INDUSTERIAL ELECTRICAL

MACHINES AND DRIVES

SERVICING
Level II

LEARNING GUIDE #32

Unit of competence: Industrial Electrical Machines
and Drives Servicing Level II
Module Title: Maintaining and repairing industrial
electrical machines and drives
LG Code: EEL EMD2 M08LO3-LG32
TTLM Code: EEL EMD2 TTLM081019V1

LO3: Troubleshoot faults in an Electrical System

or equipment
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 Instruction Sheet :1
Learning Guide 32

This learning guide is developed to provide you the necessary information regarding the
following learning outcome and content coverage
Follow safety policies and procedures
 prepare maintenance records
 Isolate Circuit or equipment to be diagnosed
 identify Indicators/Symptoms of fault or failure
 Perform necessary electrical test on the system or equipment
Estimate Extent of the fault to accomplish the job and the spare parts
needed
 Coordinate other works associated with the problem
 Record details of fault, possible cause, corrective action,
recommendation to eliminate the problem
 respond unforeseen events
This guide will also assist you to attain the learning outcome and contents stated in the
cover page. Specifically, upon completion of this Learning Guide, you will be able to:-

 Follow safety policies and procedures

 prepare maintenance records
 Isolate Circuit or equipment to be diagnosed
 identify Indicators/Symptoms of fault or failure
 Perform necessary electrical test on the system or equipment
 Estimate Extent of the fault to accomplish the job and the spare parts
needed
 Coordinate other works associated with the problem
 Record details of fault, possible cause, corrective action,
recommendation to eliminate the problem
 respond unforeseen events

Learning Instructions:

1. Read the specific objectives of this Learning Guide.

2. Follow the instructions described below 3 to 6.
3. Read the information written in the “Information Sheet 1, Sheet 2, Sheet 3, Sheet 4,
Sheet 5, Sheet 6, Sheet 7, Sheet 8 and Sheet 9” in page 4,8,11,16,22,27,31,34 and
38 respectively”.
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4. Accomplish the “Self-check 1, Self-check 2, Self-check 3 , Self-check 4 , Self-check 5
, Self-check 6, Self-check 7, Self-check 8 and Self-check 9” in page
7,10,15,21,28,30,33,37 and 39 respectively”.
5. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation
Sheet 1 and Operation Sheet 2” in page 40 and 41 respectively.
6. Do the “LAP test” in page 42

Information Sheet :1 Follow safety policies and procedures

1.1. Introduction
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Safety is the number one priority in any job. Every year, electrical accidents cause
serious injury or death. Many of these casualties are young people just entering the
workplace. They are involved in accidents that result from carelessness, from the
pressures and distractions of a new job, or from a lack of understanding about
electricity. This content is designed to develop an awareness of the dangers associated
with electrical power and the potential dangers that can exist on the job or at a training
facility.

 Electrical Safety Work Practices Plan

This safety procedure provides guidelines for safely working around electrical hazards.
It includes provisions for training, lockout requirements, and specific types of work
practices and the required precautionary practices when using portable electric
equipment. Employees will be trained in specific hazards associated with their potential
exposure. This training will include isolation of energy, hazard identification, premises
wiring, connection to supply, generation, transmission, distribution installations,
clearance distances, use of personal protective equipment and insulated tools, and
emergency procedure

 Qualified Person

Those persons who are permitted to work on or near exposed energized parts and are
trained in the applicable electrical safe work practices. Qualified persons shall, at a
minimum, be trained in and familiar with:
 the skills and techniques necessary to distinguish exposed live parts from other
parts of electric equipment,
 the skills and techniques necessary to determine the nominal voltage of exposed
live parts, and
 The clearance distances specified in Table I and the corresponding voltage to
which the qualified person will be exposed.

1.2. General Safety Rule

 Get the right tool for the right job

 Report immediately defective equipment or measuring devices such as melt
meter
 Keep your work shop clean always
 Work care fully
 Learn the use tools and measuring device correctly

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  Learn the correct procedure before doing any jobs
 Report all accident
 Do not open or close avian switch or any power supply with out permission
 Be sure your hands are dry before you handle electrical appliances
 Make a change in wiring only after the current has been put off
 Every circuit must be fused
 Bare wire must be insulated to around short circuit
 Do not work close to power lines

1.3. Personal Protective Equipment (PPE)

Construction and manufacturing worksites, by nature, are potentially hazardous places.

For this reason,safety has become an increasingly large factor in the working
environment. The electrical industry, in particular, regards safety to be unquestionably
the most single important priority because of the hazardous nature of the business. A
safe operation depends largely upon all personnel being informed and aware of
potential hazards. Safety signs and tags indicate areas or tasks that can pose a hazard
to personnel and/or equipment. Signs and tags may provide warnings specific to the
hazard, or they may provide safety instructions (Figure 1-2).To perform a job safely, the
proper protective clothing must be used. Appropriate attire should be worn for each
particular job site and work activity.

