brushes be formed?

17
ELECTRICAL
Module 10.3
INSTALL AND TEST A
SINGLE-PHASE
MOTOR
 TABLE OF CONTENTS

Unit 10: Install and Test Motors

Module 10.3

Install and Test a Single-Phase Motor

TRAINEE HANDBOOK
Information Sheets 1
 INFORMATION SHEET

Enabling Objectives Terminal Objective

10.3.1 Given diagrams, vendor
Unaided, the trainee will correctly state the manuals, tools, equipment
functionof a capacitor-start motor’s parts. and material, the trainee
will install and test
10.3.2 a single-phase motor.
Unaided, the trainee will correctly state the The motor must operate
functionof a universal motor’s parts. according to manufacturer’s
specifications.
10.3.3
Unaided, the trainee will correctly state
motorinstallation, maintenance, and
troubleshootingtechniques.

INTRODUCTION

In the last module, you learned the theory of how

single-phase electric motors operate. In this module
you will gain some practical experience installing and
testing single-phase motors.

To be able to install and test a motor, you must be

able to identify the parts and understand their
function. This module begins by giving you
information on motor parts and their functions.

1
 INFORMATION SHEET

PART I OBJECTIVE 10.3.1

State the Function of a Capacitor-Start Motor’s

Parts

1/ 8 hp = approx. 90W
There are many different sizes and models of
71/2 hp = approx. 5.6 KW
capacitor start motors. Depending on their
application, they range from about 1/8 hp up to
71/2 hp. No matter the size, all capacitor start
motors have the same major parts.

PARTS AND FUNCTIONS

CAPACITOR
ROTOR HOUSING
END ASSEMBLY CENTRIFUGAL
SHIELD CAPACITOR SWITCH
FAN
CONTACT
PLATE
ROTOR
SHAFT

STATOR END SHIELD

FRAME
CENTRIFUGAL
SWITCH STATOR CORE
BEARING

Figure 1
A Disassembled Capacitor-Start Motor

2
 INFORMATION SHEET

Capacitor

A capacitor is attached to the stator assembly. It is

always located inside a protective housing.

Never touch the

TERMINALS capacitor terminals. You
can receive a large
electrical shock. Even with the
voltage source disconnected,
the capacitor remains charged.
For safety, always discharge
CONNECTION LUGS the capacitor through a resistive
load, then ground the terminals
to the motor frame before
disconnecting the grounding
conductor.
Figure 2
Capacitor and Terminals

Windings

The capacitor-start motor start

windings are almost the same
SLOTS
as those in a split-phase
motor. However, in a capacitor CORE
start motor, the start windings
produce a stronger starting
torque. This is because the
SUPPLY
capacitor keeps the starting CONNECTION
TERMINAL
circuit closer to 90° out of STRIP

phase with the run windings.

The start windings of these

motors have many turns of WINDINGS
fine wire. The run windings
Figure 3
are turns of heavier wire. (See Capacitor-Start Stator Windings
figure 3).

3
 INFORMATION SHEET

Stator

The stator is the stationary part of the motor. It is

made up of strips of layered steel. There are slots in
the stator core where the wire is wound in coils.

Rotor Assembly

The rotor assembly is the rotating (moving) part of

the motor. Figure 4 shows a rotor assembly with an
enlarged view of the centrifugal switch.

FAN

ROTOR ASSEMBLY
CORE
ROTOR SHAFT

ENLARGED VIEW
OF THE CENTRIFUGAL
SWITCH
SQUIRREL
BEARING
CAGE

CENTRIFUGAL
SWITCH

Figure 4
Rotor Assembly
To pick up the drive connection, the rotor shaft
extends through the bearings and the end shields.
(See figure 1).

Rotor Core

The framework for the rotor core resembles an

animal exercise cage. Because of this, it is called a
squirrel-cage.

