MI31100017A

GEI85167A

COMMUTATOR MAINTENANCE

CONTENTS what to do, you can often correct the trouble before it be-
comes serious.
Page
The more you know about a commutator, the better
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
you can maintain it.
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COMMUTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FUNCTION
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 A commutator has three functions:
COMMUTATOR SURFACE CONDITIONS . . . . . . . 4
SURFACE FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1. It provides the required sliding electric contact
COLOR PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . 5 between the fixed brushes and the moving arma-
MARKING, ETCHING, AND FLAT SPOTS . . . . . 6 ture to remove or apply electrical energy to the
THREADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 machine.
COPPER DRAG . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BANDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2. It acts as a reversing switch. As the ends of the
ECCENTRICITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 armature coils pass the brush positions, the
SURFACE BREAKS . . . . . . . . . . . . . . . . . . . . . . . 10 commutator switches them from one circuit to
HIGH BARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 another where the current is flowing in the oppo-
HIGH MICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
site direction. Thus all the coils have current flow-
FLASHOVER DAMAGE . . . . . . . . . . . . . . . . . . . . 12
ing through them in the proper direction at all
OTHER FACTORS AFFECTING COMMUTATION 12
COMMUTATOR INSULATION . . . . . . . . . . . . . . . . . 13 times.
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3. It also brings to the brush surface the voltage of
RESURFACING THE COMMUTATOR . . . . . . . . . . 14
each armature coil in the circuit. These voltages
POLISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
add up bar by bar between brushes. As a result,
STONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 the total operating voltage of the machine ap-
UNDERCUTTING . . . . . . . . . . . . . . . . . . . . . . . . . 15 pears at the brushes.
SLOT RAKING AND BRUSHING . . . . . . . . . . . . 16
AIR CURING THE COMMUTATOR . . . . . . . . . . . . . 16 COMMUTATION
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . 17
Commutation is the successful reversal of current in
a coil being short circuited by a brush.
INTRODUCTION The current flow through the brushes and armature
The commutator is a vital part of every DC motor and windings of a DC machine normally takes several paths
generator; therefore, it deserves the very best of care. through the armature windings as it enters from the
The fact that a commutator usually shows signs of dis- commutator. After flowing through the windings, the
tress before trouble actually occurs, is big help to the paths again join and it leaves through the outgoing
maintainer. If you can recognize these signs and know brush.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or mainte-
nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to the General
Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has no
obligation to keep the material up to date after the original publication.

THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your
General Electric representative for assistance.
Do not order from this publication.
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE
FIG. 1. SKETCH OF ARMATURE SHOWING
DIRECTION OF CURRENT FLOW THROUGH
THE COILS. POLARITY OF A GENERATOR IS
SHOWN. E-8686.
As each coil passes under the brush (Fig. 1) the cur-
rent flows in one direction when on one side of the brush
and in the opposite direction when on the other side; so
the current must go to zero, then reverse in the split sec-
ond it takes for the coil to pass under the brush. Note
each brush is wide enough to bridge two adjacent com-
mutator bars and short circuit the armature coil for an in-
stant. This is commutation.
What happens if the current doesn’t reverse in time?
The coil will come out from under the brush with the cur-
rent still flowing in the initial direction. The meeting point
FIG. 2. RELATIVE POSITIONS OF MAIN POLES,
COMMUTATING POLES, AND SHORT-
CIRCUITED COILS IN WHICH CURRENT IS
BEING REVERSED. E-8687.
2
with the current in the other path (called the “neutral
point”) will no longer be under the brush. This moving of
the “neutral point” crowds the current to one edge of the
brush. Then it breaks out over the surface of the com-
mutator in a spark to reach this shifted point.
These machines operate over a wide range of load
current, and the greater the current, the harder it is to
achieve a complete reversal as the coil races under the
brush. Thus most large DC machines have interpoles
(or commutating poles) to speed up this current reversal
and keep the “neutral point” under the brush. These are
smaller poles located between the main poles in the
generator or motor frame (Fig. 2). The polarity is the
same as the next pole in the direction of rotation for a
generator and the same as the last preceding pole for a
motor. They do no work outside of helping with the com-
mutating job. The magnetism of these poles builds up a
voltage in the armature coils as they pass through the
zone covered by brush contact. This voltage speeds up
the current reversal to complete it before the coil leaves
the brush contact.
These poles are designed to do a good commutating
job up to, and even beyond, full load. When, however, a
very sudden overpowering current flows through the
windings, the magnetism in the iron cannot build up
quickly enough. It is like suddenly turning on a garden
hose - it takes a few seconds to fill before water comes
out the nozzle. This means there is not enough voltage
to reverse the current in time and sparking results. Be-
sides, you can force only so much magnetism through a
piece of iron. Then it becomes filled up or “saturated.” It
is like trying to force more water through the hose than it
can handle. Hence, there is a limit to the help the poles
can give in reversing the current in the coil. When the
current gets so heavy that this help is not enough, you
have more load than the machine can handle and spark-
ing results.
Equalizer Coils
Multiple or Lap Winding
Since the flux per pole is never exactly the same for
all poles, the voltage in the parallel circuits (the number
of such circuits depending on the number of poles) will
not all be equal. This will result in circulating currents,
since the circuits are in parallel. Even a small voltage
 MI-31100-017A
COMMUTATOR MAINTENANCE, GEI-85167A

FIG. 3. SCHEMATIC DIAGRAM OF MULTIPLE OR LAP ARMATURE WINDING IN A

6-POLE MACHINE. E-8688A.

change would cause large circulating currents, because often called “bars” so hereafter, in this publication, we
resistance is relatively low (Fig. 3). will use the term bar instead of segment.

