BESO T py ELECTRIC MOTOR REPAIR TEXT AND APPENDIX Both alternating-current and direct-current motors are treated thoroughly, and extensive consideration is given to the connections and troubles in controllers. Since synchros and electronic control are coming into greater use than ever, an introduction to these units is included. Last but by no means the least feature of the book is its physical design — a design which permits text and related illustrations to be exposed to view simultaneously, which permits any desired illustra- tion to be located instantly, allows the open book to lie fiat on the bench, and utilizes type large enough to be easily readable from the bench while the repairman is working on a motor. Even the cover material and the special paper within the book were selected for their unusual sturdiness and resistance to soiling under shop working conditions, This opportunity is welcomed to express my sincere thanks to Samuel Zwilling, Alan Tobias, Philip Cane and Emanuel Kissner for their suggestions and help, and to the many manufacturers who supplied photographs. ROBERT ROSENBERG. Brooklyn, New York. M-H.B Duo-Book ® ‘Trade Mack Registered in the United States. Patent Otkoe, Number 30,824,ELECTRIC MOTOR REPAIRELECTRIC MOTOR REPAIR : A PRACTICAL BOOK ON THE WINDING, REPAIR, AND TROUBLESHOOTING OF A-C AND D-C MOTORS AND CONTROLLERS by ROBERT ROSENBERG, BS. Chairman, Building Trades Department Alexander Hamilton Vocational High School ' Brooklyn, N. Y. : ENLARGED EDITION ‘ 1 RINEHART & COMPANY, INC. ‘ TECHNICAL DIVISION NEW YORKCOPYRIGHT, 1946, 1949, 1951, BY ROBERT ROSENBERG PRINTED IN THE UNITED STATES OF AMERICA DUENEWALD PRINTING CORPORATION ALL RIGHTS RESERVED Spiral Binding, U. S. patents 1516932, 1942026, 1985776, Other patents pending ReadForeword Robert Rosenberg’s Electric Motor Repair is a book which, in my opinion, meets a very definite need and will be enthusiastically weleomed by those who are training as electric motor repairmen, whether in schools or shops, and by all who have a hand in their training. This book presents an intensely practical, nonmathematical treatment which will serve the reader not only during his training but long after that; therefore a minimum of theory is included. T consider it a tool of the trade, as well as a text—a guide for the student and a part of the bench equipment of the apprentice and the fullfledged repairman, This book, with its wealth of illustrative material, can be used to supplement standard texts on electricity and electric motors or as instructional material for vocational and other trade schools. In the shop it will satisfy a defi- nite demand for practical reference material. The intensely practical arrangement of the illustrations makes the book continuously useful in school and shop. The author’s intimate knowledge of the requirements of the vocational school student. gained during a decade as a teacher, and his familiarity with the needs of those actively engaged in motor repairing, a result of his many years spent in shops, make him particularly well qualified as the author of a work which is intended to satisfy the needs of student and worker alike. The book reflects conscientious and painstaking research, as well as the author’s excellent teach- ing ability. I. DAVID COHEN, Principal George Westinghouse Vocational High SchoolContents Foreworp sy I, Davin CoHEN . Cuarrer 1. Spiit-pHase Motors Main Parts . Operation : Procedure for Analyzing ‘Troubles Rewinding fe Reversing : Two-speed, Split phase . Troubleshooting and Repair . 2. Capacitor Mortors The Capacitor Capacitor-start . : Capacitor Start-and-run Troubleshooting and Repair . 3. Reputsion-type Motors Construction Repulsion-start, Induction-run Repulsion Repulsion-; induction Troubleshooting and Repair 4. PorypHase Motors . Three-phase . Two-phase : Rewinding and Reconnecting . Troubleshooting and Repair . 5, ALTERNATING-cURRENT Motor ConTROL . Starters Controllers : Troubleshooting and Repair fi vi PackCONTENTS cuarrer 6, Direct-currENT ARMATURE WINDING . . Typical Winding for a Small Armature . Lap Windings Wave Windings . ee Rewinding Procedure. . 2 2. 