Electric Motor Maintenance and Troubleshooting 2nd Edition by Augie Hand 9780071763967 0071763961

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ISBN 10:0071763961
ISBN 13:9780071763967
Author: Augie Hand

A fully up-to-date, hands-on guide to electric motors Keep electric motors running at peak performance! Electric Motor Maintenance and Troubleshooting, Second Edition explains in detail how all types of AC and DC motors work. Essential for anyone who needs to buy, install, troubleshoot, maintain, or repair small to industrial-size electric motors, this practical guide contains new information on three-phase motors along with coverage of the latest test instruments. Drawing on his more than 40 years of experience working with electric motors, expert author Augie Hand provides a wealth of tested procedures to pinpoint and correct any kind of issue. He’ll help you decide whether to replace a motor, take it offline for repair, or repair it in place–decisions that can reduce down time. End-of-chapter questions reinforce the material covered in the book. Quickly and accurately diagnose electric motor problems and find effective solutions with help from this fully updated classic. Electric Motor Maintenance and Troubleshooting, Second Edition covers: Troubleshooting and testing DC machines AC electric motor theory Single-phase motors Three-phase induction motors Troubleshooting less common motors, including synchronous, two-speed one-winding, and multispeed Test instruments and services

Electric Motor Maintenance and Troubleshooting 2nd Table of contents:

Chapter 1 The DC Machine

Basic Electricity as It Applies to Motors

Volts

Resistance

Amperes

Additional Information on Copper Wire

Ohm’s Law

Watt

Magnets and the Magnetic Circuits

The Bar Magnet

The Electromagnet

The Magnetic Pole

Ampere Turns

The Magnetic Circuit

Magnetic Saturation

Magnetic Balance

Neutral Position in the Stator

Circuits of the DC Machine

Rules for Generating Direct Current

The Shunt Generator

The Armature and Interpoles

The Shunt Field

Operation of the Self-Excited Shunt Generator

Shunt Generator Control

The Series Generator

Operation of the Self-Excited Series Generator

The Compound Generator

The Armature and Interpoles

The Series Field

The Shunt Field

Operation of the Self-Excited Compound Generator

Compound Generator Control

The Cumulative Compound Connection (Generator)

The Differential Compound Connection (Generator)

Series Field Connections for a Motor and a Generator

Special-Purpose Machine Connections

The DC Arc Welder

Operation of the DC Welder Generator

Operation of the Welder’s Reactor

Interpoles

Operation of Interpoles

The Compensating Winding

Operation of a DC Motor

One Armature Conductor in a Generator as It Passes Two Poles

One Armature Conductor in a Motor as It Passes Two Poles

Counter-voltage

Counter-voltage Compared to Charging a Battery

Counter-voltage in a Motor Armature

Base Speed

Below Base Speed

Above Base Speed

Torque of the DC Motor

The Shunt Motor

The Armature and Interpoles

The Shunt Field

Operation of the Shunt DC Motor

The Permanent Magnet DC Motor

Operation of the Permanent Magnet Motor

Restoring Magnetism

The Series Motor

Operation of the Series Motor

The Compound DC Motor

The Armature and Interpoles

The Shunt Field

The Series Field

Operation of the Compound Motor Connected Cumulative Compound

The Stabilized Shunt Motor

Speed Control for a Compound DC Motor

Armature Control for Starting and for Below Base Speed

Shunt Field Control for Starting and for Above Base Speed

The Differential Connection (Motor)