4
 INFORMATION SHEET

Refer to figure 5. Note that:

❏ the cage bars are set at an angle

❏ when the cage is set in the rotor assembly, an
insulating compound (resin/mica) separates the
bars
❏ each bar is shorted by end rings completing the
rotor’s magnetic circuit
Figure 5
Squirrel-Cage Rotor

Centrifugal Switch

The centrifugal switch mechanically disconnects the

ROTOR SHAFT
start windings from the motor’s power supply. Refer
to figure 6. This shows a centrifugal switch mounted
on a rotor shaft.

Bearings CENTRIFUGAL SWITCH

Bearings align the rotor shaft and allow it to turn Figure 6

Centrifugal Switch
smoothly with little friction. A fan on the rotor
shaft and fins on the squirrel-cage end plate’s help to
circulate air to cool the motor.

Sleeve bearings need

ROTOR SHAFT COOLING FINS
BEARINGS lubrication frequently, but
sealed ball bearings seldom
need lubrication.

ROTOR SHAFT
Figure 7
Bearings

5
 INFORMATION SHEET

MOTOR ELECTRICAL CIRCUIT

Refer to the motor circuit diagram and component

identifiers in figure 8 which shows the following:

❏ The capacitor is connected in series with the

start windings.
❏ The run windings are connected in parallel to
the supply.
❏ The centrifugal switch is connected in series
with the start windings, and capacitor.
❏ There are no connections to the rotor.

CAPACITOR ROTOR

CENTRIFUGAL
SWITCH
COIL WINDING
SW - START WINDING
AC RUN START RW - RUN WINDING
SUPPLY WINDING WINDING
SQUIRREL - CAGE
ROTOR CENTRIFUGAL SWITCH
NORMALLY CLOSED

CAPACITOR

Figure 8
Diagram of a Capacitor-Start Motor

6
 INFORMATION SHEET

EXERCISE A
Directions: Write the correct answers in the spaces
provided.

1. What part makes the start circuit 90° out of

phase to the run windings?

2. What part disconnects the start windings from

the power supply?

3. Why are their slots in the stator core?

7
 INFORMATION SHEET

PART II OBJECTIVE 10.3.2

State the Function of a Universal Motor’s Parts

As you now know, the universal motor gets its name

from the fact that it can run on either ac or dc
power. These motors are important because of their
many applications including:

❏ powered hand tools

❏ hoists
❏ vacuum cleaners
❏ fans

PARTS

Figure 9 shows the motor parts. These parts can be

divided into three main areas:

❏ field winding assembly

❏ armature
❏ brushes and commutator

8
 INFORMATION SHEET

RETAINER
CAP BALL
SPRING BEARINGS
BRUSH
HOLDER

END SHIELD
COMMUTATOR

BEARING ARMATURE
RETAINER

FIELD ASSEMBLED
END COIL BRUSH HOLDER
SHIELD ASSEMBLY

Figure 9
Universal Motor, Exploded View

Field Windings

Universal motors usually have

two field winding coils. Figure
10 identifies the parts in the
lower coil:
SOLDERED JOINT
INSULATED WHEN MOTOR
❏ insulated wire for IS ASSEMBLED

winding CONNECTING
LEAD

❏ flexible insulated wire for

leads INSULATED WIRE
WINDING

❏ cloth wrap or tape for COVER

(CLOTH TAPE WRAPPED AND VARNISHED)
cover
Figure 10
❏ insulating varnish Field Coils

9
 INFORMATION SHEET

The field winding assembly (figure 11) can

be removed from the frame. The coils can
also be removed from the laminated core.

