Connecting electric motors

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 Table of Directions to ROVC Techcenter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting electric motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Contents Measurement of resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Inspection of AC induction motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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 Connecting Connecting 3 phase AC-motors
Figure 1 shows the workbench where you will
electric motors build the electric circuits.

Figure 1 Workbench for practical lesson “connecting electric motors”

This practical lesson focuses on the

connection of electric motors and conducting
measurements on these circuits. Figure 1
shows the layout of the workbench and some
components that you will use when building
these circuits.
Following steps are important throughout the
entire day :

1. Make sure power is switched off before

building or changing any circuit.
2. Build the electrical circuit.
3. Check your circuit once more, visually,
before applying power.
4. Apply power.
5. Run the test or check the circuit-functions
as described in the exercise.
6. Switch off power before disassembling the
circuit.

7
 Star-connection
In this exercise a three-phase motor is
connected in star and operated with a
manually operated motor protection switch.
Figure 2 shows part of the diagram.
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Figure 2 Motor in star-connection

Opgaven Direction of rotation can be:

1. Finalise the drawing in Figure 2 with the Counterclockwise (CCW), also called “to the
motor in star-connection. left”.
2. Add the terminal numbers according to Clockwise (CW), also called “to the right”.
the documentation of the components.
3. Build the electric circuit in accordance
with the drawing that you prepared earlier
and test the operation of the circuit.
Determine the direction of rotation.
4. Change the direction of rotation of the
motor. Attention! Switch off power before
making any changes.
Note :
Direction of rotation is defined by looking at
the face of the motorshaft.

8
Delta connection
In this exercise a three phase motor is
connected in delta. Figure 3 shows the main
circuit and the control circuit.

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Figure 3 Main circuit and control circuit of a motor to be connected in delta

Opgaven
5. Complete the drawing in Figure 3 to
connect the electric motor in delta
connection.
6. Add the terminal numbers in your drawing
using the documentation of the
components.
7. Build the electric circuit in accordance
with the drawing that you prepared earlier
and test the operation of the circuit.
Determine the direction of rotation.
8. Change the direction of rotation of the
motor. Attention! Switch off power before
making any changes.

9
 Opgaven
9. Select the correct settings on the
multimeter and measure the motor-
voltage. Record the settings of the meter
and the measurements in the table
below.
10. Measure the motor current. You may
decide which instrument to use. Do the
measured values correspond with the
values on the rating plate on the motor?
Please explain your answer.
11. Which value should be set on the thermal
protection relay? If necessary set it to the
correct value.

Range Selection Terminals used Umotor

AC DC 20 A mA Com V/Ω U1 - U2 V
V1 - V2 V
W1 - W2 V

Range Selection Terminals used Imotor

AC DC 20 A mA Com V/Ω IL1 A
IL2 A
IL3 A

10
Reversing circuit
Figure 4 shows the main circuit and control
circuit of a reversing circuit for an AC motor.

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Figure 4 Reversing circuit for an AC motor

Exercises
12. Add the terminal numbers in your drawing
using the documentation of the
components
13. Build the reversing circuit and check if the
actual direction of rotation corresponds to
the function of the startbuttons S2 (to the
left, CCW) and S3 (to the right, CW). If
the actual direction of rotation is not
correct please change the circuit accor-
dingly.
14. Is it allowed to change the direction of
rotation when the motor is running ?
15. You want to measure a voltage in the
control circuit. Which range do you select
on the meter?

11
 Excercises
16. Figure 5 once again shows the control
circuit. Please use Figure 6 to write down
the voltages you expect to find between
the indicated points in the control circuit,
for both operation modes as listed in the
table. First write down the values you
expect to find. After that, do the actual
measurements when the motor is not
running.
17. Repeat the measurements when the
motor is running counterclockwise (to the
left) and record the values in the table.

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Figure 5

Motor stopped Motor runs CCW (to the left)

Measu- Expected Measured Measu- Expected Measured
rement value value rement value value
1-8 V V 1-8 V V
2-8 V V 2-8 V V
3-8 V V 3-8 V V
4-8 V V 4-8 V V
5-8 V V 5-8 V V
6-8 V V 6-8 V V
7-8 V V 7-8 V V
1-2 V V 1-2 V V
3-4 V V 3-4 V V
4-6 V V 4-6 V V
5-7 V V 5-7 V V

Figure 6

18. Do the actual measurements correspond

with the values you expected? Discuss
the results with your instructor.

