इंटरनेट मानक

Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.

“जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न' 5 तरफ”

Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
“The Right to Information, The Right to Live” “Step Out From the Old to the New”

IS 13466 (1992): Brushes for Electrical Machines [ETD 15:

Rotating Machinery]

“!ान $ एक न' भारत का +नम-ण”

Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता ह”

है”
ह
Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”
 IS 13466 : 1992
[Superseding IS 3003 (Parts 3 and 4 )]

( Reaffirmed 2003 )

Indian Stundard
BRUSHES FOR ELECTRICAL MACHINES -
SPECIFICATION

UDC 621*313*047*4

0 BlS 1YY2

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, Y BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

December 1992 Price Group Y

 Rotating Machinery Sectional Committee, ET 15

CONTENTS

1. SCOPE
2. REFERENCESTANDARDS
3. . TERMINOLOGY
4. BRUSH MATERIAL
5. FLEXIBLE SHUNT
6. TERMINATIONS OF BRUSHES 3
7. CLIPS 8
8. INSULATED TOP 9
9. PRBSSURBAREA I0
IO. DUST GROOVES IO
1 I. CHAMFERS FOR BRUSHES II
12. ANciLbs FOR BEVELS I1
13. DIMENSIONS AND TOLBRANCES I2
14. MARKING I3
15. PACKING I3
16. Tss~s 13
ANNEX A INFORMATION TO BB PROVIDED BY BRUSH MANUFACTURER 17
ANNEX B LIST OF REFERRED INDIAN STANDARDS 17
ANNEX C SAMPLING PROCEDURB AND CRITERIA FOR AC~~PTAN~B 18
ANNEX D CONNECTION DROP TEST 18
ANNBX E PROCEDURE FOR PULL-OUT STRBNGTH TEYI 21

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards after the draft finahzed by the
Rotating Machinery Sectional Committee had been approved by the Electrotechnical Division Council.
The brushes are used in electric machines operating on dc, ac or ac/dc systems. The brush technology
in the country is sufficiently developed and the brush manufacturers found the existing standard IS 3003
( in parts ) la c k’mg in clearly specifying the requirements of brush material and individual brushes
fabricated out of blocks. In the new approach it is decided to prepare the following standards out of
existing parts of IS 3003.
a) Definitions and nomenclature of carbon brushes, brush holders, commutators and slip rings for
electrical machinery ( IS 13586 : 1992 ),
b) Brush materials for electrical machinery - Specification ( IS 13584 : 1992 ), and
c) Brushes for electrical machines - Specification ( IS 13466 : 1992 ).
This standard is applicable to carbon brushes fabricated from carbon blocks ( see IS 13584 : 1992 )
and fttcd with its flexibles. The requirements specified earlier in 1S 3003 ( Part 3 ) : I978 and IS 3003
( Part 4) : 1978 have been combined and updated in this standard. However, the methods of tests fog
the following operational characteristics have been included in specification for brush m:\tcrinl f’ol- clcc-
trical machinery ( IS 13584 : 1992 ).
a) Contact drop voltage,
b) Coefficient of friction. and
 IS 13466: 1992

Indian Standard
BRUSHESFO.RELECTRICALMACHINES-
SPECIFICATION
1 SCOPE 5.4 The values of nominal area, maximum dia-
meter, and recommended current per flexible are
1.1 This standard COVETS dimensions, require- given in Table 1
ments and test nrocedures for rectanrular and
cylindrical carb;n brushes used in celectrical NOTES
machinc~. 1 If the flexible is insulated, the brush manufacturer
mny adjust the flexible size to take this into account.
1.2 Reicrcncc may bc made to 1S 9919 : 1981
fw guidance or! <elc’ction of brushes for pnrticu- 2 Ill cast of exceptional current overloads 01
restricted ventilation. the brush manufacturer should
;:I:, applicl;lionz. be advised so that flexihlc size can bc adiusted
accol-dinply.
1‘3 Information to he provided bv brush manu-
t‘acturcr while quoting- to purcha&r is given in
Table 1 Brush Flexibles
Annex A.

2 REFERENCE STANDARDS Nominal Maximum Current

Sectional Overall per Flexible
2.1 The stantiards given in Annex I3 have been Area Diameter ( Tolerance 15% )
referred nnti are necessary adjunct to thi!; mm2 mm A
srandartl. (1) (2) (3)
Copper Flexibles
3 TERMINOLOGk 0’06 0’4 2
0’10 0’5 3
3.1 For the purpose of this standard, definitions
0’15 0’6 4
and terms given in IS 13586 : 1992 shall apply.
0’20 0’7 4’8
4 BRUSH MATERIAL 0’25 0’8 5’5
0’35 0’9 7.0
4.1 The brush material used for manufacture of 0.50 1.1 9-o
carbon brushes shall be one of the grades given
0’75 1’3 12’0
in 3.2 al‘ IS 13586 : 1992.
I ‘00 1’5 15’0
4.2 The b;.u~h material used shall ccnform to 1’25 1’7 175
rcquiremenh given in JS 13584 : 1992. 1’30 19 20 0
2’w.l 2’2 24 0
5 FLEXIBLE SHUNT 2’50 2’4 28 0
3’20 2’7 32’0
5.1 The brush flexible shall be made of elcctroly-
4’00 3’1 38’0
tic grade of copper wires. If required by the
6’00 3’8 50 0
u?er, the flexible shall be suitable reinforced with
8’00 4.3 60‘0
stainless steel wires. Tf required by the user, the
copper \vires shall be silvered or tinned. The 10’00 4.x 75 0
llexibles shall conform to IS 13525 : 1992. 12’50 5’3 X.5.0
1600 6’0 100’0
5.2 Unless othcrwisc specified by the purchaser,
Rein fovccd F lcxibles
the length of ilexibles or shunt shall be chosen
1 GO 1’5 12 0
t.i,clrn one ot‘ tlic fullowing values:
1.‘.F 1’7 15 0
I”) 17’5
7.7
-_ 20’0
d.
1’3 22’0
2’7 27 0
3’1 32 0
3’3 37 0
3’8 43 0
4’3 51.0
4.x 04 0
IS 13466 1992