The field core is made with:

PIN THROUGH
CORE ❏ laminations (layers of soft iron)
❏ two pole pieces

POLE PIECES

Figure 11
Field Winding Assembly and Striped Field Core

Armature

The rotor of the universal motor is called an

armature. As shown in figure 12, the rotor has the
following parts:
❏ shaft
SHAFT COMMUTATOR ARMATURE SHAFT
WINDING COILS
❏ bearings (not shown in
figure)
❏ armature windings
❏ commutator
❏ soft iron laminations
MICA COILS ENDS SOLDERED SOFT IRON
INSULATION TO COMMUTATOR RISERS LAMINATIONS
❏ mica insulation
Figure 12
Armature Assembly
In figure 12, you can see the connections between:

❏ copper segments in the commutator

❏ leads from the coils in the armature windings

10
 INFORMATION SHEET

Refer to figure 13 which shows the armature core

on the shaft. The core is made of many thin pieces
of soft iron called laminations. Each lamination has:

❏ a circular shape
❏ holes
❏ slots
❏ a coating of insulating varnish

SLOTS

Figure 13
Armature Core on Shaft (without windings)

These laminations are pressed on to the armature

shaft. This makes a laminated core with slots and
holes that give:

❏ support for the coil windings

❏ a controlled path for magnetic flux (thus
reducing energy loss)
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 INFORMATION SHEET

Brushes and Commutator

In the universal motor, there is a connection

between the armature winding and the power
supply. This connection is through the commutator
and the carbon brushes. Current flows to the coils in
the armature windings by going through the brushes
and the commutator (figure 14).

COMMUTATOR SLOTS FOR SOLDERING

RISER COIL LEADS

MICA

SLOTS FOR SOLDERING

COIL LEADS

COPPER COMMUTATOR
SEGMENTS

Figure 14
Sectional View of Commutator

COPPER SEGMENT
Mica is an insulator that separates each of the
MICA
commutator copper segment from:

❏ the sleeve and shaft (figure 14)

❏ the copper segments on both sides (figure 15)

Figure 15
Mica Between Copper Segments of
the Commutator

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 INFORMATION SHEET

Refer to figure 16. This shows the connections

between the commutator and the armature
windings. Each bar segment is connected to the start
of one armature winding and the end of the next
armature winding. For example, bar segment #1 is
connected to coils A and B.

A B
C
D

12
3
4

Figure 16
Connections Between Commutator and Armature Windings

Because universal motors run at high speed, they

produce heat. Therefore, they have a fan attachment
to cool the brushes, commutator, and armature
windings.

The parts of the universal motor which usually

require servicing and maintenance are:

❏ brushes
❏ brush mountings
❏ bearings
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 INFORMATION SHEET

Brushes are made of carbon. They wear out and

must be replaced. There are many types of brushes
and brush mountings. Figure 17 shows how one
type of brush mounting fits into the motor frame
and holds the brush against the commutator.

SPRING CLIP
CONNECTION

BRUSH HOLDER METAL INSERT

BRUSH CAP
BRUSH

BRUSH
LOADING
SPRING

CASTING

COMMUTATOR
CAP
THREADS

Figure 17
Brush Mounting

For efficient operation, the position, seating, and

support given to the brush is critical. If incorrectly
seated, this causes loss of power and overheating.

Refer to figure 18. Different motors use different

brushes. They vary in:

❏ size, width, and shape

❏ grade (current-carrying capacity)
❏ type of lead or conductor connections

The brush must fit properly into its holder against

the commutator (seating). To achieve this, a spring is
Figure 18 attached either to the brush or to the brush holder.
Brushes

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 INFORMATION SHEET

This pushes the curved brush face against the

commutator with enough force to maintain correct
contact with the commutator surface.

The universal motor is a series motor. Its field and

armature windings are connected in series. (See
figure 19).

FIELD WINDING

ARMATURE

MOTOR
WINDING
LEADS

COMMUTATOR

ARMATURE
SHAFT WINDINGS

BRUSHES

Figure 19
Series Connections for Basic Universal Motor

Figure 20 shows the basic

motor wiring diagram. ARMATURE

Current flows from the line

FIELD WINDING FIELD WINDING
conductor to the:

❏ field winding
❏ brush SUPPLY SOURCE BRUSHES

❏ armature windings
❏ brush
❏ field winding
Figure 20
❏ line conductor Wiring Diagram for a Universal Motor

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 INFORMATION SHEET

EXERCISE B
Directions: Write the correct answers in the spaces
provided.

