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 REPAIRELECTRIC 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 YORKCOPYRIGHT, 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
ReadForeword
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 SchoolContents
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
PackCONTENTS
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
292viii CONTENTS
Cuarrer Pace
V. Full-load Current for Three-phase A-C Motors 292
VI. Possible Synchronous Speeds. . . . . . 293
Lx LL 205ELECTRIC MOTOR REPAIRCHAPTER |
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.
34 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