I I 1 I

IA 10 IC

FIG. I MEASUREMENT of: LENGTHS OF THE FLEXIBLES

5.5 The flexibles shall be securelv fixed in the The permitted values of g depend on t md o.
brush by any one of the following methods: These values given in Tables 4 to 6, which app?!
to all brush materials, include a tolerance fo:.
a> Tamping: discrepancies in drilling the connection holes and
represent the maximum values of g for brushei
b) Riveting; fitted with 1, 2 and 4 Oexibles respectively. The
4 Soldering; safe length of a worn brush Lvill be slightly in
excess of the values ofg. A line or other mark.
d) With nuts and bolts; and showing the safe worn length, shall be made on
the new brush by the manufacturer if required
e) Any other method, for example, the
by the LLSCI ( sre 5.8 ).
following melhod may be used for fixing
the flcxibies in the brush:
The original value of I’ may also be marked on
the brtlsh at tbc request of the user, provided
there is sp:~ce for this on tlic r~_\idual por!;on ~11
This method consists of drilling two holes
the worn blush.
in any two faces of the brush, which com-
municate with each other. The lead is
inserted from one hole and it is secured by In the case of tandem and split brushes, the $
ramming tamping powder under pressure value should be taken from Tables 4 to 6 corrc+
from the other hole. ponding to the cross section of each part.

5.6 Carbon to flexible joint shall bc sound both If the brush manufacturer cannot ensure a hati+
mechanically and electrically. It shall have the factory connection by applying the values given
connection drop across the joint not more than in Tables 4 to 6, hc should inform the purchase:]
the value given in Table 2 and pull-out strength and advise the amcndcd g value necessary.
not less than the value given in Table 3.
57.1 The principal dimensions of brusilcs :I -L
5.7 Depth of Insertion g of the Flexible ( Shunt )
in the Brush given in 13.3 also.

The brush manufacturer may use for the insertion 5.8 Tamping Powder
of the flexible m the brush material in the part of
the brush ncarcst to the top. Tt is clcfincd by Fig.
2A and 2B. g is measured parallel to I’ ( .rt~
Fig. ‘A and 20 ). For brushes with top levels. g
is measured from the intcrscction between Lhc
IiJp srlrfacc and the smaller filce ( .TW I?@. 2K ).
 IS 13466 : 1992

Table 2 Maximum Values of Connection Drop When Tested in Accordance with 16.6
( Clause 5.6 )

Brush Grade Classes Types of Connections

r------------ _-__-h___-__-_____-___~
Moulded or Moulded 01 Riveted Connection Metal Top
Tamped Tamped Connection or Method (e) Soldered or
Connection in in Face or Side of 5.5 Riveted or
Top of Brush of Brush mV Nut-Bolt
and Soldered mV Connection
Connection mV
mV
(1) (2) (3) (4) (5)
hletal-graphite 10 20 15 20
Metal-impreg graphite
Hard carbon 25 80 30 40
Natural graphite
Electra graphite
Carbon-graphite 40 100 00 60
Resin-bonded materials with
resistivity up to 25 400
micro-ohms, cm
*carbon-graphite 60 100 70 70
Resin-bonded materials with
resistivity above 25 400
micro-ohms, cm
*Test made at half current.

Table 3 Values of Pull Out Strength 5.9 Sealant

( Clause 5.6 )
A suitable sealant may be used for sealing the
Maximum Flexible Diameter* Minimum Pull Out carbon to the flexible conductor ( pigtail joint ),
mm Strength if necessary.
daN
0’5 to 0’8 ( both inclusive ) 2 6 TERMINATIONS OF BRUSHES
I’0 to 1‘3 ( both inclusive ) 4
6.1 Terminal Types, Slots or Holes and Suitable
I ‘6 6 Screw Sizes
1’8 to 3’0 ( both inclusive ) R
2’2 to 2’4 ( both inclusive 1 10 6.1.1 The terminal shall be one of the following
2’7 12 types:
3‘0 15 a) Open spade ( see Table 7 ),
3’3 20
b) Closed spade ( see Table 7 ),
4’2 25
4’7 to 6’7 ( both inclusive J 30
c) Open flag ( see Table 8 ),
NOTE -The minimum values of pull out slrengtn d) Closed flag ( see Table 8 ),
given in this table shall bc doubled for any specially e) Open double shoe ( see Table 9 ),
strcnglhencd connections such as in the case of
carbon brushes used in mobile vehicles. f) Closed double shoe ( see Table 9 ), and
*See Table 1. g) Box or tubular terminal ( see Table 10 )_
IS 13466: 1992

Table 4 Maximum Values for g for Brushes Fitted with 1 Flexible

( Clnzrse 5.7 )

Al! dimensions in millimetrcs.

-
I \I a 8 10 12’5 16 20
_~.___~_
.____.___~_
25
_~-32 40 50 I
___-.______ __
I
I
5 7 8 0 IO i3 Ii -

6’3 8 9 10 II I3 13 -

8 -- I0 II I? iJ I5 - -

10 10 - 12 I3 15 16 I7 -

12’5 I1 12 - If- I6 I7 IX -

I6 12 I3 14 _- 17 I :i 18
20 13 14 I5 I6 IS IS - -

25 14 1s I6 I7 -

32 - 16 17 18 - - -

40 - - 18 !8

50 - -

Table 5 Maximum Values for g for Brushes Fitted with 2 Flexiblcs

(’ Clciuse 5.7 )

8 10 12’5 16 20 25 32 50

5 - - - 7 8 9 10 -

6’3 - 7 8 9 10 II

8 - 7 8 9 IO 11 12

10 7 - 9 IO II 12 13

12’5 8 9 _- II 12 13 14

16 9 10 11 - 13 14 15

10 11 12 I.3 - I5 16
?O

115 11 12 13 I4 IS 17

13 14 15 I6 18 -
32

;o - 1 15 I6 18 IS I9

-
-A
- - I9
-~
so IS

4
 JS 13466 : 1992

Table 6 Maximum Values for g for Brushes Fitted with 4 Flexibles

( Clause 5.7 )
Al! dimensions in millimetres.