1. What is another name for an armature?

2. How does the manufacture of the armature

core reduce energy loss?

3. What happens if a brush is seated incorrectly?

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 INFORMATION SHEET

PART III OBJECTIVE 10.3.3

State Motor Installation, Maintenance, and

Troubleshooting Techniques

Like many of the tasks you will perform as a

craftsmen, requirements for installation of single-
phase motors are included within the NEC and AES.

Article 430 of the National Electrical Code and

Aramco Engineering Standards P113, 02 determine
the requirements for the installation of both single-
phase motors and motor branch circuits.

1. When the motor’s current rating is used to set

the ampacity of branch circuit conductors, use
the values given in NEC Table 430-248 for the
actual current rating marked on the motor
nameplate.
SINGLE-PHASE FULL-LOAD CURRENT IN AMPERES Where a motor is marked in
ALTERNATING CURRENT MOTORS amperes but not in horsepower
(HP), the horsepower rating
shall be assumed to be that
HP 110 – 120 V 220 – 240 V
corresponding to the value
AMPERES AMPERES given in NEC Table 430-248.
1/ 4.4 2.2
6
1/ 5.8 2.9
4
1/ 7.2 3.6
3
1/ 9.8 4.9
2
3/ 13.8 6.9
4
1 16 8
11/2 20 10
2 24 12
3 34 17
5 56 28
71/2 80 40
10 100 50

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 INFORMATION SHEET

2. Motor terminals shall be suitably marked or

colored where needed to indicate the proper
connections. (NEC article 430-9).

3. Grounding connections [NEC article 430-

12(e)]. (See figure 21).

MOTOR TERMINAL HOUSING

A MEANS FOR ATTACHMENT OF AN EQUIPMENT
GROUNDING CONDUCTOR TERMINATION IN
ACCORDANCE WITH SECTION 250 - 113 SHALL BE
PROVIDED AT MOTOR TERMINAL HOUSING FOR
1. WIRE - TO - WIRE CONNECTIONS
2. FIXED TERMINAL CONNECTIONS

THE MEANS FOR SUCH CONNECTION SHALL BE

PERMITTED TO BE LOCATED EITHER
1. INSIDE OR
2. OUTSIDE THE MOTOR TERMINAL HOUSING.

Figure 21
Grounding Connections 4. Branch circuit conductors supplying a single
motor (continuous duty) shall have a current
carrying capacity of not less than 125% of the
motor full-load current rating. (NEC article
430-22(a) and AES P, 113, 02-5.2).

The cable shall be sized to

Example:
carry 125% of the motor full-
load current after applying any Motor full-load current rating = 9.8 amps
ambient temperature or any
other derating factors.
9.8 amps x 1.25 = 12.25 amps

Therefore, Branch circuit conductors must have

a current carrying capacity of 12.25 amperes.

5. NEC article 430-32 (c) states that any motor

of 1 horsepower (1hp) or less that is started
automatically shall be protected against overload
by an overload device. That protective device
may be a separate overload device that responds
to motor current.
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 INFORMATION SHEET

MOTOR

SEPARATE OVERLOAD DEVICE THAT IS

RESPONSIVE TO MOTOR CURRENT

Figure 22
NEC Article 430-32 (c)

The protective device shall be selected to trip or

rated at no more than the following percentage of
the motor, or nameplate full-load current rating.