The following points should be observed:

i. Hard hats, safety shoes, and goggles must be worn in areas where they are
specified. In addition, hard hats shall be approved for the purpose of the
electrical work being performed but metal hats are not acceptable!
ii. Safety earmuffs or earplugs must be worn in noisy areas.
iii. Clothing should fit snugly to avoid the danger of becoming entangled in
moving machinery. Avoid wearing synthetic-fiber clothing such as polyester
material as these types of materials may melt or ignite when exposed to high

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 temperatures and may hard hat Goggles Cotton only, no polyester Tight
sleeves and trouser legs No rings on fingers Safety shoe.
iv. Remove all metal jewelry when working on energized circuits; gold and silver
are excellent conductors of electricity. Confine long hair or keep hair
trimmed when working around machinery

Self-Check -1 Written Test

Directions: Choose the best answer.

1. Which one of the following safety equipment?

A. Measuring instrument C. Glove
B. Hand tool D. All of the above
2. _______ must be worn in noisy areas.
A. Safety shoos
B. Ear plug
C. Hat
D. All of the above

Note: Satisfactory rating - 1 points Unsatisfactory - below 1 point

Score = ___________

Rating: ____________
Name: _________________________ Date: _______________

Information Sheet :2 Prepare maintenance records

2.1. Preventive maintenance schedule

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Preventive maintenance is the maintenance which has to be carried out to the
equipment, in a preplanned way before serious breakdown takes place. If a record is
maintained for certain measurable parameters like body and bearing temperature,
insulation resistance, earth resistance etc., it is possible from the scrutiny of this record
to predict the occurrence of future trouble and necessary steps can be taken to prevent
the occurrence of serious breakdown.
The interval of doing various maintenance operations, depend upon the type of
equipment, ambient condition and other factors. It is difficult to lay down hard and fast
rules covering all conditions but for average normal industrial duty under-mentioned
time schedule will serve as guide. This can be modified to suit other conditions at site.

 Daily maintenance

1) Examine visually earth connections and motor leads. 2) Check motor windings for
overheating. 3) Examine control equipment. 4) Check condition of bearings. 6) Add
oil, if necessary, 7) Check end play.

 Weekly maintenance

1) Check belt tension. In the case of sleeve bearing machines the air gap between-rotor
and stator should be checked. 2) Blow out dirt from the windings of protected type
motors situated in dusty locations. 3) Examine starting equipment for burnt contacts
where motor is started and stopped frequently. 4) Examine oil in the case of oil ring
lubricated bearings for contamination by dust, grit etc. (this can be roughly judged
from the color of the oil). 5) Check the intensity of vibrations during operation of the
motor. 6) Clean filters where provided.

 Monthly maintenance

1) Overhaul controllers. 2) Inspect and clean oil circuit. 3) Renew oil in high speed
bearings in damp and dusty locations. 4) Wipe brush holders and check bedding of
brushes of slip-ring motors. 5) Check that the connections of temperature detectors
and space heaters, where provided, are proper and these are in working order.

 Haly-Yearly Maintenance

1) Clean windings of motors subjected to corrosive or other elements, also bake and
varnish them, if necessary. 2) In the case of slip-ring motors, check slip-rings for
grooving or unusual wear. 3) Check grease in ball and roller bearings and make it up
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where necessary taking care to avoid overfilling. 4) Drain all oil bearings, wash with
petrol to which a few drops of oil have been added, flush with lubricating oil and refill
with clean oil.

 Annual Maintenance

 Check all high speed bearings and renew, if necessary.

 Blow out all motor windings thoroughly with clean dry
air. Make sure that the pressure is not so high as to
damage the insulation.
 Clean and varnish dirty and oily windings.
 Overhaul motors which have been subjected to severe
operating conditions.
 Renew switch and fuse contacts if damaged.
 Check oil for its dielectric strength.
 Renew oil in starters subjected to damp or corrosive
elements.
 Check insulation resistance to earth and between
phases of motor windings, control gear and wiring.
 Check resistance of earth connections.
 Check air gaps.
 Check condition of all fasteners.

Self-Check -2 Written Test

Directions: Answer all the questions listed below. Choose the best answer

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 1. One is not a type of Daily maintenance?

A. Check motor winding for overheating.

B. Check resistance of earth connections.
C. Check condition of bearing
D. none of the above

2. Which one of the following Monthly maintenance?

A. Over haul controllers.

B. Inspect and clean oil circuit.
C. Renew oil in high speed bearings in dampand dusty locations
D. all of the above
3. One is not a type of Annual maintenance?