f
-I
a 8 10 12’5 16 20 25 32 40 50
\

5 - - - - - - - - -

6’3 - -- - - - - - -

8 - - - - - - -

IO - - - - - - - -

12’S - - - - - - - - 13

16 - - - - - - 13 14

20 - .- - -_ - - 13 14 15

25 - - - 14 15 17

32 - -. - 13 14 - 17 19

40 - - - 13 14 15 17 - 21

50 - - - 1.5 17 19 21 -
i ----__

6.1.2 While the dimensions given in Tables 7 Table 7 Spade Terminals

to 10 shall be adhered, the details of terminal ( Clauses 6.1.1 and 6.1.2 )
shapes are left to the manufacturer.
All dimensions in millimetres.
NOTES
1 Any type of terminals other than those covered
in 6.1 may be used by prior agreement between manu-
facturer and the user.
2 Dimensions .X in Tables 7, X and 10 and dimzn-
sion 2x in Table 9 provide the minimum clenrancc
for a box spanner.
6.2 Joints Between Terminals and Shunt
The joints between tclminals and flcxiblo conduc-
tor shall be crimped or crimped and soldered as
specified by the purchaser.
6.3 Current Carrying Capacity and Minimum
Thickness of Terminals
This clause defines values of the current recom-
mended in the flcxiblcs and the minimum
thickness of terminals according to their cross
section and sizes recommended for the terminals.
In order to prevent small terminals being used Open Spade Closed Spade
with large section flexibles or vice versa, it is d B L
desirable to determine the current capacity fol %: To1 + 0’3 Max Max M-z
each recommended terminal. (1) (2) (3) (4) (5)
Table I I gives the values which may be applied, “5
__ 2’8 7 14 -
hut higher values may bc used by agreement - 34 9 I6
bctwcen the manuFacturer and the user. 4 4’3 11 18 6
The current values given m Table I I correspond 5 5‘2 13 20 7
to the maximum section of one or scvcral flexi- h A’S 17 2x 8’5
hlc\ which may be flltcd correctly to a given x 8‘5 ?I 32 10’5
terminal. These values relate to terminals with a I0 IO 5 2.1 40 13
rollctl or crrmpzd shank but 1w1 to terminals NO1 I;?;
lnade from tubes or box terminal:, ( as shown in 1 C‘oppcr ( SPC’ 1s
1897 : 19x3 ) :rnd brnss ( S(‘<’
‘F’ablc i0 ), which are nut included 111 this table. IS 410 : 1977 ) stripthrckncss xhoulcl pr’cfel-ably bi,
The use of the smallest terminal compatible with relected from the R20 series of IS I I.17 : 1950.
the maximum current value required, as far as 2 For the minimum recommended thickness of strip
po<siblc, is recommcndcd, see Table II
IS 13466: 1992
Table 8 Flag Terminals
( Clauses 6.1.1 and 6.1.2 )
All dimensions in millimetres.

Open Flag Closed Flag

Screw Size d A x
To1 +0’3 Min Min
-0
(1) (2) (3) (4) (5)
2’5 2’8 7 8 -
- 3’4 9 9 -
4 4’3 II 12 6
5 5‘2 13 13 7
6 6’5 17 16 8’5
8 8’5 21 20 10’5
10 10’5 23 25 13
NOTES
1 Copper ( see 1s 1897 : 1983 ) and brass ( SPCIS 410 : 1977 ) strip thickness should preferably be <ejected f,.oen
the R20 series of IS 1137 : 1959.
2 Standard strip widths may be used for dimension B of flag terminals.
3 For the minimum recommended thickness of strip, see Table 11.

Table 9 Double Shoe Terminals

( Clauses 6.1.1 and 6.1.2 )

Ail dimensions in millimetres.

Open Double Shoe Closed Double Shoe

Screw Size d B b 2x
Toli- 0’3
Max Mill .1 in
-0
(1) (2) (3) (4) (5)
4 4’3 11 6 I2
5 5’2 13 7 14
6 6’5 17 9 17
8 8’5 ?I II ‘I
10 IO’S 73 II 26
NOTES
1 Copper ( see IS 1897 : 1983 ) and hIa\\ ( SW IS 410 : 1077 ). Stl-i[? IllichncSs \hOilld plcf‘cl:~l~li ’ : e.‘cG:(cs.i
from the R20 serlcs of IS 1137 : 1959.
2 Standard strip widths may bc used for climcnsion 11 of tlo~~blc hoe LCIInin:llx.
3 For the minimum recommended thic6ncss trf atrip ( scc ‘Table 11 1.
4 Dimension h applies only in the case of open double shot terminals.

6
 IS 13466 : 1992

Table 10 Box or Tubular Terminals

( Clauses 6.1. I and 6.1.2 )

All dimensions in millimetrzs

--P-L-

Box or Tubular Terminal

Screw Size d V A x
To, + 0’3 Na.t Min Min
-0
(1) (2) (3) (4) (5)
4 4’3 11 12 6

5 ii 13 I
6 17 18 8’5
8 21 20 10’S
10 23 2.5 13

7
. IS 13466: 1992

Table 11 Minimum Thickness and Current

Capacity of Terminals
7.1.1.1 Type A
( Clause 6.3, and Tables 7 to 9 )
Type A clip consists of a metal strip bent to lit
on the top of the brush and ntfached to the side
Diameter of Minimum Current Cnpacity of the brush by one 01 more rivet,,
Screws Corres- Thickness at Continuous Rating ( see Fig. 3A ).
pending to the #-____--A_~ _-_-7
Hole or to the Spade Terl;li- I:huote 7.1.1.2 Type A-cxtrcr ll,ide
Slot of nals and Flag
Terminals d, Ternlina 1 Terminal Type A-extra wide clip is similar to the type A
Illlll 117111 A A
clip, except that it covers nearly the whole top
(1) 69 (3) (4) of the brush ( see Fig. 313 ).
2’5 0’56 15 -
7.1.1.3 Ofiset A
- 0’56 2u
4 0’8 32 64 Offset A clip is similar to the Type A-extra wide
100
clip cxccpt that the rivet is not placed at the
5 0’8 50
centrc !ine of the brush ( see Fig. 3C ).
6 1 .o 76 120
8 1’12 100 150 7.1.1.4 Extended A
10 1’6 150 2-10 Extended A clip is similar to th\: Type A ciip but
extends beyond the side of the brush to accom-
modate the brush pressure finger ( see Fig. 3D ).
7 CLIPS