12
Star-delta circuit 19. Record in Figure 7 which switches you
need to operate to connect the motor in
To limit the starting-current of an AC
accordance with the diagram that is
(induction)motor, a star-delta circuit may be
shown on the righthand side.
used.

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Figure 7 Star-delta circuit

13
 Star-delta circuit using relays
Figure 8 shows the main circuit and control
circuit of a manually controlled star-delta
circuit.

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Figure 8 Star-delta circuit

Opgaven
20. Please indicate in the main circuit in
Figure 8 which relay is the star-relay, the
delta-relay and the mains-relay. Please
write down the correct connection for the
motorterminals. Please discuss the result
with a supervisor before building the
circuit.
21. Add the terminalnumbers in your drawing
using the documentation of the
components.
22. Build the start-delta circuit and test it for
correct operation.

14
Opgaven
23. Measure the motorvoltage and motor
current when the motor runs in star-
connection. Which instrument do you use
to measure the current? Record the
measured values in the table below.
24. Measure the motor voltage and motor
current when the motor runs in delta-
connection. Record the measured values
in the table below.
25. Which value do you set on the thermal
protection relay? Set it to the correct
value.

Motor in star
U1 - U2 V IL1 A
V1 - V2 V IL2 A
W1 - W2 V IL3 A

Motor in delta
U1 - U2 V IL1 A
V1 - V2 V IL2 A
W1 - W2 V IL3 A

Figure 9

26. Change the direction of rotation of the

motor. Attention ! Switch off power before
changing the circuit !
27. Change the circuit into an automatic star-
delta circuit using available components.
First, the motor should run in star-
connection for 7 seconds and then switch
automatically to delta-connection.

15
 Automatic star-delta circuit with Exercises
reversing circuit (extra exercise) Figure 10 is the control circuit of an automatic
In this exercise you combine the star-delta star-delta circuit with two directions of rotation.
start with the reversing circuit

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28. You operate pushbutton S2. Which relay

is the first to be energised ?
29. Which relays are energised after 5
seconds ?
30. You operate pushbutton S3. Which relay
is the first to be energised ?
31. Which relays are energised after 5
seconds?
32. Write down the functions of relays and
lamps in Figure 10.

16
Exercises
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Figure 11

33. Identify the components in the main

circuit (Figure 11) based on the answers
on the previous questions and write down
the correct relay numbers in Figure 11.
34. In this circuit the mains voltage is 23/40
V. What should be the rated voltages of
the electric motor to allow for a start-delta
start?
35. Add the terminal numbers in the main
circuit and control circuit using the docu-
mentation of the actual components that
you will use to build the circuits.
36. Build the complete circuit and test it for
correct operation.

17
 Connecting DC motors
Series motor
Figure 12 shows the diagram of a DC series-
motor.
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Figure 12 Diagram DC series-motor

Opgaven
37. Add the terminal numbers in Figure 12.
38. Select the correct motor for building this
circuit. In order to verify your selection
measure the resistance of the field-
winding using the multimeter.
Rwinding = . . . . . . . Ohm
39. Build and test the circuit. Observe the
direction of rotation of the motor.
40. Modify the circuit to change the direction
of rotation of the electric motor. Attention!
Disconnect power before changing the
circuit.

18
Shuntmotor
Figure 13 is a diagram where a manually
operated, dual pole switch changes the
direction of rotation of a DC shuntmotor.

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Figure 13 Reversing circuit of a DC shuntmotor

Opgaven
41. Verify the operation of the diagram in
Figure 13.
42. Modify the diagram, if necessary, to
ensure proper operation.
43. Mark the terminals in the (revised)
diagram.
44. Select the correct motor for this circuit.
Verify your selection by measuring the
resistance of the fieldwinding with a
multimeter.
Rwinding = . . . . . Ohm
45. Build and test the circuit.
46. To reverse the direction of rotation of a
DC series- or shuntmotor you can change
polarity on either the fieldwinding or the
armature-winding. Build the circuit in
such a way that polarity is changed on
the fieldwinding instead of the armature
winding.
47. What happens when you change polarity
on the supply voltage?
Attention!
Switch off voltage before making any
changes.

19
20
Measurement of Figure 14 shows four different circuits with
resistors. The value of the resistors is shown
resistance in the diagrams.

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Figure 14

Excercises 49. On the test bench you will find printed-

circuit-boards with the circuits A to D.
48. Calculate the equivalent resistance for
Using a multimeter you can measure the
circuits A to D and write your result in
resistances to verify the values you
Figure 15 in column “Calculated equi-
calculated earlier. Write the measu-
valent resistance”.
rement results in the column marked
“Measured equivalent resistance”.