A. Renew switch and fuse contacts if damaged.

B. Check oil for its dielectric strength.
C. Examine control equipment.
D. none of the above

Note: Satisfactory rating - 2 points Unsatisfactory - below 2 points

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Information Sheet :3 Isolate Circuit or equipment to be diagnosed

3.1. Introduction

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Before any plant is inspected, maintained, cleaned or repaired, where
practicable, it must be shut down and its energy sources locked out and
tagged as part of an isolation procedure (often called Lockout Tagout) to
ensure the safety of those doing the work. Equipment can malfunction for a variety
of reasons. Mechanical contacts and parts can wear out; wires can overheat and burn
open or short out; parts can be damaged by impact or abrasion; etc. Equipment may
operate in a manner far different than it was designed to, or not at all. Typically, when
equipment fails there is a sense of urgency to get it fixed and working again. If the
defective equipment is part of an assembly line, the whole assembly line could be down
causing unexpected “time off” and lost revenue. If you are at a customer site to repair
equipment, the customer may watch you, knowing that they are paying for every minute
you spend troubleshooting and repairing their equipment. Either one of these scenarios
– and there are more, can put a lot of pressure on you to solve the problem quickly.

So, What is troubleshooting? It is the process of analyzing the behavior operation of a

faulty circuit to determine what is wrong with the circuit. It then involves identifying the
defective component(s) and repairing the circuit.
Depending on the type of equipment, troubleshooting can be a very challenging task.
Sometimes problems are easily diagnosed and the problem component easily visible.
Other times the symptoms as well as the faulty component can be difficult to diagnose.
A defective relay with visual signs of burning should be easy to spot, whereas an
intermittent problem caused by a high resistance connection can be much more difficult
to find.

What makes an expert Troubleshooter? One trait of expert troubleshooters is that they
are able to find virtually any fault in a reasonable amount of time. Easy faults,
complicated faults, they find them all. Another trait is that they typically replace only the
components that are defective. They seem to have a knack for finding out exactly what
is wrong. No trial and error here. So what is their secret?
You might think that a person who has a very good understanding of how the equipment
works, should be able to troubleshoot it effectively. Being a good at troubleshooting
requires more than this.
Expert troubleshooters have a good understanding of the operation of electrical
components that are used in circuits they are familiar with, and even ones they are not.
They use a system or approach that allows them to logically and systematically analyze
a circuit and determine exactly what is wrong. They also understand and effectively use

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 tools such as prints, diagrams and test instruments to identify defective components.
Finally, they have had the opportunity to develop and refine their troubleshooting skills.
If you want to troubleshoot like the pros you will need to develop your skills in each of
these areas. Let’s look at them in more detail.

 Understand how the circuit works.

This consists of understanding the operation of all the components that are used in the
circuit. This could include such components as: push buttons, contactors, various types
of switches, relays, sensors, motors, etc.

Electrical circuits typically control or operate mechanical systems and components. You
also need to understand how these mechanical aspects of the equipment operate to
carry out the work.
You need to be able to determine how the circuit works under normal conditions and
what effect changing one of the circuit inputs has on the circuit operation. For example,
what happens to the overall circuit operation when a push button is pressed; which
relays energize, which lights illuminate, does the pump start or stop, etc. You also need
to be able to determine what effect a faulty component may have on the circuit
operation.

 Use a logical, systematic approach to analyze the circuit’s behavior.

This is critical. There are several approaches that troubleshooters use. They may have
different steps or processes but they have the following in common: They all approach
problems systematically and logically thus minimizing the steps and ruling out trial and
error. One such approach used to teach troubleshooting is called the “5 Step
Approach”. A summary of the key steps are: Observe Most faults provide clues as to
their cause. There could be visual clues such as signs of damage or improper
operation. Don’t forget to use your other senses; sounds and smells can also provide
valuable clues. Through careful observation and some reasoning, most faults can be
identified to the actual component with very little testing.

3.2. Isolation Procedures

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An isolation procedure is a set of predetermined steps that should be followed
when workers are required to perform tasks such as inspection, maintenance,
cleaning, repair and construction.

The aim of an isolation procedure is to:

 isolate all forms of potentially hazardous energy to ensure that an

accidental release of hazardous energy does not occur
 control all other hazards to those doing the work
 ensure that entry to a restricted area is tightly controlled.

The following lock-out process is the most effective isolation procedure:

 shut down the machinery and equipment

 identify all energy sources and other hazards
 identify all isolation points
 isolate all energy sources. In the case of electrical equipment ‘whole
current isolation’, such as the main isolator, should be used instead of
‘control isolation’ by way of the stop button on a control panel
 control or de-energise all stored energy
 lock-out all isolation points, using padlocks, multi- padlock hasps and
danger tags.
 Danger Tag machinery controls, energy sources and other hazards.