Armature Components

Commutator

Commutator Film

Armature Windings

Equalizer Shunts

Laminated Iron

Chapter 1 Review

Chapter 2 Troubleshooting and Testing the DC Machine

Armature Problems

Burned Commutator Bars

Dirty Commutator

Dead Spots from an Open Armature Coil

Open Equalizer

Stalled Motor

Control and Load Problems

Brushes

Brush Problems

Conduction Zone

Spiral Groove

Multiple Brushes

Brush Box and Commutator Spacing

Distance Between Brushes

Brush Holder Alignment

Spring Tension

Brush Shunts

Side Wear

Uneven Commutator Segments

Brush Dusting

Low Load Current

Silicone Vapor and Adverse Ambient Conditions

Seating Brushes

Neutral Location in the Stator and Armature

Setting Neutral in a Motor

Black Band Adjustment

Setting Neutral in a Generator

Restoring Residual Magnetism After Setting Neutral

Overheated Motor

Field Testing the DC Machine

Field Testing the Armature

Field Testing for Grounds in the Armature Circuit with an Ohmmeter

Field Testing the Shunt Field

Field Testing the Series Field

Locating Problems in the DC Machine

Locating Problems in the Armature

Locating a Grounded Interpole with AC and a Clamp-on Ammeter

Locating a Shorted Interpole Using the AC Voltage Drop Test

Locating a Shorted Interpole Using the Smoke Test

Locating Problems in the Shunt Field

The Comparison Test

Needle Probes

Variations in the Shunt Field Circuitry

Drawing Simple Schematics of a Shunt Field

Drawing a Diagram of a Two-Circuit Shunt Field

Drawing a Diagram of a Two-Circuit, Two-Coils-per-Pole Shunt Field

Ground to the Frame Symptom

Shorted Turns in the Shunt Field Symptoms

Shunt Field with an Open Circuit

Shunt Field Shorted to the Series Field Symptoms

Locating Problems in the Series Field

Ground to Frame Symptoms

Shorted Turns in the Series Field Symptoms

Locating an Open Circuit in Series Field

Identifying Leads of a Compound DC Motor with an Ohmmeter

Chapter 2 Review

Chapter 3 Electric Motor theory

AC Terminology

Generating Alternating Current

Cycles and Hertz

Electrical Degrees and Time

Electrical Degrees and Mechanical Degrees

Degrees and Location

Two-Phase Power

Two-Phase Rotating Magnetic Field

Revolutions per Minute, Poles, and Hertz

The Single-Phase Alternator

Current, Ampere, Power, and Reactive Terms

Inductive Reactance

Impedance

Inductive Reactance and Counter-voltage

Power Factor

Unity Power Factor

Magnetizing Amperes and Lagging Power Factor

Power Factor in Motors

Low Power Factor Concerns

Inductive Reactance and Hertz Change

Formula for 50-Hz to 60-Hz Power Change

Impedance in a Three-Phase Winding

Capacitance and Capacitive Reactance

Capacitor Function

Capacitor Value

Capacitors for Single-Phase Motors

Oil-Filled Capacitor

Oil-Filled Capacitor in Single-Phase Motors

Oil-Filled Capacitor Components

Oil-Filled Capacitor Connection in a Two-Value Capacitor Single-Phase Motor

Mounting the Oil-Filled Capacitor

Electrolytic Capacitors

Electrolytic Capacitor Function in the Capacitor-Start Motor

Electrolytic Capacitor Components

Electrolytic Capacitor and Start-Winding Connections

Parallel Electrolytic Capacitor Connection

Series Electrolytic Capacitor Connection

Testing the Electrolytic Capacitor

Capacitor Test Formula

Determining the Right Size Capacitor

Operation of the Single-Phase Capacitor-Start Motor

Transformer Theory

Transformer Components

Transformer Function

Transformer Rating

Solder Gun Transformer

The Squirrel Cage Rotor

Current Flow in Stator Coils

Function of the Squirrel Cage Rotor

Rotor Hertz and Amperes

Slip, Hertz, and Motor Speed

Synchronous Speed and Zero Torque

Rotor Bar Stress

Broken Rotor Bars

Cracked End Rings

Misaligned Rotor Iron

Chapter 3 Review

Chapter 4 The Single-Phase Motor

Shaded-Pole Motor

Multispeed Shaded-Pole Motor

Troubleshooting the Shaded-Pole Motor

Split-Phase Motor

Components of the Split-Phase Motor

Operation of the Split-Phase Motor

Troubleshooting the Split-Phase Motor

Capacitor Motors

The Capacitor-Run Motor

The Capacitor-Start Motor

Two-Value Capacitor Motor (Capacitor-Start, Capacitor-Run Motor)

Capacitor-Start Motor Connections

Thermal Protective Devices

Components of the Bimetal Thermal Protective Devices (for Single-Phase Motors)