7.1 Brush clips, referred to as &clips’ in this

standard, are metal parts attached to the brush Angular A clip is similar to the Type A clip but
which serve to accommodate the spring finger or is attached at an angle to accomplish the same
hammer or to act as guides. Where these clips purpose as bevelin, m the holder end of the brush
serve to prevent the,wear of the carbon due to ( see Fig. 3E ).
the pressure finger, these are called ‘hammer’ or 7.1.1.6 Channel A
ifinger’ clips. Rotary converter brushes may have
clips which serve the dual purpose of lifting the TJ’his type is similar to Type A except that it ]:;I\
brushes and of preventing wear from the spring the edges turned up as a guide to position the
finger. These are generally called <lifting’ clips. spring finger OII top of the brush ( see Fig. 3E ).

3C Offset A 3E Angular A
3A Type A

RACK FRONT

3D Extended A 3F Channel A
36 Type A-Exra Wide

I‘IG. 3 HAMMER CLIPS

 1s 13366: 1992

1.1.2 Lifitlg and Guide Clips 7.1.2.7 TvJ?e N

7.1.2.1 Type B Type H is a lifting clip similar to the Type E
Type B is lifting clip having two lugs, in one of ( hook type ; clip, except that it has a minor
which there is a hole and in the other a slot projection at the top of the brush (see Fig. 4G )_
opening towards the side of the brush. For pilot
brushes, the slot opening is upwards (see 7.1.2.8 Type K
Fig. 4A ).
7.1.2.2 Type C Type K is a lifting clip combining the features of
a Type E lifting clip and an angular A hammer
Type C is a guide clip. It is generally fastened clip ( see Fig. 4H ).
into a groove in the brush by one or more rivets
(, set Fig. 4B ). 8 INSULATED TOP
7.1.2.3 Type D
Type D is a bail-type lifting clip. The bnii is 8.1 Insulated top is made of one material or is a
tixed to the brush by a metal plate ( see Fig. 4C ). combination of more than one material bonded
together. The insulated top shall provide the
7.1.2.4 Tpt’ E
following:
Type E is r? lifting clip formed into the shape of
the hook ( see Fig. 4D ). a) Resilience between brush and br ush-holdel
spring so as to absorb the dynamic forces
7.1.2.5 ,Typet-
and ensure better riding of the brush on
Type F is a lifting clip similar to the extended A the commutator;
type of hammer clip and i< usually made in
double thickness or tn,o pieces ( set Fig. 4E ). b) To prevent passage of current between
brush and the brush-holder spring; and
7.1.2.6 Type G
Type G is a lifting clip having a raised portion c) Distrtbuting the contact force evenly,
which proiects outwards from the side of the apart from permitting small relative move-
ments between carbons of the brush.

4A Typa B 4C Type D 4E Type F 46 Type H

4B Type C 4D Type E IF Type G 4H Type K

]:I(;. 4 LIF’IINC; AND CilJIDI: CLIPS

9
IS13466:1992

8.1.1The insulated top shall either be embedded pressure may bc applied, through an appropriate
in the brush top face bonded to it or a separate arrangement.
loose unit. Some of the typical insu!nted tops
are illustrated in Fig. 5. Materials used for mak- 9.2 The minimum value of width P of pressure
ing the insulated top and the adhesive used for area shall be as given in Table 12. The values of
bonding it to .the brush shall meet the following P are related to tither c1 ( Fig. 6 ) or I ( Fig. 71.
requirements:
10 DUST GROOVES
4 Capable of withstanding the maximum
temperature likely to be encountered in 10.1 Dust is harmful [or commutation perform-
service without unduly losing physical ante since it causes:
properties; and a) raprd wear of brushes; and
‘3 The insulated top should not break, crack b) reduction in brush to brush-box clearances
or the bonding between the dlfferent mate- resulting in <ticking of the b:-!lsh in the
rials and also between top and the brush brush-box.
should not fail due to -the mechanical
forces encountered. 10.2 Wear snd Grooving of Commutator or Ring

9 PRESSURE AREA Provision of dust grooves enables to a consider-

able cxtcnt in overcoming the difficulties given
9.1 The top of the brush shall have an area in 10.1.The dust-grooves also help to some
symmetrical on the central lines of the brush top extent in cooling of the brushes. Figure 8 shows
left clear of brush connections, on to which the some of the typical type of dust grooves.

,TJJFNOL

TUFNOL

FIG- 5 ~~RLJ~HIS w'111 ~NS~XATFD TOPS

 IS 13466 : 1992

Table 12 Pressure Area 11 CHAMFERS FOR BRUSHES

( Clause 9.2 ) 11.1 An angle of 45” shall be preferred for the
chamfer of brushes.
Q ( Fig. 6 ) or P, Min
t ( Fig. 7) NOTE - In case of multiple 2nd split brushes, .~!lglc
mm mm of chamfer shall be provided nc requital by thi: JJIIV-
(2) chaser.
(1)
12‘5 6’3 11.1.1 The values of dimensions c which are
16 6’3 related to the dimensions t or n of the boyish
20 10 ahal! be as given in Table 13 ( see Fig. 9 ).
25 12’s*
12 ANGLES FOR BEVELS
32 16
40 20 12.1 Angles for Contact Bevel ( CL)
50 25
The angics for contact bevel ( CC) shall he O”,
*When brush-holders MC: pressure figui-cs equal to or 7.5”, I5”, 22*5”, 30’ and 37-S” ( see Fig. IOA ).
more than 12’5 mm wide for brushes with n or I
equal tc 25 mm, the brush manufacturers should The tolerance allowed on these an_clca ~11~11
increase P to a suitable value or use two flexiblcs. be f- 1”.