3.3. Locks and danger tags

Every person working on isolated equipment should fit their own lock and/or
danger tag. Alternatively, another management approved system that achieves
an equivalent level of safety may be used.

When using locks or danger tags, consider the following:

 tags should be dated and signed

 locks should be accompanied by a corresponding tag to identify who has
locked out the plant
 tags and locks should only be removed by the person who applied them or
by the supervisor after consultation with the signatory of the danger tag. In
the event

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 that the person who applied the danger tag is unavailable, their tag or lock
may only be removed in accordance with a management approved
procedure
 danger Tags and/or locks should be fitted to all isolation points.

3.4. Out-of-service tags

Out-of-service tags are used to identify equipment or machinery that has been
taken out of service due to a fault, damage or malfunction (refer to Figure 3).

The out-of-service tag is to be securely fixed to the operating control power

isolator with the appropriate details completed on the tag (explaining the
reason for the machine being ‘out of service’).

The out-of-service tag should not be removed until the equipment is safe to be
returned to service, or the reason for the out-of-service tag no longer exists.

The out-of-service tag may be removed by:

 the person who attached it

 the supervisor responsible for the operation or repair of the equipment
 the maintenance person who carried out the repairs.

Self-Check -3 Written Test

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Directions: Choose the best answer

1. Which one the aim of an isolation procedure

A. control all other hazards to those doing the work
B. ensure that entry to a restricted area is tightly controlled
C. safety materials
D. A, and B
2. ______ is not the following lock-out process is the most effective
isolation procedure:
A. shut down the machinery and equipment
B. identify all energy sources and other hazards
C. identify all isolation points
D. none of the above
3. out-of-service tag may be removed by
A. the person who attached it
B. the supervisor responsible for the operation or repair of the
equipment
C. the maintenance person who carried out the repairs.
D. all of the above

: Note: Satisfactory rating - 2 points Unsatisfactory - below 2 point

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Information Sheet :4 Identify Indicators/Symptoms of fault or failure

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 Self-Check -4 Written Test

Directions: Choose the best answer

1. _____ is not the following cause noisy a.c magnet?

A. improper assembly
B. Broken shading coil
C. low voltage
D. none
2. _____ is not the following cause frequent coil failure?
A. high voltage
B. Gap in magnetic circuit
C. Ambient temperature may be high
D. none of the above

3. Which one of the causes of failure of contact operation?

A. actuating screw not correctly adjusted

B. worn
C. broken parts in snap switch
D. all of the above

Note: Satisfactory rating - 2 points Unsatisfactory - below 2 point

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 Perform necessary electrical test on the system or
Information Sheet :5
equipment

5.1. Introduction

Testing electric motors doesn’t have to be a mystery. Knowledge of the basics together
with powerful new test equipment vastly simplifies the job. Electric motors have had a
reputation for being a mix of science and magic. So when a motor fails to operate it may
not be obvious what the problem is. Knowing some basic methods and techniques
along with having a few test instruments handy helps detect and diagnose problems
with ease. When an electric motor fails to start, runs intermittently or hot, or continually
trips its over current device, there my be a variety of causes.

Sometimes the trouble lies within the power supply, including branch circuit conductors
or a motor controller. Another possibility is that the driven load is jammed, binding or
mismatched. If the motor itself has developed a fault, the fault may be a burnt wire or
connection, a winding failure including insulation deterioration, or a deteriorating
bearing. A number of diagnostic tools, such as clamp-on ammeters, temperature
sensors, a Megger or oscilloscope, can help illuminate the problem. Preliminary tests
generally are done using the ubiquitous multimeter. This tester is capable of providing
diagnostic information for all kinds of motors. If the motor is completely unresponsive,
no ac humming or false starts, take a voltage reading at the motor terminals. If there is
no voltage or reduced voltage, work back upstream. Take readings at accessible points
including disconnects, the motor controller, any fuses or junction boxes, and so on, back
to the over-current device output at the entrance panel. What you’re looking for is
essentially the same voltage level as measured at the entrance panel main breaker.
When there is no electrical load, the same voltage should appear at both ends of the
branch circuit conductors. When the circuit electrical load is close to the circuit capacity,
the voltage drop should not exceed 3% for optimum motor efficiency.

