NEMA

DC MACHINES
( GROUP NO. 2)

Reported By:
# 5 ATTA, MOHAMED
# 6 BANHAON, CARLWAYNE
# 7 - BATTAD, RYAN MARLOU
# 8 BAUTISTA, KARL

DIMENSION OF DC MACHINE
A DC motor is any of a class of electrical machines that converts direct
current electrical power into mechanical power. The most common types rely
on the forces produced by magnetic fields. Nearly all types of DC motors
have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current flow in part of the motor. DC
motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems.
DC machine dimensions are important to enable replacing of old motor
by new ones. To have a compatibility.
Types of DC Machine
1. Permanent Magnet DC Motor
The permanent magnet dc motor consists of an armature winding as in
case of an usual motor, but does not necessarily contain the field windings.
The construction of these types of DC motor are such that, radially
magnetized permanent magnets are mounted on the inner periphery of the
stator core to produce the field flux. The rotor on the other hand has a
conventional dc armature with commutator segments and brushes.
2. Shunt Wood DC Motor
In case of a shunt wound dc motor or more specifically shunt wound
self excited motor, the field windings are exposed to the entire terminal
voltage as they are connected in parallel to the armature winding.
3. Series Wound DC Machine
In case of a series wound self excited dc motor or simply series wound dc
motor, the entire armature current flows through the field winding as its connected
in series to the armature winding.

4. Compund Wound DC Machine

The compound excitation characteristic in a dc motor can be obtained by
combining the operational characteristic of both the shunt and series excited dc
motor. The compound wound self excited dc motor or simply compound wound dc
motor essentially contains the field winding connected both in series and in parallel
to the armature winding.

TERMINAL MARKINGS AND CONNECTION

Terminal markings shall be placed on or directly adjacent to terminals to
which connections must be made from outside circuits or from auxiliary
devices which must be disconnected for shipment. Wherever specified, color
coding may be used instead of the usual letter and numeral marking. Its a
combination of capital letters or symbols and an arabic numeral shall be
used to indicate the character or function of the windings which are brought
to the terminal.* The following letters and symbols shall be used for motors
and generators and their auxiliary devices when they are included within or
mounted on the machine.

Resistance (shunt field adjusting)V1, V2, V3, etc.

Shunt braking resistorDR1, DR2, DR3, DR4, etc.
Space heatersH1, H2, H3, H4, etc
. Stator T1, T2, T3, T4, etc.

DC Motor
A DC motor is any of a class of electrical machines that converts
direct current electrical power into mechanical power.

Full loads of DC Machine

Starting of DC Motors
At the moment a DC motor is started the armature is stationary
and there is no counter EMF being generated. The only component to
limit starting current is the armature resistance, which, in most DC motors is
a very low value (approximately one ohm or less), as shown in Equation
Ia=

Vt Eemf
Ra

In order to reduce this very high starting current, an external

resistance must be placed in series with the armature during the starting
period. To show why this is essential, let us consider a 10-hp motor with
an armature resistance of 0.4 ohms. If the motor were supplied by a 260
VDC source, the resulting current would be as shown in Equation given:
Ia=(260-0)/0.4 =650 Amperes
This large current is approximately twelve times greater than
actual full-load current for this motor. The high current would, in all
probability, cause severe damage to the brushes, commutator, or
windings. Starting resistors are usually incorporated into the motor
design to limit starting current to 125 to 200 percent of full load current .

Interpoles
Interpoles are used for negating the effect of Armature
Reaction which causes shifting of the Neutral Plane. The field
generated by the interpoles produces the same effect as the compensating
winding. This field, in effect, cancels the armature reaction for all values of
load current by causing a shift in the neutral plane opposite to the shift
caused by armature reaction.

Motor Reaction in a Generator

When a generator delivers current to a load, the armature current
creates a magnetic force that opposes the rotation of the armature. This is
called MOTOR REACTION. When the conductor is stationary, no voltage is
generated and no current flows. Therefore, no force acts on the conductor.
When the conductor is moved and the circuit is completed through an
external load, current flows through the conductor. This sets up lines of flux
around the conductor in a direction opposite to its rotation; i.e; Motoring
reaction

Voltage Control
Voltage control is either manual or automatic. It is the process
that involves of the changing of the resistance of the field circuit. By
changing the field circuit resistance, the field current is controlled.
Controlling the field current permits control of the output voltage .
The major difference between the various voltage control systems is merely
the method by which the field circuit resistance and the current are
controlled.