FIG. 6 WIDTH OF PRESSURE AREA FIG. 7 WIDTH OF PRESSURE

IN RELATION TO a AREA IN RPLAIJON TO t
IS (13-166 : 1992

Table 13 Dimensions of Chamfers 12.2 Angles for Top Bevel ( p )

( Cluuse 11.1.1 )
hnglc:; for the lop bevel ( B ) shall be O’, 7*5”,
F or a Whichever c i5’, 22.5",30",37.5"nnd 45"(see Fig. 1 IA ).
is SmaltCl
mm mm The tolerance allowed on theac angles shail IX
!I) (2) 2 I”.
Lp to 1’5 0’1 to 0’2
1'6 IO 3'2 0’2 to 0’3 12.2.1When B is greater than 15”, a flat surface
3'3 to s 0’5 to 0’8 of not more than I mm width may be Ief :~t tile
8'1 to 20 1’0 to 1’5 apex ( see Fig. I IB ).
Gt‘catcr lll.lll 20 2’0 to 2’5

lmm MAX-

FIG. 9 CHAMFERS
12.1.1WllsnOL is greater than 15" and ‘t'is
greater than 8 mm, a flat surface of not more
than I Illi wldill IllLI~ be left a! the apex ( se0
Fiy.IOR ).

11A Ill3

”/
FIG. 1I ANGLE FOR TOP BEVEL

13 DIMENSIONS AND TOLERANCES

13.1 Standard symbols ( t x u x I’ ) shall be
followed for carbon brushes in accordance with
IS 13586 : 1992 where t represents tangential
dimension of carbon brush, a axial dimension
and I’ the radial dimension. The s:anclard values

--a in millimetres
dimensions
for tangential, axial and radial
shall be l-6, 2.0, 2.5, 3.2, 40, 5.0,
6.3, 8 0, 10.0, 12.5, 16,0, 20.0, 25.0, 32+, 40.0,
I-, -2 50.0, 64.0, 80.0 and lOO*O.
h-4-1 mm
13.2 Unless otherwise stated, tolerances on the
10A 106
principal dimensions t, a and r of the carbon
F~ti. IO ANGLE FOR CONTACT BEVBL brushes shall be as given in Table 14.
 IS 13466 :1992

13.3 The brushes shall be generally chosen in suitable location such as to be visible even when
the preferred combinations of principal dimen- the brush is fully worn:
sions f, n and r as in accordance with Table 15.
Particulars Suitable Location]Plncc rd’
NOTE --- For replaccnient of brushes already in use, Marking
the siz.: of the carbon brush shall be agreed to bet-
wcen the user and the st:pplicr. Grade of carbon block Carbon portion;
used
13.4 Safe Length of n Worn Brush, Dimension I’~PI
Manufacturer’s Jl;llllC Carbon portion, prefe-
The dimension rm, the safe length of a worn or trac!e-mark rahly axial face with
brush, depends on certain number of factors dimension n; and
huch as real values of g or elements or parts of
elements fitted on to brush material and which, Batch No. and the At a suitable placr.
taking part in the pressure application, are year of manufacture
included in the initial r. on the request of the
purchaser
13.4.1 Definition
NOTE - Small brushes, on \\I:ich nux killp :. .;ot
rm is the distance between two planes normal to possible, are excmptcc! front mxrkicg.
Ihe ccntre line passing over the extremities:
14.1.1 The wearing length ofthe brush (set 5.3 )
a) Of the contact surface at the minimum
may be suitably indicated by a line drawn on
bafc length of worn brush; and
the larger side or any other mark as may be
b) Of the elements of brush or parts of agreed to between the iuppliel and the
elements, which take part in pressure purchaser.
application.
14.1.2 The carbon brushes may also be mariied
An example of this is given in Fig. 12. with the Standard Mark.

15 PACKING
T-he value of rm is not mentioned in this
standard, it depends upon the design of the 15.1 The brushes should bc suitably protci:tcd
brush and is left as the responsibility of the and packed so as to avoid any damage to
manufacturer. flexibles, terminals and carbons.

For the purpose of guiding, marking, etc, the 16 TESTS

dimension rm is limitd to minimum value.
16.1 Type Tests
FOI- radial brushes inclined
ant! brushes with
GL< I5”, r/n shdl
he not lower than 35 pcrccnt ‘type tests are intended to c%,.lahlish tcc!:n;cal
of the preferential r ( see Table 15 ), whatever parameters and pcrformnncc characlcrisfics of
the real value r of the brush may be. llnless othc~ wi~c r:grecd
grades of brushes.
between brush mnnufacturcr and purchaser, a11
For inchncd brushes with tc > 15”, YW shall be tests shall bc cnrrirci out by brush
type
> 0.3 I’ preferential. manufacturer on 4 number brushes.
Tt is the user who shall supervise the brush wear,
lhe purpose being to replace the brush when the The brush manufaciurer rmy IX exempiecl I[-om
carrying tests for brush m:ltcrial if 11:c t> pc
out
safe worn length rm is Xachcd.
tests were already cnrricd out by br-ush i~l:l.!crinl
A malking showing its safe worn length and the manuracturcr and a cerlificalc: of conforln!t1; to
grade of brush material shall be marked by the IS 13584 : 1992 \V;IS JTldC avnilablc.
brush manufactlu-cr, if rcquircd by the user. Vhe
marking shall be made on one of the brush Against repe:lt orders for 111~ same h:.t1.,:1~.>,
sides. When the contact surface reaches the Jll[)rcbrushes may be type tested intcrvrls h;,,
marking the brush shall be taken as worn. agtecmcnl. betwcin 1liC ni~~nirfacturer :~ncl ihc
purchaser.
14 MARKING

14.1 The fO~lOWiJlg parliculars d1a11 bc Icgibly

:\nd indelibly marked 011 each car-bon brush :It a

I?
 IS 13466 : 1992

Table 15 Preferred Combinations of Dimensions

( Clause 13.3 )
( Preferred values of 1, n and Y are underlined. )
All dimensions in millimetres.