If this circulating current were allowed to pass The mica plates physically separate and electrically
through the commutator into the brushes and complete insulate the bars and provide arch pressure essential to
its circuit through the brushholder connecting bus rings, commutator stability. The plates are undercut below the
it would upset commutation and result in sparking at the commutator surface to prevent interference with the
brushes. To avoid this, equalizer coils are used to con- sliding action of the brushes on the surface of the com-
nect commutator segments of the same potential (i.e., mutator.
segments at double the brush spacing intervals), Fig. 3.
The circulating current then passes through these
equalizer coils instead of through the commutator, into
the brushes. This circulating current produces a magne-
tomotive force in such a direction that it tends to bring
the fluxes of several poles into equality. Hence, the net
circulating current is reduced to a relatively small value.

Series or Wave Winding

In this type of winding there are two parallel paths

through the armature, each path consisting of one-half
of all of the armature conductors in series with each oth-
er. The voltage generated in either half of this parallel
circuit adds up to the terminal voltage of the machine.

With this type of winding, no equalizer coils are re-

quired.

CONSTRUCTION

A commutator is formed of alternate copper seg- FIG. 4. CUTAWAY SECTION OF THE

ments and mica plates (Fig. 4). Copper segments are COMMUTATOR. E-5018.

3
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE
FIG. 5. ARCH–BOUND COMMUTATOR
ASSEMBLY. E–3059B.
The bars are wedge shaped and form a cylinder
when assembled. Each bar has a riser at one end to
make armature coil connections.
The bars are held in position by the clamping action
of a steel cap bolted to a steel shell (Fig. 5).
Mica cones, contoured to fit between the shell and
cap, insulate the bars from ground (armature).
A Teflon* creepage band, applied on the exposed
cone insulation, protects the mica from damage and
presents a smooth creepage-surface that is easy to
keep clean.
Arch-Bound Commutator
An arch-bound commutator exerts pressure on the
30-degree surface of the copper segments only, Fig. 5.
This pressure is supported by the arch-pressure of the
segments pressing against each other around the com-
plete periphery, as the name “arch-bound” implies. An
actual clearance (usually 1/16 in.) exists between the 3
or 6 degree surface of the copper segments and the
*Product of E.I. DuPont de Nemours & Co., Inc.
4
mica cone covering the outer slope of the commutator
cap. The clearance opening is sealed to prevent the en-
trance of carbon dust which could short circuit or ground
the bars.
The arch-bound type of construction produces a
commutator which is less subject to roughening of the
brush surface from heat shock. Also, it is less sensitive
to machining tolerances and mica shrinkage-variations,
since it does not require the critical balance of pressure
between the 3 and 30 degree surface as does a “Vee-
bound” commutator.
PROCESSING
Long term engineering and manufacturing experi-
ence is applied to achieve maximum commutator stabil-
ity. This results in:
1. A commutator surface that will not roughen at
high speed.
2. A commutator surface that will not roughen when
heated (i.e., during high current standing starts)
or, if smooth while hot, will not roughen when
cooled.
3. A commutator surface that will not roughen due
to movement of the bars after having been in ser-
vice for a period of time.
To produce a stable commutator, a series of high-
temperature bakings and capscrew tightenings are per-
formed on the fixture-held cylinder of bars and mica
plates before they are machined and also after the com-
mutator has been completely assembled. The baking
temperatures exceed any the commutator would nor-
mally encounter in service.
A large number of transportation commutators are
“seasoned” in spin stands, after they have been as-
sembled on armatures and the armature coils applied.
In the spin stands, the commutators are subjected to re-
peated cycles of heating and cooling while running at
speeds approximately 20 percent above maximum op-
erating speed. A common cycle is to heat the commuta-
tor to 160 C in one hour, hold this temperature for 1/2
hour, and cool to room temperature in 1/2 hour - all at
high speed. This cycle is repeated a number of times to
obtain the desired results.