2 Troubleshooting and Repair 7. Direct-current Motors Construction Connections of D- C Motors Construction of the Field Coils . Connecting Reversing fo eG Troubleshooting ‘and Repair See oe 8. Direcr-current Motor Controu . Manual Controllers Automatie Controllers . Troubleshooting and Repair . 9, Universal, SHADED-POLE, AND Fan Motors. . 10. Direct-curRENT GENERATORS; SYNCHRONOUS Morors anp Generators; SyncHRos; Euec- TRONIC ConTROL or Motors . . APPENDIX I. Table for Bare Copper Wire . . 2. we I. Full-load Motor Current for D- lee Am- peres . . a. III. Full-load Current for Singie-phase A-C Motors, ee IV. Full-load Current for Two- phase A-C Motors with Four Wires Pace 154 155 158 161 168 186 186 187 188 191 194 195 215 216 231 241 263 289 291 291 292viii CONTENTS Cuarrer Pace V. Full-load Current for Three-phase A-C Motors 292 VI. Possible Synchronous Speeds. . . . . . 293 Lx LL 205ELECTRIC MOTOR REPAIRCHAPTER | Split-phase Motors MAIN PARTS OF MOTOR The split-phase motor is an a-c motor of fractional-horse- power size and is used to operate such devices as washing machines, oil burners, and small pumps. This motor has four main parts. These are (1) a rotating part, called the rotor; (2) a stationary part. called the stator; (3) end plates, or brackets, that are fastened to the frame of the stator by means of serews or bolts; and (4) a centrifugal switch that is located inside the motor. The general ap- pearance of a split-phase motor is shown in Figure 1-1. This motor is generally operated from a single-phase light- ing or power circuit. The Rotor The rotor, one of which is shown in Figure 1-2, consists of three essential elements. One of these elements is a core that is made up of sheets of high-grade electrical sheet steel called laminations. Another is a shaft on which the lami- nated iron core is pressed. The third element is a squirrel- cage winding consisting of heavy copper bars which are placed in slots in the iron core and are connected to each other by means of heavy copper rings located on both ends of the core. In many motors the rotor has a one-piece cast- aluminum winding. This type is shown in Figure 1-2. The Stator The stator of a split-phase motor is composed of a laminated iron core with semiclosed slots, a heavy cast-iron or steel frame into which the core is pressed, and two wind. 34 ELECTRIC MOTOR REPAIR ings of insulated copper wire that are wound into the slots and are called the running and starting windings. A photo- graph of the stator is reproduced in Figure 1-3, and a sche- matic diagram of the two windings is shown in Figure 1-4. Both windings are connected to the power line when the motor is started; however, after the motor has reached a predetermined speed the starting winding is automatically disconnected from the power line by means of a centrifugal switch located inside the motor. The End Plates (End Shields or Brackets) The end plates, which are illustrated in Figures 1-5 and 1-7, are fastened to the stator frame by means of screws or bolts and serve mainly to keep the rotor in position. The bore of the end plates, in which the rotor shaft rests, is fitted with either ball bearings or sleeve bearings.. These sustain the weight of the rotor, keep it precisely centered within the stator, and permit rotation without allowing the rotor to rub on the stator. The Centrifugal Switch The centrifugal switch is located inside the motor. Its function is to disconnect the starting winding after the rotor has reached a predetermined speed. The usual type consists of two main parts, namely, a stationary part (shown in Figure 1-6) and a rotating part. The station- ary part is located on the front end plate of the motor and has two contacts, so that it is similar in action to a single-pole, single-throw switch. The rotating part is lo- cated on the rotor, as shown in Figure 1-7. The action of a centrifugal switch is explained as fol- lows: Reference to Figure 1-8 shows that when the motor is at a standstill, the two contacts on the stationary part of the switch are kept closed by the pressure of the rotating part. At approximately 75 per cent of full speed, the rotating part releases its pressure against the contacts and