In a three-phase hookup, all legs should have substantially equal voltage readings, with
no dropped phase. If these readings vary by a few volts, it may be possible to equalize
them by rolling the connections, taking care not to reverse rotation. The idea is to match
supply voltages and load impedances so as to balance the three legs. If the electrical
supply checks out, examine the motor itself. If possible, disengage the load. This may
restore motor operation. With power disconnected and locked out, attempt to turn the
motor by hand. In all but the largest motors the shaft should turn freely. If not, there is
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an obstruction inside or a seized bearing. Fairly new bearings are prone to seizure
because the tolerances are tighter. This is especially true if there is ambient moisture or
the motor has been unused for a while. Often good operation can be restored by oiling
front and rear bearings without disassembling the motor. If the shaft turns freely, set the
multimeter to its ohms function to check resistance. The windings (all three in a three-
phase motor) should read low but not zero ohms. The smaller the motor, the higher this
reading will be, but it should not be open. It will usually be low enough (under 30 Ω) for
the audible continuity indicator to sound.

5.2. Necessary electrical test

 Earth Continuity and Resistance Test

With a multimeter, measure the resistance between motor frame (body) and earth. A
good motor should read less than 0.5 ohms. Any value greater 0.5 ohms indicate
trouble with the motor. Further troubleshooting maybe required Continuity refers to
being part of a complete or connected whole. In electrical applications, when an
electrical circuit is capable of conducting current, it demonstrates electrical continuity. It
is also said to be “closed,” because the circuit is complete. In the case of a light switch,
for example, the circuit is closed and capable of conducting electricity when the switch
is flipped to “on.” The user can break the electrical continuity by flipping the switch to
“off,” opening the circuit and rendering it incapable of conducting electricity. In short, by
performing continuity test, we can determine the following
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  existence of continuity in the electrical wiring circuit
 existence of any open circuit in the circuit
 existence of any short circuit in the circuit

 AC Motor Winding Continuity Test

Using a multimeter, check the continuity of motor winding from phase to phase ( U to V,
V to W , W to U ).Each phase to phase must have a continuity if winding is OK. If any
particular phase fails the continuity test, your motor is probably burnt. Please see how to
identify three phase windings for proper winding identification. U, V, W is a European
winding designation

 Multimeter/Continuity test

Continuity testers are simple devices designed to verify a complete electrical path
through an object or circuit. They are especially useful for checking fuses of all types,
light-bulbs, and wire paths. This tester is usually comprised of: 1. Two leads 2. A small
body where the leads meet and contain... 3. Some form of indicator.A number of
devices are manufactured to assist consumers in testing electrical continuity, ranging
from multimeters, which have a wide range of additional applications, to simple
electrical continuity testers that light up if electrical continuity is present. These devices
use two electrical probes, which form a complete circuit when touched together.
Consumers can test the device to ensure that it is working properly by turning it on and
touching the probes together – the meter should read zero, or the indicator light should
turn on, indicating a closed circuit. When the probes are not touching anything, the
metered device will read infinity, showing that the circuit is open

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  Power Supply Test

For three phase motors, the expected voltage for a 230/400V system is 230V phase to
neutral and 400V between each of the three phase supply lines. Check that the correct
voltage is applied to the motor using a multimeter. Ensure the terminal for power supply
is in good condition. Check the connection bar for terminal (U, V, and W). For three
phase motors, connection type is either Star (Y) or Delta

 Ac motor winding resistance test

Check the motor winding resistance or ohms reading using a multimeter or ohmmeter
for phase to phase terminal ( U to V,V to W ,W to U ).The ohms reading for each
winding must be the same (or nearly the same). Remember that the three phases have
identical windings or nearly so!

 Insulation Resistance test

Insulation resistance failure of an electric motor is one of the first signs that the motor is
about to fail. For a three-phase motor, insulation resistance is usually measured
between each motor winding or phase and between each motor phase and motor frame
(earth) using an insulation tester or megger. Set the voltage setting of the insulation
resistance tester to 500V. Check from phase to phase (U to V, V to W, W to U). Check
from phase to motor frame (earth) (U to E, V to E , W to E ). Minimum test value of

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motor insulation resistance is 1 Meg Ohm (1 MΩ). See how to measure insulation
resistance of Electric Motor

 Running AmpsTest

With the motor running, check the full load amps (FLA) with a suitable meter or
preferably a clamp on meter and compare with the name plate FLA. Deviations from
rated FLA could signify problems with the motor under test.

 No-load Test

Finds magnetizing reactance and combined friction, core and windage power losses
No-Load Test Procedure

 Apply rated voltage and frequency with no mechanical load.

 Measure current voltage and power.
 Uses same test instrument setup as locked-rotor test. Measure IL, VL and PT.

 Open circuit test and Short circuit test:

Multimeter can be used for this test. For this, multimeter should be set in resistance
mode of measurement. To check the existence of any open circuit or short circuit
between any two points in the wiring circuit, the electrical supply to the circuit should be
switched off first. Then put the multimeter probes between the two testing points in the
circuit. If multimeter reads ohm, it indicates open circuit. If multimeter reads ‘0’ ohm, it
indicates short circuit.