Brush Holders
and
the Performance of Carbon Brushes

DC Motor Carbon Brush

A DC Motor carbon brush is an electrical contact which makes a
connection with a moving surface.
Carbon brush deliver or collect current from a rotating part of an
electric Machine. The brushes should maintain a close contact with
rotating part in order to ensure sparkles operation without wearing
itself too quickly.
DC Motor Carbon Brush Holder
The DC Motor brush holder holds the brush so that the brush can
perform properly. Holders provide stable support in the proper position
in relation to the contact surface and often provide the means for
application of the contact force on the brush.

Factors that affect Carbon Brush Perfromance

1. Maximum Stability
Carbon brush must be well
stable to fit with adequate
space left in the carbon brush
holder. The main reason for it is
to have a stable and sufficient
electrical flow between the
brush and the holder.
Guideline for brushholders:
industrial sizes typically
oversize to a tolerance of

Micro size units w/ brushes of

thickness <=.125
-should have holders held
to a tolerance of
+.001/+.003
Objects tend to expand when
subjected to high temperature.
In accordance to this, motor
and generator brushholders
subjected to high temperatures
are provided w/ extra
compensation for thermal
expansion.
In these cases it is easier to
reduce the brush thickness and
width dimensions

+.002/+.008.
Smaller frame w/ .125 <brush
thickness <.500
-should have holders with a
tolerance of
+.001/+.005.
slightly to avoid sticking in the holder rather than adjusting holder
dimensions.

 The length of the carbon brush is also a factor in stability.

The longer the carbon brush is, the higher the electrical flow of the
electricity to the armature thus, the carbon brush must be proportional
to the size of the armature.

2. Positioning of Brush Holder

Proper positioning of the holders in relation to the field poles in DC

machines are critical.
The brushes should be equally spaced around the commutator.
The brushes must also contact the commutator within the neutral zone
where voltage levels are near zero. When the holder position allows the
brush to make contact outside the neutral zone there will be higher bar
to bar voltages under the brush, circulating currents, bar edge burning,
and damage from arcing.
Holder angle the most common angle for the brush to be position is
(zero degrees) or perpendicular to the contact surface (commutator)
Slip rings and reversing commutator make use of the radial mount
method for its ease of holder installation, maximum spring force
transferred to the contact surface, and fair stability of brush contact
upon reversal of direction.
Angle holder mountings were developed to increase this stability and
the effective area of the brush contact, however, stability will occur
only when the correct angles are used in relation to the direction of
rotation.

A commutator is the moving part of a rotary electrical switch in certain

types of electric motors and electrical generators that periodically reverses
the current direction between the rotor and the external circuit.

Slip ring is an electromechanical device that allows the transmission of

power and electrical signals from a stationary to a rotating structure.

Holder Mounting Height

When a brushholder is mounted too high above the contact surface or

when the surface has been turned down to a significantly smaller
diameter, there will not be adequate support for the carbon as the
brush wears to a short length.


Problems For Misplace Height

When a commutator has been turned down several times, angled

brushes will make contact in a different position. With steep bottom
bevels and significant decreases in diameter the location of the brush
contact could even move outside the neutral zone. There will be a
significant increase in wear unless the holder is moved closer to the
commutator or the neutral is adjusted.

3. Electrical Conductivity

The primary function of the brush involves conducting current.

The connection must have a low resistance to provide optimal current
flow from the main lead to the contact surface.
Corrosion, contamination, or electrolytic action over a period of time
can cause dramatic increases in resistance which then require
cleaning.
Careless installation of the brushes or the holders can lead to loose connections.

 Troubleshooting
of
dc commutator

Commutator

is the moving part of a rotary electrical switch in certain types of

electric motors and electrical generators that periodically reverses the current
direction between the rotor and the external circuit.

Suitable Commutator

1. Light Film Commutator

Indicates good brush performance. Light load, low humidity,

brush grades with low filming rates, or film reducing
contamination can cause lighter color.

2. Medium Film Commutator

Is the ideal commutator condition for maximum brush and

commutator life.

3. Heavy Film Commutator

Results from high load, light humidity or heavy filming rate

grades. Colors not in the brown tones indicate contamination
resulting in high friction and high resistance.

Attention Need Commutator

1. Streaking

Cause- Metal transfer from the brush to the contact surface

- Contamination by chlorine, hydrochloric acid,

silicon
vapors, or other harsh chemicals can also
cause
streaking.

Solution Remedy the contributing factors (adjusting brush,

cleaning contaminants, etc.) to prevent streaking
progress.