Connections and Operation of the Thermal Protective Device

Limitations of Thermal Protective Devices

Alternative Start-Winding Switches

Potential Relay Start Switch

Electronic Start Switch

Time-Delay Electronic Start Switch

Heat-Activated Start Switch

Current Relay Start Switch

Chapter 4 Review

Chapter 5 The Three-Phase Induction Motor

Components of the Three-Phase Motor

Rotor and Fan

Stator Core

Shell and Frame

End Brackets

Bearings

Operation of the Three-Phase Motor

The Rotating Magnetic Field in a Three-Phase Motor

Single-Phase Condition

Amperes and Rotor Bar Design

Phase Angle

Small Rotor Bars

Large Rotor Bars

Code Letter

Torque and Speed

Design Letter

Introduction to Three-Phase Motor Types

The Nine-Lead Induction Motor

Nine-Lead Wye Connection

Nine-Lead Multiple-Wye Connection with T10

Thermal Protector for the Nine-Lead Wye-Connected Motor

Nine-Lead Delta Connection

Multiple-Delta Connection

Twelve-Lead Connection

Multispeed Motors

Single-Winding Two-Speed Motors

Constant-Horsepower Motor

Constant-Torque Motor

Variable-Torque Motor

Multispeed Multiwinding Motor

Two-Speed Two-Winding Motor

Multimode Nine-Lead Three-Phase Motors

Comparing Multimode Motors to Standard Motors

Triple-Mode, Nine-Lead Three-Phase Motor

Identifying the Triple-Mode, Nine-Lead Three-Phase Motor

Quadruple-Mode, Nine-Lead Three-Phase Motor

Identifying the Quadruple-Mode, Nine-Lead Three-Phase Motor

Synchronous Motor

Components of the Synchronous Motor

Operation of the Synchronous Motor

The Synchronous Motor Control

Power Factor Correction with a Synchronous Motor

The Brushless Synchronous Motor

Three-Phase Alternator

Wound Rotor Motor

Components of the Wound Rotor Motor

Operation of the Wound Rotor Motor

Liquid Used for Speed Control

Reversing the Wound Rotor Motor

Wound Rotor Motor Used as a Variable-Voltage Transformer

Wound Rotor Motor Used as a Hertz Changer

The Brushless DC Motor

Components of Brushless DC Motors

Operation of the Brushless DC Motor

Three-Phase Servo Motors

Identifying the Three-Phase Induction Motor

Nine-Lead Dual-Voltage Motors

Three-Lead Motors

Six-Lead Motors

Twelve-Lead Single-Speed Motors

Dual-Voltage Multispeed Motors

European Connections

Chapter 5 Review

Chapter 6 Troubleshooting Three-Phase Motors

The Dual-Voltage Nine-Lead Motor’s Internal Connections

Understanding the Nine-Lead Wye Connection

Understanding the Nine-Lead Delta Connection

Smaller Wire Size with Delta and Multicircuit Winding

Identifying Unmarked Leads in a Nine-Lead Three-Phase Motor

Identifying Unmarked Leads in a Wye Connection

Identifying Unmarked Leads in a Delta Connection

Theory of Unmarked Lead Test

Typical Winding Problems

Shorted Turns

Ground

Phase-to-Phase Short

Open Winding

Burned Windings from Operating on Single Phase

Submerged Motor

Assorted Rotor Problems

When Motors Overheat

Line-Caused Overheating

Operator-Caused Overheating

Control-Caused Overheating

Motor Fault Overheating

Location-Caused Overheating

Maintenance-Caused Overheating

Chapter 6 Review

Chapter 7 Troubleshooting Less Common Motors

Troubleshooting Logic Using Voltage Rules

Troubleshooting Less Common Motors

Troubleshooting Identified Motors

Troubleshooting the Synchronous Motor

The DC Exciter Field and Discharge Resistor

The Amortisseur Winding

Stator Winding

Troubleshooting the Two-Speed One-Winding Motor

Troubleshooting Multispeed Multiwinding Motors

Circulating Current in Multiwinding Multispeed Motors

Rotor Problems in the Multispeed Motor

Testing Motors in Place

Test Instruments for Testing in Place

Core and Rotor Damage

Troubleshooting the Nine-Lead Motor (Wye or Delta) in Place

Visual Check of the Nine-Lead Motor (Wye or Delta)

Testing from Control (Wye or Delta)

Starting the Motor After the Comparison Test from Control

Line/Lead Interchange Test for Uneven Amperes

Recording Motor Faults

Locating Motor Faults

Test Equipment for Locating Motor Faults

Locating Shorted Turns in a Wye-Connected Nine-Lead Motor

Locating Voltage Spike Damage in a Wye-Connected Nine-Lead Motor

Locating Shorted Turns in a Delta-Connected Nine-Lead Motor

Megohmmeter Test for Ground

Bearing Maintenance

Motor Storage Concerns

Bearing Failure Causes

Lubrication Schedule and Bearing Life

Grease Types

Changing Grease Types

Lubrication Procedure

Alternate Lubrication Methods

Gearbox Lubrication

Shielded Bearings

Sealed Bearings

Labyrinth Seal

Bearing Removal

Bearing Installation

Identifying Bearing Breakdown Causes

Specialized Bearing Tools

Sleeve Bearings

Chapter 7 Review

Chapter 8 Test Instruments and Services

Instruments for Initial Testing

Voltmeter

Clamp-on Ammeter

Ohmmeter

Microhmmeter

Tachometer

Megohmmeter

Infrared Gun

Stethoscope

Instruments for In-depth Testing and Scheduled Maintenance

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