 Performing ground test on phase coils

Electrical circuits have a separate ground, or ‘earth’, circuit that provides an alternate
low-impedance path for electricity to safely reach the ground, in case of accidental
physical contact. Ground testing is used to measure the performance of this circuit and
check if it meets requirements. Before you begin testing a ground circuit, there are a few
essentials elements you must understand:

 Use the Correct Instruments Use devices specifically designed for ground
testing, like a dedicated ground tester.
 Understand the Test Apart from the test itself, familiarize yourself with the tools
you’re going to use and how they operate.
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  Understand the Test Environment You must measure the entire area surrounding
the electrode, which is critical to performance.
 Probe Placement The probes should be placed properly in relation to buried
objects, moisture pockets etc.

 Ground Testing Techniques

There are several agencies and organizations which issue guidelines,

recommendations and standards for testing grounding safety. Whichever one you
follow, the key components are the same, like the ground connections and stakes.
These should be carefully inspected annually at the very least, for issues like corrosion,
which can increase the resistance.

 The Importance of Ground

Ground testing is of two basic types – testing when a facility is being built, and routine
testing to ensure that the grounding system is performing as it is meant to.Both types
are crucial for a number of reasons

 A system with faulty grounding can cause catastrophic losses of data, equipment
and even human life in case of electrical malfunctions.
 Equipment operating with inadequate grounding may be exposed to voltage
surges and spikes that can damage it.
 Sensitive equipment is prone to processing data incorrectly or losing it altogether
in case grounding is lost.
 Intermittent faults from bad grounding can create a range of problems, from
random shocks to failures that cannot be pinpointed easily.

A build-up of surface static electricity may give shocks, which are easily misdiagnosed
as internal faults. This leads to unnecessary and costly repairs or replacement of parts.
Grounding protects both equipment and human lives, so it is absolutely essential to
make sure it’s done right and checked routinely. The world’s best grounding system
bonding will be useless unless it can reach a low-impedance ground stake, which
makes ground testing all the more essential.

Self-Check -5 Written Test

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Directions: say true or false

1. For three phase motors, the expected voltage for a 230/400V system is 230V
phase to neutral and 400V between each of the three phase supply lines.
2. Insulation resistance failure of an electric motor is one of the first signs that the
motor is about to fail.
3. Running Amps Test With the motor running, check the full load amps (FLA) with
a suitable meter or preferably a clamp on meter and compare with the name
plate FLA
4. Ac motor winding resistance test Check the motor winding resistance or ohms
reading using a multimeter or ohmmeter for phase to phase terminal
5. Earth Continuity and Resistance Test With a multimeter, measure the resistance
between motor frame (body) and earth.

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 point

Name: _________________________ Date: _______________

Estimate Extent of the fault to accomplish the job and the

spare parts needed
Information Sheet :6

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6.1. Introduction
The purpose of estimating is to quickly develop reasonably accurate and consistent time
estimates. The technique is simple and based on the following principles:
 Experience: for persons who have had practical experience performing
maintenance jobs, it is relatively easy to visualize and establish a time
requirement for simple, short duration jobs. Because of their experience, ex-
craftsmen usually make the best planners.
 Job breakdown: long, complex jobs cannot be estimated as a whole.
Estimation of such jobs is easier and more accurate when the job is broken
down into separate steps or tasks and estimated at that level, then summarized
into an estimate for the total job.
 Accuracy: pinpoint accuracy in estimating is not justified or achievable
because all the variables in maintenance work cannot be known until after
the job is completed. In maintenance we therefore look for ± 15% accuracy.

Estimate is called a damage report or appraisal

 Calculates the cost of parts, materials, and labor for repairing a vehicle
 Printed summary of the repairs needed, used by the customer, insurance
company, shop management, and technician

Self-Check -6 Written Test

Directions: say true or false

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 1. The purpose of estimating is to quickly develop reasonably accurate and
consistent time estimates.
2. long, complex jobs cannot be estimated as a whole.

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 point

Name: _________________________ Date: _______________

Information Sheet :7 Coordinate other works associated with the problem

7.1. Mechanical Repair section

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The Mechanical Repair section of AR100 covers the major mechanical components of
the motor (e.g., shafts, bearings, frames, bearing housings, and laminations). The text
here is generously supplemented with tables that provide many important dimensions
and tolerances. For electric motor rebuilders, a distinct advantage of AR100 is having
these tables in one readily available place, rather than needing to find them in individual
source documents from the American Bearing Manufacturers Association (ABMA),
International Electro technical Commission (IEC), and National Electrical Manufacturers
Association (name).