COMMUTATOR
SURFACE CONDITIONS
A commutator cannot work properly unless the
brushes make good electrical contact. This requires a
smooth, polished, cylindrical surface that runs true with
its center. When you realize the maximum speed at
which this surface must slide under the brushes, you
can see why it must be as smooth and true as possible.
Remember a commutator is not a solid piece. It is
made up of many copper bars and mica plates clamped
between steel parts. These materials react differently to
temperature changes (expanding and contracting at dif-
ferent rates). This establishes forces which tend to shift
the parts. Also, the parts tend to shift during operation
because of centrifugal action. In spite of all that is done
in an attempt to maintain a perfect commutator surface,
small variations are usually present. Brushes, forced
against the commutator surface by spring pressure, will
follow these variations if they are not too sudden.
It is the maintainer’s job to spot a commutator sur-
face heading for trouble and correct it before failure oc-
curs. A knowledge of various surface conditions and
how they affect commutation and current collection will
be helpful.
SURFACE FILM
The successful operation of all DC machines de-
pends on maintaining a proper film on the surface of the
commutator. This film of carbon, graphite, copper oxide
and water vapor is deposited on the commutator sur-
face by electrochemical action. It is formed by the wiping
action of the brush against the commutator and by the
normal current flow between the brush and the commu-
tator.
The fact that a commutator surface is never abso-
lutely smooth, although it may feel so to the touch and
look so to the eye, enables the film to stick. Normally, on
a new or reconditioned commutator, the brush begins to
establish its characteristic film as soon as current flows.
It may take several hours or several days to establish a
good film - after which the main job is to maintain this
film.
Temperature, atmosphere and grade of brush used
all affect this film. If the film is damaged electrically or
MI-31100-017A
COMMUTATOR MAINTENANCE, GEI-85167A
mechanically, both brush and commutator wear is ac-
celerated.
A sliding contact such as a carbon brush is very sen-
sitive to even the slightest variation in the atmosphere.
Acid or base contaminations, dust, and oils react with
the brush and commutator surface to cause disturbing
conditions. Even normal changes in humidity cause no-
ticeable changes in contact voltage drop and friction of a
brush. These variations may result in the formation of ir-
regular patterns on the commutator surface.
Chemical contamination probably causes the great-
est disturbance, since formation of materials other than
copper oxide is usually harmful. Abrasive dust wears
away the film, while other types of suspended particles
react with the vaporized copper to form nonconductive
films. Many organic materials are just as harmful as
chemical contaminants.
Oil vapors have a decided effect on film condition.
Not only does the oil introduce an insulating surface, it
also prevents bonding of film on the commutator and
causes a torn or mottled film surface. It will also promote
rapid metal transfer and, eventually, threading.
Some types of brushes establish a heavier film than
others depending on the brush grade. Some grades re-
quire greater current densities (amperes per square
inch average current) to establish and maintain a satis-
factory film than do other grades.
The machine manufacturer selects and recom-
mends a brush grade suited to the application of the ma-
chine. Use the recommended brush grade. Do not mix
or change the brush grade as it could seriously affect
commutation, surface film and brush life.
The importance of maintaining a proper commutator
surface film cannot be overemphasized. With this film
established and properly maintained, good brush per-
formance (reduced brush and commutator wear) and
satisfactory commutation (no destructive sparking) is
assured. Changes in color from copper to deep brown or
chocolate should give no cause for worry, as long as the
surface is smooth and has a polished glossy appear-
ance (Fig. 6).
COLOR PATTERN
This term indicates only that the color of the commu-
tator bars is not uniform and a definite pattern exists.
5
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE

FIG. 8. ONE DARK-TWO LIGHT, 3 COIL PER

SLOT COLOR PATTERN. E-8763.

nite pattern around the whole commutator, do not be

FIG. 6. GOOD COMMUTATOR FILM OF
UNIFORM COLOR. E-8761A. concerned.

The pattern is almost always related to the arrangement
of coils in the armature slots. In itself, this condition is not
a sign of damage. The color pattern may show up in sev-
eral sequences (Figs. 7 and 8). As long as there is a defi-
A check for surface damage should be made at
scheduled commutator inspection periods. If no dam-
age exists, no further action is required.
MARKING, ETCHING, AND
FLAT SPOTS
The following conditions indicate discoloration and/
or etching of commutator bars - but in varying degrees.
Possible causes of etching and discoloration include:

1. Excessive load on the machine.

2. Electrical adjustment off; such as, wrong shims

behind commutating poles or wrong interpole
gap.

3. Wrong brush grade.

4. Uneven or rough commutator surface.

5. Contaminated atmosphere.

6. Incorrect brush spacing.

7. Incorrect brush shift.

The best way to overcome these conditions is to de-

FIG. 7. ONE LIGHT-TWO DARK, 3 COIL PER termine the cause and make the necessary corrections.
SLOT COLOR PATTERN. E-8762A. If damage has not progressed too far, it may clear itself
once the cause has been eliminated. If it is determined

6
 MI-31100-017A
COMMUTATOR MAINTENANCE, GEI-85167A

FIG. 9. COMMUTATOR FILM REMOVED WITH A

PENCIL ERASER TO SHOW A SMOOTH
COPPER SURFACE UNDERNEATH. E-8764. FIG. 11. IRREGULAR FILM AND ETCHING
CAUSED BY A ROUGH COMMUTATOR. E-8766.

that some resurfacing of the commutator is necessary, it
should be done sparingly.
Marking
This condition appears as an opaque darkened sur-
face or black deposit on the bars, usually at their trailing
edge, with no etching or corrosion of copper under-
neath.
The term “burned bars” is sometimes used to indi-
cate bar surface etching. This merely represents an ad-
vanced stage of etching.
Bar Corner Etching
When this condition prevails, the corner of the bar is
eroded, leaving a chamfered corner but little or no evi-
dence of marking or bar surface etching.

