Motors and Generators

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Unit 222 – Maintaining Electrical wiring systems

Lecturer: Mr. Keemal Ali


Version 2021

Motors and Generators

Motors and generators are electromagnetic devices. They have current-carrying loops that
rotate in magnetic fields. Electric motors and generators are the opposite of each other.
Electric motors convert electrical energy into mechanical energy, while
electric generators convert mechanical energy into electrical energy.

Let us recall,

Alternating Current (AC) is a type of electrical current, in which the direction of the flow of


electrons switches back and forth at regular intervals or cycles. Direct current (DC) is
electrical current which flows consistently in one direction.
Unit 222 – Maintaining Electrical wiring systems
Lecturer: Mr. Keemal Ali
Version 2021

Theoretically, all motors and generators operates based on the principle of Michael’s Faradays
law of Induction, which is the cutting of a changing magnetic field by a conductor inducing
current into it. As we noticed in the graphs of AC vs DC, the only waveform that has a changing
magnetic field is an alternating current. Therefore all motors and generators will produce AC.

So then how do we get a DC motor or Generator? The solution to that question lies in the
construction of both the DC motor and generator. They have a special component, called a
commutator, whose primary function is to act like a rectifier changing that alternating current to
direct current.

The main difference then between any AC machine and DC machine shall be that AC systems
in-corporate the use of slip rings which allow for continuous flow of electricity and DC systems
use commutators to restart the motion at every half interval or 180 degree of rotation producing
DC.

Instruments used for testing purposes.

A voltmeter is an instrument used for measuring electrical potential difference between two
points in an electric circuit.

An ammeter is a measuring device used to measure the electric current in a circuit.


Unit 222 – Maintaining Electrical wiring systems
Lecturer: Mr. Keemal Ali
Version 2021

The wattmeter is an instrument for measuring the electric active power (or the average of the
rate of flow of electrical energy) in watts of any given circuit. Its construction is such that it has
two coils, a series coil for measurement of current and a voltage coil which is to be measured in
parallel.

The above diagram shows how these three instruments shall be connected across a load.

The basics of motor testing.

Testing electric motors doesn’t have to be a mystery. Knowledge of the basics together with
powerful new test equipment vastly simplifies the job.
Unit 222 – Maintaining Electrical wiring systems
Lecturer: Mr. Keemal Ali
Version 2021

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 overcurrent
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.

Electrical measurements
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.
Unit 222 – Maintaining Electrical wiring systems
Lecturer: Mr. Keemal Ali
Version 2021

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 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.

Small universal motors, such as those used in portable electric drills, can contain extensive
circuitry including a switch and brushes. In the ohmmeter mode, connect the meter to the plug
and monitor the resistance as you wiggle the cord where it enters the enclosure. Move the
switch from side to side and, with a trigger switch taped so it remains on, press on the brushes
and turn the commutator by hand. Any fluctuation in the digital readout may point to a defect.
Often a new set of brushes is what’s needed to restore operation.

Amperage or current readings are useful in motor testing as well. With a voltage reading, you
know the electrical energy available at the terminals, but you don’t know how much current
flows. Multimeters always have a current function, but there are two problems with it. One is that
the circuit under investigation must be cut open (and later restored) to put the instrument in
series with the load. The other difficulty is that the typical multimeter is not capable of handling
the amount of current present in even a small motor. All the current would have to flow through
the meter, burning the probe leads if not destroying the entire instrument.

An essential tool for motor current measurement is the clamp-on ammeter. It circumvents such
difficulties by measuring the magnetic field associated with the current, displaying the result in a
digital or analog readout calibrated in amperes.
Unit 222 – Maintaining Electrical wiring systems
Lecturer: Mr. Keemal Ali
Version 2021

Clamp-on ammeters are user friendly. Just open the spring-loaded jaws, insert either the hot or
neutral conductor, then release the jaws. The wire need not be centered in the opening and it’s
OK if it passes through at an angle. However, an entire cable containing hot and neutral
conductors cannot be measured this way. That’s because the current flowing through the two
wires travels in opposite directions so the two magnetic fields cancel out. Consequently, it’s not
possible to measure the current in a power cord, as is often desired. The use of a splitter fixes
the problem. This is a short extension cord of adequate rating with about six inches of jacket
removed so that one of the conductors can be separated and measured.

Digital and legacy analog clamp-on ammeters work well and are capable of measuring up to
200 A, which is adequate for most motor work.

The basic procedure is to measure the start-up and running current for any motor while it’s
connected to a load. Compare the reading to documented or nameplate specifications. As
motors age, the current drawn generally rises because winding insulation resistance drops.
Excess current causes heat, which must be dissipated. Insulation degradation accelerates until
there’s an avalanche event, causing motor burn out.
Unit 222 – Maintaining Electrical wiring systems
Lecturer: Mr. Keemal Ali
Version 2021

The clamp-on ammeter reading will tell you where you stand on this continuum. In an industrial
facility, as part of routine motor maintenance, periodic current readings can be taken and put
into a log posted nearby so damaging trends can be spotted in advance to avoid expensive
downtime.

Insulation testing
The insulation resistance tester (or megohmmeter), generally known by its trade name Megger,
can provide critical information regarding the condition of motor insulation. In an industrial
facility, the recommended procedure is to perform periodic tests and record the results so
damaging trends can be detected and corrected to prevent an outage and extensive downtime.

The insulation resistance tester resembles a conventional ohmmeter. But rather than the typical
three-volt test voltage derived from an internal battery and present at the probes, the Megger
provides a much higher voltage applied for a proscribed length of time. The leakage current
through insulation, expressed as resistance, is displayed so it can be graphed. This test may
take place on installed or on-the-reel cable, tools, appliances, transformers, power distribution
subsystems, capacitors, motors and any type of electrical equipment or wiring.

The test may be non-destructive, for in-service equipment, or prolonged at elevated voltage to
test prototypes to the point of destruction. A bit of a learning curve is involved in using the
Megger. The correct settings, connection procedures, test durations and safety precautions
must be implemented to avoid damaging the equipment or electrocuting the operator or
coworkers.

The motor under test must be powered down and disconnected from all equipment and wiring
that’s not to be included in the test. Besides invalidating the test, such extraneous equipment
could be damaged by the applied voltage. Additionally, unsuspecting individuals could be
exposed to hazardous high voltages.

All wiring and equipment has an inherent amount of capacitance, which is generally significant
in large motors. Because the equipment is in effect a storage capacitor, it’s essential that
lingering electrical energy be discharged before and after each test. To do this, shunt the
relevant conductor(s) to ground and to each other before reconnecting the power source. The
unit should be discharged at least four times as long as the test voltage was applied.

The Megger is capable of applying different voltages, and the level should be coordinated with
the type of equipment under test and the scope of the inquiry. The test generally applies
between 100 and 5,000 V or more. A protocol involving voltage level, time duration, intervals
between tests and connection methods must be composed, taking into account the type and
size of the equipment, its value and role in the production process and other factors.

The readings obtained when testing a 3 phase motor are as follows:

Test/phase brown black grey


Unit 222 – Maintaining Electrical wiring systems
Lecturer: Mr. Keemal Ali
Version 2021

Resistance 15Ω 15Ω 5Ω


Insulation resistance 20MΩ 20MΩ 0.3MΩ
test to earth

If we were to compare results it is clear that the faulty phase coil will the be grey. Three phase
motors spin at constant speed which means that each phase should have theoretically again,
the same resistances. A possible reason for the faulty grey phase, could be due to an over-
current, or short circuit resulting in overheating of the coil.

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