I I I I ..___-__
i I I
I 1 I 1 i ____-
I I-
-,81 8 / 8
Ion’ g 10
’ 1
/ 10
I
12’5
-.- / 12.5
._____~_ I

lo
iI 18
j!? 10
I 1 8
10
i / 12’5
I#12’! _12’5 12’5
_.~_
111 j
161 I / 16
- -7 -II____
I
10 10 ( 10
-- I- /
i_12’5 12’5 12’5
fi _1_6 16 16
20
- -20 20
I
--
i I 12’5 ’ 12’S

-16 16 16 16

/ 5 -20 20
25 25

32 32

40 40
--.
I -i-

12.5
I (
12’5

:6

-16 I6 20

-25 25 25
32
-32 - 32 32 32

-6.3 40 40 40
50 50 50
_.- -_ -
16
20 20
25 25 2.5
32 32 32
40

50
/ 64
_- .‘.
--i- -_
I

20 ( /
/ ,-
25 - 25 -3

._
7’ j ._
3’ I 3? 31
-
I
!i-
40 40
I
50

--I 64 ,

14
 IS 13466 : 1992

Table 15 ( contimd )
All dimensions in millimetrw

--I I-
8 10
-.._I
12’5 16 II- 20 25 32
--I
40 .-50 / r
1 ____-_
_20
i I
I 20
25 2s
-
I
25 ! 25
I

12’S
I- 12
I
I
- 32
40
32
40
- 40
--
32 32

40 40
i

, -lo
33

50 !.50 50 -50 50 j SO
64 64 64 64 / 61
- i
80 80 80 i SO
___- - __.__
- !O
- i
25 25 I 1;;

-32
77
z.z -32 32 32 ’ 32
30 40 40 40 40 / JO 40
16 / --
50 50 50 50
64 64 / 64
80 1 80

IL25
-
32 -32 32 32 ’
40 I -_40 -40 40
50 50 50 SO 50 50
j k4 64 6-l
64 1 64
80 / 80 X0 / so

I -- .‘_
I 1 I
I il00 /100
32 I 32 12 32 / :3-
40
SO
I- 40
50
40 40
- 40
- 40 10
50 50 50 50 50 ~ i0
, 64 64 64 64
- I, 64 ’ h4
_
I
I

I I I 32
- 32 32
80
100
so j 80
/IO0
SO

1100

40 -40 40
-_
SO 50 SO SO I so
32 64 64 64 j 64 63
I --
80 80 x0 I x0
I
00 ;I00 !100
,125 $25
-
40 ; i 40

I
-_.
IS 13466 : 1992

Table 15 ( concluded)
All dimensions in millimetres

_. _- .-- _
7-
I r
2
\/
a I- - 5 6.3 - 8
I
__ _
12’5
I 25
_.._.
--32 40 : 50 /
/
r

40 40 I 40
I
- 50 -50 50 i 50
64 64 64 64 ! 64
80 80 80 80 80
- 50
100 IO0 100 100 1100
I 125 125 125 1135
- -~- _’

NOTES
I Square section brushes arc not rccommcndcd.
2 Cal-c should be exercised when contemplating using brushes with high I’ values that Lhcy can bc s:itisf;iclorjl:.
used in the design of brush holder in use.

16.2 Acceptance Tests

FIG. 12 SAFE LBNGTH OF A WORN BRUSH

16.2.3 Test Certijcate

r 0

The following shall constitute the acceptance Three copies of test certificate shall be supplied
tests which shall be carried out at the time of which shall give following details:
acceptance of supplies:
a) Brush to drawing No. conforminS to
a) Workmanship ( 16.4 ). TS 13466 : 1992;
b) Dimensional accuracy ( 16.5 ). b) Brush grade and name or brush manufac-
c) Connection drop test ( 16.6 ). turer; and
d) Pull-out strennth test ( 16.7 ) ( see Note ), c) Results of type tests and acceptance tests
NOTE - The number of samples for pull-out carried out in accordance with 16.1 and
~c~ng~h test may be reduced if’ agrcctl between 16.2.
the manufacturer and the purchnscr.
16.3 Routine Tests
16.2.1 Unless otherwise spccificd, the sampling
for The following shall constitute the routine tests.
procedure and criteria for conformity
:~cceptance tests ahnll be as given in Annex C. a) Workmanship ( 16.4 ),
b) Dimensional accuracy test ( 16.5 ), an(i
16.2.2 If rcquircc! by the purchaser, the test
ii%:tcd in 16.1 may be repeated as acceptance test. c) Connection drop test ( 16.6 ).

16
 IS 13366 : 1992

16.4 Workmanship 16.6 Connection Drop Test Across Flexible !o

Carbon Joint
16.4.1 The brushes shall be examined with a
magnifying glass of magnification factor not less 16.6.1 The brushes shall be subjected to :hc
than 10, fcr the following: connection drop test. The test which ensure\
sound electrical joint hztwcn carbon :~nrl
a) Craking, chipping or distortion; and flexible shunt is conduc!ed by measuring the
b) Smoothness of surfaces. voltage drop across the joint on passing the
specified current as indicated in Table I for ;L
16.4.2 The brushes shall also be examined for: particular diameter of the pigtail. Equipment
and test procedure are given in Annex D.
a) Sound and proper jointing of pigtail to
16.6.2 The connection drop for the different
carbon, and
types of connection shall not be more than the
b) Appropriate marking. values specified in Table 2.