Check for this condition quickly by using a common

pencil eraser to remove the deposit; then examine the
copper surface for roughness or pitting. If none is seen,
the condition is marking, which can readily be removed
with a canvas cloth (Fig. 9).

Bar Surface Etching

This condition gives the appearance of severe mark-
ing, and a pencil eraser uncovers pitting, eroded, or
burned bar surfaces. Such a condition results from arc-
ing between the brush and the copper commutator bars FIG. 10. HEAVY ETCHING ON A 2-COIL PER
and the etching is usually visible with the naked eye SLOT COMMUTATOR. E-8765A.
when the marking is removed (Figs. 10 and 11).

7
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE

Bar corner etching may best be seen by holding a

light source at an angle which will reflect light from a
chamfered corner to the eye.

Flat Spots
If etching is not corrected and progresses too far, flat
spots will develop. Flat spots may also develop from a
mechanical disturbance, such as the vibration from a
defective bearing. As a rule, however, flat spots result
from failure to correct some faulty condition which is first
indicated by burned bars (Fig. 12).

THREADING
Threading is a commutator-surface condition that
shows as circumferential grooves on the commutator.
Threading is the result of abrasive or electro-chemical
action of the brushes.
In light threading, grooves may just barely be appar-
ent where the surface film or color is disturbed or differ-
ent. In heavy threading, a rippled surface can be felt if
you rub a fingernail along the surface of a bar (Figs. 13
and 14).
FIG. 13. HEAVY THREADING OF COMMUTATOR.
E-8768A.
The brush faces wear to fit these grooves. When the
commutator shifts due to armature end-play, the
brushes are lifted out of the grooves. Then contact be-
tween the brush and the commutator is disturbed,
sparking occurs, and commutation is disrupted.
Possible causes of threading include:

1. Low current-density in the brush (machine is not

heavily loaded).

2. Abrasive dirt or other foreign material imbedded

in the face of the brush.

3. Mica flakes or copper imbedded in the brush

face.

4. Wrong brush grade.

Determine the cause of the threading and resurface

by grinding (with a rigidly mounted grinding fixture as
listed in the Tool Catalog) or by turning on a lathe.

COPPER DRAG
Under certain conditions copper is dragged over the
trailing edges of the commutator bars and has the ap-
pearance of small metal flakes or feathers. Copper drag
is caused by particles of copper, copper oxide and con-
taminates that do not bond firmly to the surface of the
commutator. As the commutator rotates, the brushes
shove small flakes of this material toward or into the
FIG. 12. FLAT SPOT ON A COMMUTATOR THAT
commutator slots. This decreases the distance be-
ALSO SHOWS FLASHOVER DAMAGE. E-8767.
tween the bars. An arc formed at any brush can then be

8
 MI-31100-017A
COMMUTATOR MAINTENANCE, GEI-85167A

FIG. 15. COPPER DRAG ON TRAILING EDGE OF

COMMUTATOR BARS. E-8769A.

FIG. 14. ILLUSTRATION OF THREADING OF

COMMUTATOR SURFACE. E-5023. or they may extend over a sizeable percentage of the
brush path. See Fig. 17 for example of banding.
more easily carried over to an adjacent brush resulting Possible causes of banding include:
in a flashover.
1. Brush film too heavy (film tears from surface).
Copper drag should not be confused with bar-corner
2. One brush is the wrong grade.
etching (Figs. 15 and 16).
3. Hard spot in a brush.
Possible causes of copper drag include:
Banding can be corrected by hand stoning after the
1. Contaminated atmosphere. cause has been eliminated.
2. Copper imbedded in brush face. ECCENTRICITY
3. Hard spot in brush. Even though a commutator surface is smooth, it can
be running off center. This is a common fault and is usu-
4. Wrong brush grade.
ally the easiest of all surface variations for the brushes
5. Excessive vibration.

6. Low current density.

A temporary solution to copper drag is to clean the

commutator occasionally with a light brush-seater
stone. If drag has progressed too far, the slots must be
raked and cleaned.

BANDING
Banding is a surface defect in the form of bands
around the commutator in which the surface film has
been partially or completely removed. These bands FIG. 16. ILLUSTRATION OF COPPER DRAG.
may be quite narrow (not to be confused with threading) E-8770.