Motors with a marked service factor not less

than 1.15 ................................................. 125%

Motors with a marked temperature rise not

over 40°C ................................................ 125% Service factors are rarely
outside 1.15 to 1.25

All other Motors ...................................... 115%

Example 1:
MOD 5KC35 JN10
Motor full-load current rating: 5.8 amps HP 1/4 HZ 60
V 115/230 PH 1
Operating at 115V RPM 1725 CODE N
Service factor: 1.2

Ambient temperature: 40°C

Therefore, Maximum Rating of over-load

A 5.8/2.9 SF 1-2
device would be:
FR 48
AMB 40C INSUL NEMA
CLASS A DESIGN
5.8 amps x 125% = 5.8 x 1.25 = 7.25 amps. TIME
CONT.
RATING
SER.
No. BRD/
STK NO. C - 147

Figure 23
Motor Nameplate
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 INFORMATION SHEET

Example 2:
Motor full-load current rating: 10 amps

Operating at 115V

Service factor: 1.25

Ambient temperature: 45°C

Therefore, Maximum Rating of over-load device

would be:

10 amps x 115% = 10 x 1.15 = 11.5 amps

SAFETY PROCEDURES FOR REMOVAL/

INSTALLATION OF MOTORS
Just like any piece of electrical equipment, before you
begin any work on an installed motor, you must:

✓ ensure that all moving parts are stationary

✓ the power supply circuit is de-energized
✓ lockout and hold tag procedures are followed

Only when these actions are true can you begin to

perform maintenance work on the motor.

On a capacitor-start ❏ To disconnect the motor from the supply

motor, remember that source, first make sure you know the type of
the capacitor must be
discharged before removing
motor.
any connections.
❏ Before disconnecting any wiring, mark and
identify each conductor to be disconnected.
When the motor is reinstalled, this ensures that
all connections are correct.
❏ Tape and insulate the supply leads individually.
This prevents the danger of shock and short
circuits if the circuit is accidentally energized.

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 INFORMATION SHEET

❏ Replace the connecting box covers to protect

the motor leads.
❏ When removing a motor, identify each set of
Shims are very thin pieces of
mounting bolts, nuts, washers, and shims, metal used to adjust the motor
removed, and the order of removal. Mark or height and align the motor to
the load.
make a sketch if needed. When the motor is
remounted, your marks or sketch ensure that it
is mounted and located correctly.
❏ When moving a motor, follow the correct Never try to lift a heavy
lifting safety procedures. Estimate the weight of object on your own.
the motor. If it is not heavy, it can be lifted Always wear the correct
and carried manually using the procedures protective equipment.

outlined in figure 24. If you feel it is too

heavy, get mechanical assistance or help from
another person.

1 2 3 4&5
Figure 24
Lifting and Carrying Techniques

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 INFORMATION SHEET

1. Start the lift in a balanced squatting position

with your legs slightly apart, and the load held
close to your body. Ensure you have a safe,
secure grip. Before lifting, straighten your back
as close to vertical position as possible.

2. Lift the load by straightening your legs. Make

your legs do the lifting.

3. To complete the lift, raise the upper part of

your body to the vertical position.

4. When carrying the load, keep your body

upright and hold the load close in.

5. Distribute the weight evenly.

MAKING INSTALLATION CONNECTIONS

❏ windings are connected in The capacitor-start motor has two windings, a
parallel
centrifugal switch and a capacitor. (See figure 25).
❏ centrifugal switch and the
capacitor are connected in
series with the starting CAPACITOR
winding

CENTRIFUGALLY
TO LINE OPERATED
(SUPPLY SOURCE) STARTING
SWITCH

MAIN OR RUN START WINDING

WINDING

Figure 25
Schematic Diagram of a Capacitor-Start Motor

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 INFORMATION SHEET

The windings and the associated components

(centrifugal switch and capacitor) of a capacitor-start
motor are all connected at the motor connecting
terminal. (See figure 26).

MAIN
WINDING
L1

3
START
ROTOR WINDING

SUPPLY
SOURCE
4

CAPACITOR

5
CENTRIFUGAL
SWITCH
L2

GND

CONNECTING TERMINAL

Figure 26
Wiring Diagram of a Capacitor-Start Motor

When connected as shown in figure 26, the motor

will rotate in a clockwise direction.

Reversing the connections of either the main

winding or the starting winding to the supply lines
will reverse the direction of rotation (figure 27).