16.5 Dimensional Accuracy 16.7 Pull-Out Strength Test

After the wotkmanship test, the dimensions shall 16.7.1 After the connection drop test, bruih<b
lie measured with vernier callipers and screw shall bc subjected to pullout strength test. Th1,
gauges with their least count not more than test shall be conducted only for brushes \;itil
O*Ol mm. For measuring the curvatures and tamped or moulded connections and not f~:
checking trueness of the flat surfaces, dial gauge brushes \+Gth riveted, soldered or nut-bol L
should be used. The observed dimensions shall connection. Equipment and test procedure I-.\:-
be within the specified limits. Specially pigtail pull-out strength test are described i11
rabricatecl ‘go’ and ‘no-go’ gauges may be used Annex E.
for checks of dimensional accuracy on mass 16.7.2 The pull-out strength shalt be not 1~~~
scale production. than the value specified in Table 3.

ANNEX A
( c/ause I .3 )
INFORMATION TO BE PROVIDED BY BRUSH MANUFACTURER

A-l Brush manufacturer while quoting to pur- block manufacturer;

chaser shall submit the following details:
c) Density. porosity, hardnc~s, resisti\it::.
a ) Confirmation that brushes would comply transverse strength and ash CClltci7l.

with IS 13466 : 1992 for material, tole- see IS 13584 : 1992; and
rances on dimensions, testing and other Connection drop per fexiblc. pigtail ptili-
requirements bringing out deviations, if
out strength per flexible, contact drop.
any; coefficient of friction and brush \<IXI’
b) Brush Grade, indicating name of brush specified in this standard.

ANNEX B
( C%ause
2.1 )
LIST OF REFERRED INDIAN STANDARDS

IS No. Title IS No. Tiilc

410 : 1977 Specification for cold rolled brass 9919 : 1981 Guide for ~lcction and u&e ,,‘t’
sheet, strip and foil ( third reaision ) carbon brushes for applications in
rotating electrical machines
1137 : 1990 Thicknesses of sheet and diameters
of wire (first rei~ision ) 13584: 1992 Specification for brush materiai fur-
rotating ctectricals machinerk
1248 Specification for direct acting [ Superseding 1S 3003 ( Part 2 ‘1.:
f in various electrical indicating instrument and 1977 ]
parts ) their accessories 13586 : 1992
1897 : 1983 Spccificalion for copper strip foi
elcctricnl PLll posts ( .rec011tl
rni.vioiz )
.4905 : 1968
17
IS 13466 : 1992

ANNEX C
( Clause 16.2.1 )

SAMPLING PROCEDURE AND CRITERIA FOR ACCEPTANCE

C-l SAMPLING brush failing to meet any of the requirements for

acceptance tests shall be termed as defective.
c-1.1 Lot
The lot shall be considered as conforming to the
In any consignment all the carbon brushes of the requirements of acceptance tests if the number
same designatron, manufactured from the same of defectives found in the first sample is less
material under similar conditions of production than or equal to the corresponding acceptance
shall be grouped together to constitute a lot. number. The lot shall be rejected if the number
C-l.2 The number of brushes to be selected from of defectives is greater than or equal to the
each lot shall depend upon the size of the lot corresponding first rejection number ( see
and shall be in accordance with columns 1, 2 co1 5 of Table 16 ). If the number of defec-
and 3 of Table 16. These brushes shall be selected tive is in between the acceptance number and the
from the lot at random. In order to ensure first rejection number, then a second sample of’
randomness of seleclion, procedure given in the same size shall be selected from the lot at
1s 4905 : 1968 shall be followed. random and subjected to all the acceptance
tests. The lot shall be considered as conforming
C-2 CRITERIA FOR CONFORMITY
to the requirements of acceptance tests, if the
The number of brushes selected at random in combined number of defectives in both the
accordance with co1 I and 2 of Table 16 samples is less than the second rejection numbet
shall be subjected to all the acceptance tests. A ( see co1 6 of Table 16), otherwise not.

Table 16 Sample Size, Acceptance and Rejection Numbers

( Ch4se.s C-l .2 afzd C-2 )

Lot Size First Sample Seco\{ZTmple Acceptance First Rejection Second Rejection
Size I Number Number Number
(1) (2) (3) (4) (5) (6)
up to 100 5 - 0 1 -
IOl- 300 8 8 0 2 2
301- 1 000 13 13 0 2 2
1 OOl- 3000 20 20 0 3 4
3 001-10 000 32 32 1 4 5
10 001 and abovs 50 50 2 5 7
NOTES
; 711~ sampling plun as given in this table is having an AQL 2’5 pcrccnt.
2 For lots of’ sizes up to 100, dccisim warding acccptancc of lots shall be taken on the basis of first sanlple
only.

ANNEX D
( Clause 16.6.1 )

CONNECTION DROP TEST

b) A millivoltmeter having an internal resia-

tance not less than I 000 ohm/V and
accuracy not inferior to Class 2.5 ( TS
1248 ). The millivoltmetcr range shall bc
The L;ource of direct current supply able so selected that the readings do not fall
10 provide any current from ‘0’ up to the rcithin 20 pa-cent of full ncalc dcflcction;
vnluc 01‘ current spccificd in Table 1 liar C) An ammeter having accuracy not inferior
the p:irt icular llcxiblc Jinmclcr: IO Clas< 2-5 of IS 1248 with ;I xuiiable
 IS 13466 : 1992

ral:ge so that any reading is not below D-2.4 Close the switch and press the brush on
20 percent of full scale deflection; the platform as well as the pigtail on the supply
d) A switch for closing and opening the connection No. 2. Adjust the current to the
circuit to start and stop the test; and value specified in Table I and remove the brush
for cooling, as it becomes hot during adjustmen:.
e) A stand as shown in Fig. 13 to hold the
brush and to permit the requisite current D-2.5 After the brush is cooled, place it agai.1
to pass through it with as uniform distri- for a short while and check if the current setting
bution as possible. The stand is also is correct. Again. remove the brush for cooli:l:r.
provided with a probe connected to
millivoltmeter so that quick reading of D-2.6 When the brush is cooled, place it in thz
connection drop is taken. stand and check millivoltmeter reading quickI!,
D-2 PROCEDURE FOR CONNECTION DROP and in not more than 30 seconds.
TEST
D-2.7 The milli~oltmeter reading indicates I!IL’
D-2.1 Connect the circuit to supply and milli- connection drop across the joint of carbon 1%)
voltmeter as shown in Fig. 14. Ilrxiblc shunt.
D-2.2 If the number of brush flexible is more
D-2.8 Once that current sc:ting has been m:..: 2
than 1 and they are jointed at terminal lug,
for the first brush, rest of brushes shall be t<\iel!
separate them by removing the lug.
one by one taking quick reading.
D-2.3 Place the brush on the stand and adjust
the height of adjustable platform so as to ensure D-2.9 These brushes which cannot be ~c~.tcd
that : with the use of stand, shall be tested by passing
the specified current by means of suitab!c grip’
a) the distance between the brush top and clamped on the brush and the flexibic !.!lunt.
the spring loaded probe is 2 mm; and The connection drop shall be measured 17;.
b) the distance of the brush top and the means of millivoltmeter and probes touchin:
pigtail contact with supply connection the carbon and the shunt at location? $~OVYI I’d
No. 2 i$ 5 mm. Fig. 15.
IS 13466 : 1992