9
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE
FIG. 17. EXAMPLE OF BANDING. E-8771.
to follow. They simply rise and fall in the holders with
each revolution. However, as speed goes up, this ec-
centric motion becomes faster. Finally, the brushes be-
gin to break contact and gradually burn the commutator
surface. As this continues, the burning causes still fur-
ther surface destruction (Fig. 18).
Possible causes of eccentricity include:
FIG. 18. EXAMPLE OF ECCENTRIC
COMMUTATOR. (EXAGGERATED FOR
PURPOSES OF ILLUSTRATION). E-8773A.
10
1. Bent shaft.
2. Bearings not running true.
3. Commutator machined on bad shaft centers.
4. Distortion caused by wide temperature changes
and high speed.
5. An offset coupling in single bearing traction gen-
rators.
Determine the cause of eccentricity and resurface
the commutator using a rigidly mounted grinding fixture.
Eccentricity cannot be corrected by hand stoning.
If the armature is out of the frame, turn the commuta-
tor in a lathe (on its own bearings if possible). If the com-
mutator is machined on its shaft centers, the commu-
tator-end bearing-fit should run within 0.001 in. TIR to
the shaft centers. Prior to machining, scrape the shaft
centers, if necessary, to meet this tolerance require-
ment.
SURFACE BREAKS
Sometimes a sharp step occurs on a commutator
surface. This may be caused by a bump or blow to the
commutator. Though the change in surface level may be
very small, not even a heavy spring load will keep the
brush in contact with the depressed bars. The brush
may “ski-jump” from the higher level or, if rotation is re-
versed, the step strikes the brushes and “kicks” them
away from the surface. This causes sparking, followed
by electrical erosion and flat spots on the surface of the
commutator. At high speed, this “kick” may be hard
enough to shatter the brushes (Fig. 19).
Possible causes of surface breaks include:
Bumping of commutator surface during handling or
striking commutator with a heavy tool, etc.
Resurface the commutator with a rigidly mounted
grinding fixture to remove the surface breaks.
HIGH BARS
If a motor armature does not rotate while power is
applied, the commutator bars under the brushes will
overheat and expand. Expansion will cause these bars
to rise above the adjacent bars. When the armature ro-
tates, the high bars “kick” the brushes which, in turn, arc
 MI-31100-017A
COMMUTATOR MAINTENANCE, GEI-85167A

FIG. 19. EFFECTS OF DEPRESSED BARS AND

REVERSAL OF ROTATION. E-8774.

FIG. 20. EXAMPLE OF A SOFT COMMUTATOR

and burn the commutator surface. If this condition is not BAR WHICH HAS LIFTED AT HIGH SPEED.
corrected, the brushes may shatter and a flashover E-5022.
could occur (Figs. 20 and 21).

In severe cases, bar temperature may rise high

enough to anneal the copper and destroy the binder in
the mica plates. When this happens, flakes of mica will
shift from the pressure areas and reduce the clamping
action on the bars. Annealed bars wear differently than
normal bars and, being loose, they will lift at high arma-
ture speed.

Annealed bars can be detected with a scleroscope or

some equivalent means. Sometimes they can be
spotted by discoloration of the bar-ends outside the
brush track.

HIGH MICA
High mica refers to the height relationship between
the surface of the mica plate and the surface of the com-
mutator bars (see Fig. 22-A for correct relationship).
In normal use, the surface of the commutator is grad-
ually worn down. As the copper is worn away, the depth
of the undercut (slots) is reduced until the edges of the
mica plates are even with (or slightly higher than) the
surface of the commutator (Fig. 22-B). At this point, the
mica is called “high mica.”
FIG. 21. EFFECT OF HIGH BARS ON BRUSHES.
E-5021A.
High mica can be the result of either normal electro-
mechanical wear, or failure to undercut the mica after
resurfacing operations.
Feather edge mica results from the incorrect under-
cutting of high mica (Fig. 22-C) which leaves feather
edges of mica level with the commutator surface.

11
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE

Either form of high mica disrupts the process of com-

mutation. This, in turn, increases wear on the commuta-
tor bars and the brushes . . . to expose more mica . . . to
further disrupt commutation.

FLASHOVER DAMAGE
The commutator defects previously mentioned are
similar to a crack in the highway pavement. At first the
break is hardly noticeable, but if not attended to, be-
comes progressively worse until the road must be
closed.

Likewise, a commutator does not fail suddenly. Like

the pavement, it gives indications of future trouble in
time for most trouble to be prevented. To the trained ob-
server, the commutator surface-defects previously
mentioned are “cracks in the pavement” that must not
be allowed to cause the machine to fail.

Any condition or defect which causes arcing on the

surface of the commutator must be regarded as a poten-
tial cause for a flashover. When arcing becomes severe
enough, the surrounding air changes into a conductive
gas and allows power to spill-over between the brushes
in a flashover. A flashover is the commutator’s final pro-
FIG. 23. EQUIPMENT BADLY DAMAGED BY
FLASHOVER. E-18333.
test against neglect and abuse. Evidence that a ma-
chine has flashed over will be found in the form of copper
splatter on the surface and ends of the commutator
bars, on the brushholders and nearby insulation and on
the frame as shown on Fig. 23.