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 INFORMATION SHEET

Figure 27
Connections for Reversing Direction of Rotation of a Capacitor-Start Motor

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 INFORMATION SHEET

TESTING MOTOR OPERATION When the motor

has been connected
Energize the motor circuit and jog start the motor, electrically to the supply
source and mechanically in
checking the direction of rotation of the rotor shaft. location, before energizing you
must turn the rotor by hand to
Note: Jog starting a motor means starting and stopping the check it rotates freely.
motor quickly, using a START/STOP button controller. Press
the start button; then immediately press the stop button.

If the motor rotates in the wrong direction:

❏ de-energize the motor circuit

❏ change the required connections of the motor
for reversing the rotation
❏ energize the motor circuit
❏ check the direction of rotation of the rotor
shaft with a jog start test

Start and run the motor for a minimum of ten

Important: During the
minutes and complete the following checks: test run of a motor, look
and listen. If you see or
1. Noise or Vibration: Vibration can result from hear anything unusual such as,
excessive vibration, rotor shaft
loose parts. Check the motor is coupled not running smoothly, unusual
together correctly and that the motor is noises, or smoke, STOP the
motor immediately.
securely bolted to its mounting base. An out-
of-balance rotor can also cause vibration. A low
buzzing or grinding noise can be the result of a
dry or slightly worn bearing.
2. Motor Operating Temperature: In general, the
maximum ambient operating temperature for
capacitor motors is 40°C., or 104°F., or less
(when started). Maintain a safe distance
from the rotating shaft
3. Measure motors running current: Use a clamp- end of a motor. When
on meter and measure the running current of a working on an operating motor,
avoid loose clothing. This can
motor. (See figure 28). easily get caught on the rotating
shaft.

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 INFORMATION SHEET

Your instructor will now demonstrate how to perform

basic troubleshooting tests on a motor.

SUMMARY

In this module, you have learned how the motor Important: Most motor types
parts function, and how their function causes a have the same or similar parts.
This means that many of the
motor to operate. You then went on to learn how to motor faults that you have now
install a single-phase motor, how to test its learned to identify are common
to all motor types.
operation, and how to identify mechanical and
electrical faults.

In the task aid, you will build on this knowledge

and gain practical experience by installing and
testing a single phase motor.

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 TASK AID

OBJECTIVE

Given, diagrams, vendor manuals, tools, equipment Follow all workshop

safety rules when
and material, the trainee will install and test a performing these task
single-phase motor. The motor must operate steps.
according to manufacturer’s specifications.

TOOLS, EQUIPMENT, AND MATERIAL

❏ electricians tool kit
❏ hold tag and lock
❏ multimeter
❏ cable markers
❏ megohmmeter
❏ pencil
❏ replacement motor and fittings

SAFETY REQUIREMENTS

Wear safety shoes and safety glasses at all times.

DO NOT make any
Ensure the work permit is opened, hold tags attached connections with power
on.
and lockout procedures have been carried out before
starting the task.

TASK INTRODUCTION

In this task aid, you will remove a single-phase

motor, and install another in its place. You will then
check the new motor’s operation is correct for its
application.

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 TASK AID

INSTALL AND TEST A SINGLE-PHASE

MOTOR

1. Open the work permit, perform lockout and

If applicable, discharge
the capacitor. hold tag procedures and prepare the tools,
equipment and material you require.

2. Remove terminal cover plate. Identify the

power leads and test for voltage at terminals. If
no voltage, disconnect, mark and insulate the
power leads from the motor.

3. Remove the flexible conduit.

4. Remove the mounting bolts and shims. Make

sure you can identify each shims position for
mounting the new motor.

5. Remove the old motor and replace with a new

Follow lifting safety rules.
unit.

6. Refit the conduit and connect the new motor

to the correct power leads.

Before proceeding, have the instructor check

your work.

7. Remove hold tag and locks.

8. Jog start the motor to test for correct rotation,

if rotation correct, test run the motor to
determine if operation is correct.

36