Circuit Calculated equivalent resistance Measured equivalent resistance

RAB RBC RAC RAB RBC RAC
A X X X X
B
C
D

Figure 15

21
22
Inspection of AC An electric motor can be inspected using a Attention :
measuring instrument also known as
Use the megger with care. When operated
induction motors “megger”. With the megger we are able to :
incorrectly you will experience an electric
shock since it works with 500 V.
- Check wires, cables and coils for breaks
and interruptions
- Measure insulation resistance

Figure 16 Two meggers

Checking wires for breaks the megger. Insulation resistance measu-

rement can be done by pressing and holding
Analogue megger: with the selector switch in
the “test” button. Insulation resistance must be
position Ω or 20Ω, wires and coils can be
higher than 1 MΩ.
checked for breaks. If a break is found, the
indicator will sweep fully to the right, to the 20
Ω mark. This means the measured resistance
is infinite.
Digital megger : switch on the megger. Resi-
stance measurement can be done imme-
diately by holding the measurement pins
against the ends of the windings.

Measurement of insulation resi-

stance
Analogue megger: with the selector switch in
MΩ or 200 MΩ a 500V measurement voltage
is available on the measurementleads by
pressing and holding the “test” button. This
voltage can be used to determine if the insu-
lation material on the conductors is in good
condition. The insulation resistance must be
higher than 1 MΩ. Digital megger: switch on

23
 Excercises
In the practical area you will find a number of
electric motors. Some motors are defective.
Check the motors with the meggers, following
the exercises below.
50. Check for breaks in the coils. Place the
selector-switch in position 20Ω and
measure the motors to determine which
terminals are connected together through
a coil. Draw the coils in Figure 17 and
add the terminal numbers. Record the
measured values in Figure 18. With the
digital megger it is only necessary to
power on the measurement device.
Immediately after that the resistance can
be measured.
51. Check if the coils are contacting each
other, due to poor insulation or other
causes. Place the selector-switch in
position MΩ of 200MΩ. Attention! By
pushing and holding the “test” button a
voltage of 500 Volt will be available on
02725  02725 
02725  02725 
Figure 17
24
the measurement leads. After releasing
the test-button the motorcoil will
discharge through the measurement
device. On some meggers you can see
this because of a small light on the
instrument. So, hold the measure-
menttips against the motorterminals for a
couple of seconds after releasing the
testbutton to prevent any residual
voltages on the windings. Record the
measured values in Figure 18.
52. To check the insulation resistance
between the coils and ground, the
selector-switch should remain in the MΩ
position. Now measure the insulation
resistance from each coil to ground (the
motor frame). Attention! This measu-
rement is also done with 500 Volt. Record
the measured values in Figure 18.
53. Mark the measured values in Figure 18
that indicate a failure in the motor.
02725 
02725 
 Motor 1
Rwinding Rinsulation
U1 - U2 Ω U1 - V1 MΩ U1 - ground MΩ
V1 - V2 Ω V1 - W1 MΩ V1 - ground MΩ
W1 - W2 Ω U1 - W1 MΩ W1 - ground MΩ

Motor 2
Rwinding Rinsulation
U1 - U2 Ω U1 - V1 MΩ U1 - ground MΩ
V1 - V2 Ω V1 - W1 MΩ V1 - ground MΩ
W1 - W2 Ω U1 - W1 MΩ W1 - ground MΩ

Motor 3
Rwinding Rinsulation
U1 - U2 Ω U1 - V1 MΩ U1 - ground MΩ
V1 - V2 Ω V1 - W1 MΩ V1 - ground MΩ
W1 - W2 Ω U1 - W1 MΩ W1 - ground MΩ

Motor 4
Rwinding Rinsulation
U1 - U2 Ω U1 - V1 MΩ U1 - ground MΩ
V1 - V2 Ω V1 - W1 MΩ V1 - ground MΩ
W1 - W2 Ω U1 - W1 MΩ W1 - ground MΩ

Motor 5
Rwinding Rinsulation
U1 - U2 Ω U1 - V1 MΩ U1 - ground MΩ
V1 - V2 Ω V1 - W1 MΩ V1 - ground MΩ
W1 - W2 Ω U1 - W1 MΩ W1 - ground MΩ

Motor 6
Rwinding Rinsulation
U1 - U2 Ω U1 - V1 MΩ U1 - ground MΩ
V1 - V2 Ω V1 - W1 MΩ V1 - ground MΩ
W1 - W2 Ω U1 - W1 MΩ W1 - ground MΩ

Figure 18 Measured values

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