If a flashover occurs, clean the commutator, the Te-

flon creepage band, and the brushholders. Examine
these parts for damage and check the condition of the
brush faces. Repair or replace damaged parts as neces-
MICA PROPERLY UNDERCUT sary.

OTHER FACTORS
AFFECTING COMMUTATION
We have already seen that the second function of a
commutator is to act as a reversing switch. Just as me-
HIGH MICA – COPPER WORN DOWN
chanical defects on the commutator surface interfere
with proper brush contact, so electrical defects in the
machine will interfere with proper switching action.
Some of the more common electrical defects are:

1. Brushes not located on neutral point.

FEATHER EDGE MICA – INCORRECTLY CUT

2. Defects in either the armature or the field wind-

FIG. 22. HIGH OR FEATHER-EDGE MICA.
E-8776. ings. The defects may be short-circuited turns,

12
 MI-31100-017A
COMMUTATOR MAINTENANCE, GEI-85167A

grounds, open circuits, or high resistance con-

nections.

3. Reversed main or commutating-field coils.

4. Use of improper shims under pole pieces.

5. Wrong use of magnetic and nonmagnetic pole

piece bolts.

6. Nonmagnetic instead of magnetic bands, or vice

versa.

All these defects will cause sparking at the brushes

and may result in overheating. You are most likely to find
them after a hasty emergency repair job on the equip-
ment.

Anything that breaks the connection between a com-

mutator riser and its armature coil will affect commuta-
tion.

For Soldered Coil Leads FIG. 24. AN EXAMPLE OF MOLTEN SOLDER

A break will occur when the commutator becomes
hot enough to melt the solder and allow the ends of the
coils to lift out of the riser slot. Such heating may be
caused by overloads or lack of cooling air. Hence, solder
throwing warns the maintainer to check blowers, belts,
air ducts and covers, to be sure the machine is getting
enough cooling air. Look for solder spatter on the field-
coil connections, the frame, etc.
A coil connection not properly soldered, or one that
has thrown solder, may oxidize rather than lift out of the
risers. When this happens, local heating will cause a
blackened or burned area on the riser at the poor con-
nection. Look for discolored risers when making inspec-
tions.
Molten solder can short-circuit the armature coils by
collecting under the insulation. Molten solder can also
allow a coil to open up to produce burning at the edges of
adjacent commutator bars (see Fig. 24).
NOTE: For Tungsten-Inert-Gas (TIG) Welded
Coil Leads: most large armatures have coils
which are TIG welded to the commutator risers,
instead of soldered. TIG welded coil connec-
tions contain no solder; therefore, signs of
overheating for TIG welded coils are limited to
ALLOWING THE LEADS TO LIFT. THE
ARMATURE COILS HAVE ALSO BEEN
SHORT-CIRCUITED BY SOLDER COLLECTING
UNDER THE INSULATION. E-5025.
burned coil-insulation, heat discoloration of
the copper or melting of the coil leads.
An open circuit in an armature winding can also oc-
cur from a conductor being broken due to poor handling
or vibration. Then, current cannot get through the wind-
ing and an arc is drawn as the segments, to which the
broken coil is connected, move away from each brush.
This burns the copper away on adjacent edges of con-
secutive bars and makes a deep trench as shown in Fig.
25. At high speed and voltage a flashover may occur.
COMMUTATOR INSULATION
The purpose of electrical insulation is to prevent
leakage of electric current. If leakage does occur, suffi-
cient heat may result to carbonize the surface of the in-
sulation and destroy its insulating value.
The commutator is insulated from ground by the
cone and shell insulation (Fig. 4) which must withstand
the full operating voltage of the machine. The cone insu-
lation presents relatively long creepage surfaces at
each end of the commutator. On most transportation
machines, a Teflon creepage band is used to protect the