7.2. Shafts and shaft extensions

The Mechanical Repair section stipulates that shafts and shaft extensions be checked
for wear, cracks, scoring, and straightness. To that end, the tolerances for diameters,
run-out, and keyways are based on NEMA and IEC standards. The supporting text also
provides guidance to help service centers achieve reliable repairs—e.g., that key seats
(keyways) should accommodate keys to a tap fit. Dimensional conformity is critical to
assure a proper fit when end users install attachments such as couplings on the output
shaft.

7.3. Bearings

This section also provides two comprehensive tables of specific housing and journal fits
and tolerances for ball and cylindrical roller bearings. Of all the tables in AR100, service
centers probably refer to these two the most, because proper fits significantly increase
the potential for obtaining full-rated bearing life.

7.4. Lubrication

On the topic of lubrication, practical recommendations in the Mechanical Repair section

include: checking grease passages to make sure they are clean, using grease that is
compatible with the customer’s lubricant, and filling the grease reservoir to about one-
third of capacity if the motor manufacturer’s instructions are not Verifying grease
compatibility is crucial. For example, service centers often use polyurea-based greases,
which usually are not compatible with lithium-based greases that many end users
employ. Confirming the use of a compatible lubricant as AR100 recommends can
prevent a premature bearing failure. The point about grease fill is critical not only to
bearing and motor life, but also to the energy efficiency of the motor. Over-lubrication
can cause ball or roller "skidding" that increases friction; it also can churn the grease,
resulting in higher temperatures and increased losses (i.e., reduced efficiency).The
ultimate consequence could be a premature and potentially catastrophic bearing failure.

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7.5. Frame and bearing housings

Touching on other aspects of electric motors, the Mechanical Repair section

recommends inspecting the frame and bearing housings for cracks and breaks. This is
another example of how AR100 goes beyond tests and measurements, providing
guidance for more reliable repairs that will result in greater uptime for end users. This
section also provides tables for use in verifying that face and flange mounting-surface
tolerances, eccentricity, and run-out comply with NEMA and IEC standards. Verification
of these tolerances helps protect motors from excessive mechanical stress due to face
or flange distortion.

7.6. Dynamic balancing

Dynamic balance of the rotor is essential to the proper operation of a motor. In the
absence of a customer-specified level, AR100 prescribes balancing to the International
Organization for Standardization’s (ISO) quality grade of 2.5 to assure vibration levels
are well within NEMA and IEC standard values. A cautionary note also recommends
making certain that balance weights do not interfere with other components. Low
vibration levels extend bearing life; and adequate clearance between balance weights
and other components helps avoid rapid and possibly immediate failure.

7.7. Testing section

Following the good-practice procedures in AR100 builds quality and reliability into each
repair. For example, the document devotes an entire section to inspecting and testing
repaired motors-often prescribing multiple tests to verify the suitability of a motor to
perform in accordance with its nameplate ratings.

Mechanical tests: The recommended mechanical tests include checking the exact
operating speed and measuring vibration levels at no load.

Self-Check -7 Written Test

Directions: say true or false

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 1. Dynamic balance of the rotor is essential to the proper operation of a motor. In
the absence of a customer-specified level,
2. Touching on other aspects of electric motors, the Mechanical Repair section
recommends inspecting the frame and bearing housings for cracks and breaks.
3. The recommended mechanical tests include checking the exact operating speed
and measuring vibration levels at full load.
4. The Mechanical Repair section stipulates that shafts and shaft extensions be
checked for wear, cracks, scoring, and straightness
5. This section also provides two comprehensive tables of specific housing and
journal fits and tolerances for ball and cylindrical roller bearings.

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 point

Name: _________________________ Date: _______________

Record details of fault, possible cause, corrective action,

recommendation to eliminate the problem
Information Sheet :8

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8.1. Records of Maintenance
(a) It is advisable to use a primed form with yes/no or right/wrong selections for the
operator to easily fill out.
(b) Principle contents：
 Serial number of machines.
 Load machine type.
 Models and specifications of motors.
 Ordinary operating conditions and data.
 Cause, date and disposition measures at breakdown.
 Quantity and name of replaced spare parts.
 Date of maintenance and initial operation. (8) Items and date of
maintenance.
 Special remarks.
 Name of maintenance personnel.