2. Threading

Cause - a further development of the streaking condition as the

metal
transferred becomes work hardened and machines into
the commutator surface.

Solution - increased loads and increased spring pressure.

- machine the commutator in place to restore the

finish.

3. Grooving

Cause - result from an overly abrasive brush grade. The more

common cause is poor electrical contact resulting in
arcing and the electrical machining of the
commutator surface.

Solution - Increased spring pressure reduces this electrical

wear.

4. Copper Drag

Cause - Develops as the commutator surface becomes

overheated and softened. Vibration or an abrasive grade
causes the copper to be pulled across the slots.

Solution - Increased spring pressure will reduce commutator

temperature.

5. Bar Edge Burning

Cuase - Results from poor commutation.

Solution - Check 1.) that the brush grade has adequate voltage
drop,
2.) that the brushes are properly set on neutral, and
3.) that the interpole strength is correct.


6. Slot Bar Marking

Cause Results from a fault in the armature windings.

Solution - When the trailing edges of the darker bars appear
etched or burnt, you need to resurface the
commutator.

Frog leg winding

Frog Leg Winding

Frog leg winding is a combination of a multiplex wave and a simplex lap winding in the
same slots. It retains the advantages of both lap and wave windings without their inherit
disadvantages.

Advantage:

This winding has more no. of parallel paths and the current and the voltage rating is
higher than that of lap or wave winding. These frog leg wound armatures are designed for
the use with moderate current and moderate voltage.
Frog leg windings are most commmonly used in large DC machines
such as Generators.

DATASHEETS

A datasheet, data sheet, or spec sheet is a document that summarizes

the performance and other technical characteristics of a product,
machine, component (e.g., an electronic component), material, a
subsystem (e.g., a power supply) or software in sufficient detail to be used
by a design engineer to integrate the component into a system. Typically,
a datasheet is created by the component/subsystem/software
manufacturer and begins with an introductory page describing the rest of
the document, followed by listings of specific characteristics, with further
information on the connectivity of the devices.

DC MOTOR INSPECTION REPORT

Purpose:


This recommended practice is intended to be a basic or primary
document that can be utilized and referenced by owners of motors that
need repair as well as by owners and operators of establishments that
offer motor repair services.

Major Modification: Includes conversion from one type of machine

to another type of machine, conversion from one type of enclosure to
another type of enclosure, or conversion from one rating to another rating.

Motor: A rotating machine that converts electrical energy into

mechanical energy or mechanical energy into electrical energy. As used in
this recommended practice, the term can also be used to mean a generator.
For this specification the term motor can also refer to a generator.

Repair: Includes incoming inspection and test, damage appraisal,

cleaning, replacement and/or repair of damaged part(s), assembly, post
repair inspection and test, and refinishing.

Repair Facility: The entity contracted to make repairs; includes the

on site repair(s)made by employees of that entity in addition to repair(s)
made at a shop operated by or under the supervision of that entity.

User: The owner of the motor or an authorized agent of the owner

Electrical testing

High potential.
Traditionally, HI-POT is a term given to a class of electrical safety
testing instruments used to verify electrical insulation in finished
appliances, cables or other wired assemblies, printed circuit
boards, electric motors, and transformers.

Insulation test This test is to measure the total resistance of a products

insulation by applying a voltage of 500V 1000V. The minimum
acceptable value of resistance for a product to pass an insulation
resistance test is normally 1000 Mega Ohms. The insulation
resistance test is not a substitute for the high voltage test. Many

standards and safety agencies have specified this is a universal

test for all products. This test may also be carried out after every
maintenance procedure or repair.

The stator is the stationary part of a rotary system, found in electric

generators, electric motors, sirens, or biological rotors.

Dynamometer Test is a device for measuring force, torque, or power.

For example, the power produced by an engine, motor or other rotating
prime mover can be calculated by simultaneously measuring torque
and rotational speed (RPM).

split-ring resonator test (SRR) is an artificially produced structure

common to metamaterials. Their purpose is to produce the desired
magnetic susceptibility (magnetic response) in various types of
metamaterials up to 200 terahertz.

A servomotor test is a rotary actuator that allows for precise control

of angular position, velocity and acceleration.It consists of a suitable
motor coupled to a sensor for position feedback. It also requires a
relatively sophisticated controller, often a dedicated module designed
specifically for use with servomotors.

blocked rotor test is conducted on an induction motor. It is also

known as short circuit test, locked rotor test or stalled torque test.