Rh

FIG. 14 ELWIRICAL CIRCUIT - A BRUSH HOLDING ~l3’1C33s

CHOOSE THE POINT WHICH

GIVES LOWER READING

_i_

15A Moulded or Ternpad Connection 158 Riveted Con~:cction

,n Top of Erusfr

l!jC Solc!ercd Connection 133 Moulded or Tampccl Connection IX Metal Top Soldered
in Face or Side of Brush or Rivctcd Connection
i’rc;. l5 ILI.I;STKATION FOR PLACING VOLTAGE PROWS

20
 IS 13466 : 1992

ANNEX E
( Cluuse 16.7.1 )

PROCEDURE FOR PULL-OUT STRENGTH TEST

E-l EQUIPMENT flexible. The support shall be capable of

holding the brush without slipping and it
E-1.i The pull-out strength test device as shown should have a recess through which flexi-
in Fig. 16 shall be assembled. This comprises the ble can be passed. For information on
following: such supports, see Fig. 17 and 18.
A pulling device such that the tensile
force to the flexible can be applisd at :I E-2 TlXST YKOCEDURE
uniform rate. The maximum rate of
increase should be 5 daN/s; E-2.1 Adju\l !he equipment as shown in Fig, 16
by placing a suitable support on the measuring
A dynamometer for measuring the pull- dcvicc, laking into account the shape of the
out strength with an accuracy of & 2.5 brush zncl the arlgle of the connection hole.
percent. The measuring needle should Make sure that the tension is along the axis of
carry a dummy needle which should stop the ilcxiblc. Also the hold on the brush should
at the maximum value; bz ho pl:~ccd that the brush will not break 01
Dash pot or any other d-vice to limit the crack or chip before the flexible is pulled out.
shock at the moment of failure. This
E-2.2 Fix the flexible in the gripping device, each
device should bc inoperative until the
flexible should be tested separately.
connection has failed;
A gripping devics capabic of connecting E-2.3 Apply the force at a uniform rate without
the flexible of the brush to bc tested to the shock so that the connection fails in no1 les\
tension device. This should be capable of than 5 seconds after the force is first applied.
grippine the flexible adequately without E-2.4 After the failure of connection, read the
damag&g its strength; and maximum force indicated by the idle pointer.
Adjustable support to ensure the lint of This force corresponds to the pull-out strength
tensile force to be along the axis of the of the connection.

r-n - BRUSH
AXIS OF THE TAMPED
CONNECTION
OR MOULOEO

SUPPORT

- FLEXIBLE

GRIPPING DEVICE FOR

THE F ckx\0~5
DAMPING DEVICE
LlMlTlNG DEVICE
__c DYNAMOMETER

+ PULLING DEVICE

TIC;. 16 SCHE~IATI~ DIAGRAM OF MEASWKINC DLVITE FOR THE PULL-OUT STRENGTH

( Continued from second cover )

Guidance for selection and use of carbon brushes for electrical machines have been covered by 1s 9919 :
1981.
In the preparation of this standard, assistance has been derived from the following IEC Publications:
1% Pub 136 ( 1986 ) Dimensions of brushes and brush holders for electrical machinery
IEC Pub 467 ( 1974 ) Test procedures for determination of physical properties of carbon brushes
for electrical machines
IEC Pub 773 ( 1983 ) Test methods and apparatus for the measurements of operational characteris-
tics of brushes
For the purpose of deciding whether a particular requirement of this standard is complied with, the final
value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in
accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )‘. The number of
significant places retained in the rounded off value should be the same as that of the specified value
in this standard.

Standard Mark
The use of the Standard Mark is governed by the provisions of the Bureau of Indian
Standards Act, IY86 and the Rules and Regulations made thereunder. The Standard Mark on
products covered by an Indian Standard conveys the assurance that they have been
produced to comply with the requirements of that standard under a well defined system of
inspection, testing and quality control which is devised and supervised by BIS and operated
by the producer. Standard marked products are also continuously checked by BIS for con-
formity to that standard as a further safeguard. Details of conditions under which a licence
for the use of the Standard Mark may be granted to manufacturers or producers may bc
obtained from the Bureau of Indian Standards;
 Bureau of Indian Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.

Copyright

BIS has the copyright of all its publications. No part of these publications may be reproduced in any
form without the prior permission in writing of BIS. This does not preclude the free use, in the course of
implementing the standard, of necessary details, such as symbols and sizes, type or grade designations.
Enquiries relating to copyright be addressed to the Director ( Publications ), BIS.
Revision of Indian Standards

Indian Standards are reviewed periodically and revised, when necessary and amendments, if any, are
issued from time to time. Users of Indian Standards should ascertain that they are in possession of the
latest amendments or edition. Comments on this Indian Standard may be sent to BIS givmg the
following reference:

Dot : No. ET 15 ( 3102)

Amendments Issued Since Publication

Amend No. Date of lssue Text Affected

BUREAU OF INDIAN STANDARDS

Headquarters:

Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002 Telegrams i Manaksanstha
Telephones I 331 01 31, 331 13 75 ( Common to all o&es )

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1
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