13
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE
FIG. 25. OVERHEATING CAUSED SOLDER TO
MELT OUT OF THIS ARMATURE. THE OPEN
CIRCUIT IN ONE COIL CAUSED DEEP BURNING
OF ADJACENT COMMUTATOR BARS. E-7843.
exposed creepage surface of the mica cone on the end
of the commutator opposite the risers. Both Teflon and
string creepage bands should be wiped clean periodi-
cally to retain their full insulating value.
Each pair of commutator bars has the voltage of one
armature coil between them. If the mica plate, which in-
sulates the bars, is bridged by conducting material, the
bars will be short circuited. Current flowing across this
conductive bridge will heat the material and cause it to
carbonize and glow. At high armature speed this hot
spot may trigger a flashover.
INSPECTION
Visual inspection of a commutator will detect the ma-
jority of defects previously mentioned. To learn more,
you must feel, listen, or measure. If a traction motor is
out of the truck, if the wheels are jacked clear of the rails,
or if a drop-pit table is lowered, you can run the motor
and feel or hear a rough commutator. A generator and
its auxiliaries may be checked for a rough commutator
while the engine is idling.
A distinct click can be heard as each brush goes over
a step in the commutator surface; or the brushes will
chatter as rough spots disturb them. Hold a fiber or
wooden stick, about the size of a long pencil, lightly on
the brush or on the spring right over it. This will give you
the feel of the brush as it rides the commutator. The bad
spots can be felt clearly as they go by. Check traction
14
motor commutators in both directions of rotation to see if
there is a difference in the degree of roughness.
The most accurate way to check a commutator sur-
face is with a dial indicator (capable of reading 1/10 of
one mil). Attach it to the frame with a flat-tipped pointer
resting against the commutator. Slowly rotate the arma-
ture by hand and measure commutator runout on all
brush paths. On most machines (on newly resurfaced
commutators) maximum allowable runout in any brush
path is 0.001 in. TIR with a rate of change of 0.0004 in.
within any group of 20 bars and 0.001 between adjacent
bars. Refer to the device instruction book for commuta-
tor-runout data for a specific machine.
RESURFACING THE
COMMUTATOR
Commutator troubles may often be corrected by
resurfacing. This is the name given to any process
which restores a true, cylindrical, polished surface to the
commutator.
NOTE: Reference to procedures such as “Air
Curing,” “Testing” and “Resurfacing” should
not be attempted without also reading the ap-
propriate instructions for such procedures, in
the instruction book for the machine being
maintained.
POLISHING
If the commutator surface is merely smudged, you
can clean it by polishing with canvas. When this is not
sufficient, or if the commutator is slightly rough, crocus
cloth, fine (4/0) sandpaper, or 400A Triemite* paper
may be used. This should be mounted on a wooden
block curved to fit the surface of the commutator as
shown in Fig. 26.
CAUTION: Never use emery cloth on a com-
mutator. The abrasive particles not only
scratch the surface, but they are conductive
and lodge between commutator segments.
This leads to short circuits.
*Reg. trademark of Minnesota Mining & Mfg. Co.
 MI-31100-017A
COMMUTATOR MAINTENANCE, GEI-85167A

a grinding fixture mounted on the machine. A grinding

fixture has a movable carriage for traversing the stone
across the commutator surface and a feed to regulate
the cut of the stone. A vacuum attachment is also avail-
able to pick up copper chips and abrasive dust. See the
Tool Catalog for grinding fixtures and graded cutting
stones applicable to various machines.
FIG. 26. FINE GRAIN SANDPAPER ON A Stoning with a grinding fixture is faster and requires
SHAPED WOODEN BLOCK. E-8778.
less skill than hand stoning. Also the fixture, because it
is rigidly mounted, will true-up a commutator that is out-
of-round (Figs. 28 and 29).

TURNING
If a commutator is badly worn or burned, the resur-
facing operation should be performed in a lathe. Set the
cutting speed of the lathe for 300 surface feet per minute
and use a carbide tipped cutting tool. The armature
should be supported on its own bearings if possible. If
not, mount the armature between centers but be sure
the centers are true with respect to the bearing seats or
the commutator will be out-of-round. Remove only
enough copper from the commutator to give a uniform

FIG. 27. PROPER USE OF HAND STONING.

E-8779A.

STONING

If the commutator surface is mildly grooved, etched,

or burned, and only a small amount of copper has to be
removed to correct the defect, a hand stone is most suit-
able. The stone should have a surface curved to fit the
commutator. Also, it should be long enough to bridge the
defect to be removed; otherwise, the stone will ride in
and out of the defect and do nothing to correct it. The
length of the stone will usually be limited by the space
between brushholders. If there is not enough space, a
brushholder should be removed to make room for a larg-
er stone (Fig. 27).

Hand stoning will not correct an out-of-round com-

mutator. It is a fairly difficult operation and should be per-
formed only by knowledgeable, skilled personnel.

When a greater amount of copper is to be removed, FIG. 28. COMMUTATOR GRINDING FIXTURE IN
or the defect is too large to be bridged by the stone, use POSITION ON MOTOR. E-498.