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 Federal TVET Agency Industrial Electrical Machines and Drives
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 Self-Check -8 Written Test

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 1. Which one is not the Symptoms Bearing over heating Possible of the causes?
A. Lack of oil
B. Misalignment between motor and machine shafts
C. Over speed of bearing outer-ring
D. none of the above

2. Which one is Symptoms Speed falls sharply Possible of the causes?

A. Voltage drop
B. Sudden overload
C. A and B
D. Churning sound

3. Which one is not the Symptoms Electro magnetic noise induced by electricity
Possible of the causes?

A. Loose belt sheave

B. Loose coupling or skip
C. Loose screw on fan cover
D. none of the above

Note: Satisfactory rating - 2 points Unsatisfactory - below 2 point

Name: _________________________ Date: _______________

Information Sheet :9 responding unforeseen events

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9.1. Introduction

In order to know how to respond to unplanned events or conditions, one must first start
in assessing or analyzing the situation. The first response should not be making an
action right away, but thinking of the situation and possible solutions. After fully
understanding the situation and listing down possible solutions, it's time to take action
by trying all possible means to cope with the changes or unexpected events.
If working on a project, it's helpful to create a list of planned vs unplanned events so you
can also think of safety measures on how to prevent the unplanned ones even before
starting on the project.
Based on these considerations, the potential accidents, malfunctions and unplanned
events that were considered by the Study Team for the Sisson Project are
 Loss of Containment from Tailings Storage Facility (TSF);
 Erosion and Sediment Control Failure
 Pipeline Leak;
 On-Site Hazardous Materials Spill;
 Release of Off-Specification Effluent from the installation.
 Failure of a Water Management Pond
 Failure of a Water Management Pond Pump;
 Off-Site Trucking Accident
 Vehicle Collision;
 Uncontrolled Explosion; and Fire
Respond to unplanned events or conditions in accordance with established procedures.

 Establish procedures from appropriate personnel In accordance with procedures

before any contingencies are implemented.
 Test Devices / systems and/or Machine is tested whether it conforms to
requirements
 Remove parts or connections for the purpose of testing and pre-test conditions in
accordance with established procedures
Final inspections are undertaken to ensure the installed devices / systems conforms to
requirements Trainers Methodology

Self-Check -9 Written Test

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Directions: Say true or false

1. Establish procedures from appropriate personnel In accordance with procedures

before any contingencies are implemented.
2. Test Devices / systems and/or machine is tested whether it conforms to
requirements
3. Remove parts or connections for the purpose of testing and pre-test conditions in
accordance with established procedures

Note: Satisfactory rating –5 points Unsatisfactory - below 5 points

Name: _________________________ Date: _______________

Operation Sheet-1 Fault Troubleshooting three phase induction motor

Federal TVET Agency Industrial Electrical Machines and Drives

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Procedure

1. Verify the complaint

2. Determine the related symptoms
3. Analyze the symptoms
4. Isolate the trouble
5. Correct the trouble
6. Check for proper operation

Operation Sheet-2 Induction Motor No-Load Test

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PROCEDURE:

1.. Apply rated voltage and frequency with no mechanical load

2.. Measure current voltage and power.
3.. Uses same test instrument setup as locked-rotor test. Measure IL, VL and PT

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 LAP Test Practical Demonstration

Task 1. perform no load test for three phase induction motor

Task 1. perform no load test for single phase induction motor

List of Reference Materials

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 1. A. Bellini, F. Filippetti, C. Tassoni, G. A. Capolino, "Advances in diagnostic
techniques for induction motors", IEEE Trans. Energy Convers., vol. 55, no. 12,
pp. 4109-4126, Dec. 2008.

2. M. J. Devaney, L. Eren, "Detecting motor bearing faults", IEEE Instrum. Meas.

Mag., vol. 7, no. 4, pp. 30-50, Dec. 2004.

3. J. Faiz, B. M. Ebrahimi, "Mixed fault diagnosis in three-phase squirrel-cage

induction motor using analysis of airgap magnetic field", in Proc. Prog. Electro-
Magn. Res. Symp., pp. 239-355, 2006.

4. M. E. H. Benbouzid, "A review of induction motors signature analysis as a

medium of faults detection", IEEE Trans. Ind. Electron., vol. 47, no. 5, pp. 984-
993, Oct. 2000.

5. Eectric Machinery, 6e, Fitzgerald.

6. Principles of electrical machines(mehta)

7. Theraja

The trainers (who developed the Learning Guide)

No Trainer Name Education back graund Region

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1 SERKABEBA ABERA MSC DEBUB

2 MULU DAMANE MSC ADDIAABEBA

3 ABERA GEBRE BSC DIRADAWA

4 ESUBALEW AMSALU MSC HARER

5 MERON HUSEN BSC HARER

6 SHIMELS CHEKOLE BSC AMHARA

7 FISIHA BIREHANU MSC AMHARA

8 YIMER SEID MSC AFAR

9 HINDA IBRAHIM BSC SOMALI

10 TADDELE GASHAW MSC SOMALI

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