15
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE
FIG. 29. COMMUTATOR GRINDER INSTALLED IN
GENERATOR. E-485B.
surface. Then, use a coarse stone followed by a finish
polish.
UNDERCUTTING
After a commutator has been resurfaced, check the
depth of the undercut of the mica between bars. If un-
dercutting is necessary, it should be done carefully with
a proper tool of correct size. The tool must have a sharp
edge to cut the mica freely. A dull blade or saw produces
small cracks in the mica into which dirt or moisture may
find its way and break down the insulation between com-
mutator bars.
Some common mistakes are shown in Fig. 30. Avoid
these mistakes, refer to the device instruction book for
the slot width and depth dimensions.
16
ÉÉ ÉÉÉ É ÉÉ
ÉÉÉÉ ÉÉÉ É ÉÉ
ÉÉÉÉ ÉÉÉ É ÉÉ
É É
ÉÉÉÉ ÉÉ
A. MICA PROPERLY UNDERCUT.
B. UNDERCUTTING TOOL TOO NARROW, LEAVING FIN
AT ONE SIDE OF SLOT.
C. UNDERCUTTING TOOL VERY NARROW, LEAVING
FINS AT BOTH SIDES OF SLOT.
D. SLOT IMPROPERLY INDEXED, PART OF BAR CUT
AWAY AND FIN OF MICA LEFT.
E. TOOL TOO WIDE, PART OF BAR CUT AWAY.
F. UNDERCUTTING TOO SHALLOW, SERVICE LIFE
SHORTENS BEFORE NEXT UNDERCUTTING.
G.UNDERCUTTING TOO DEEP, POCKET COLLECTS
CARBON AND COPPER DUST, SHORT CIRCUITING
BARS.
FIG. 30. COMMON MISTAKES IN
UNDERCUTTING THE MICA BETWEEN
COMMUTATOR SEGMENTS. E-5024A.
A section of a hacksaw blade secured in a home-
made holder cuts a satisfactory slot for small commuta-
tors provided a sharp blade is used and kept parallel to
the sides of the slots. Do not let the blade lean or wobble.
Saw lightly until the mica is down to the required depth
(given under MAINTENANCE DATA in individual in-
structions).
For an occasional undercutting job you may want to
use a hand slotter and scraper with a tool-steel bit. Draw
this tool lightly through the commutator slots. The same
tool also cleans slots, smooths burrs, and removes mica
fins if you have undercut the commutator with a pow-
ered undercutter.
We do not recommend the use of hand-held motor-
powered undercutting tools. Select a motor powered
tool that can be rigidly mounted on a lathe. One slip of a
hand held tool can damage bars or risers or the Teflon
creepage band and ruin a serviceable commutator - or
cause an injury. If you are in the market for a powered
undercutting tool, we suggest you select a tool that has
a slot guide and a depth gage. Follow the instructions of
the tool manufacturer and make a few practice under-

(A) SLOT RAKING TOOL
(B) CLEANING OUT SLOTS IN INNER
BRUSH PATH.
FIG. 31. CLEANING COMMUTATOR SLOTS. E-25145.
cuts on a scrap commutator to get the “feel” of the tool.
In general the width of the cutter should be about 2 times
the width of the dust groove.
SLOT RAKING AND
BRUSHING
Resurfacing operations usually leave copper par-
ticles and slivers on the edges of the commutator bars
and in the slots. These must be removed before the ma-
chine is placed in service as they could cause a
flashover. Use a brush with stiff nylon bristles, a piece of
fiberboard or a special tool ground to fit the slot (Fig. 31
B,C) and clean the slots thoroughly. Use a slot raking
tool (Fig. 31A) and break the sharp edges of the bars.
MI-31100-017A
COMMUTATOR MAINTENANCE, GEI-85167A
(C) CLEANING OUT SLOTS ON OUTER
BRUSH PATH.
If resurfacing has produced considerable copper-
drag on the bar edges, a “V”-shaped slot-raking tool
should be used to remove fins and ragged edges from
the bars. Insert the point of the tool in the slot so the
sides of the tool will scrape the edge of the bar on each
side of the slot as the tool is dragged along the slot.
After the slots have been cleaned it may be neces-
sary to use very fine sandpaper or crocus cloth to re-
move small burrs and slivers from the edges of the bars.
Don’t use emery cloth.
AIR CURING THE COMMUTATOR
Air curing is a procedure which uses compressed air
centrifugal force and the machine voltage to remove the
copper particles remaining in the commutator slots after
17
MI-31100-017A
GEI-85167A, COMMUTATOR MAINTENANCE
the slots have been hand cleaned. In the process, arma-
ture speed is varied from low to maximum rpm; there-
fore, before a motor commutator can be air cured, ar-
rangements must be made to separately excite the field
to prevent the motor from overspeeding at no load and
full voltage.
To air cure a generator mounted on a vehicle, the
power contactors are blocked open and the armature
speed is controlled by regulating the speed of the ve-
hicle engine.
In the air curing procedure, the armature is rotated at
low speed and a strong jet of compressed air is swept
across the surface of the commutator. The air stream
and voltage dislodge and remove any copper particles
remaining in the slots. Small sparks seen during the cur-
ing process indicate the removal of copper particles.
When sparking stops, armature speed is increased. The
2901 East Lake Road
Erie, Pennsylvania 16531
NEW 10–83, WLF
18
curing procedure is continued until no sparking is evi-
dent at full armature speed.
SAFETY PRECAUTIONS
When working on commutators, always wear
goggles and gloves for protection against flying particles
or the possibility of a flashover when air curing. A respi-
rator should be worn during stoning and jig grinding op-
erations to filter abrasive dust from the air.
Stoning a commutator with the brushes in place will
wear the brushes away very rapidly and cause carbon
dust to deposit on insulation. Brushes that are hard-to-
reach should be removed before the engine is started if
you are working on an engine-driven generator. After
cranking, additional brushes can be taken out. In the
case of motors, the good brushes should be removed,
and worn brushes substituted. Usually one brush in
each holder is enough to run the motor light.
GE Transportation
Systems
PRINTED
IN U.S.A.
E