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Student Resource Package No: NRE8. Competence in this training program can be achieved through either a formal education setting or in the workplace environment. The student/candidate may be granted recognition of prior learning if the evidence presented is authentic and valid which covers the content as laid out in this package. This package provides the student with the underpinning knowledge and skills to identify and test three / single phase motors and their associated power / control circuits. In addition the operation of three phase motors, contactors, thermal overloads, single phase motors and their starting devices. Australian Refrigeration and Air Conditioning Vol 1&2. Electrical Principles for the Electrical Trades, J.R. Jenneson The assessment of this package is holistic in nature and requires the demonstration of the knowledge and skills identified in the student package content summary. To be successful in this package the student must show evidence of achievement in accordance with the package.
Delivery:
Package Purpose:
Suggested Resources:
Assessment Strategy:
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Assessment Events: 1. 2. Practical Test Theory Test 20/40 40/40 50% 50%
Practical Test:
Simulated practical exercises in regards to three phase motors, single phase motors, DOL contactors and associated circuits.. Short answer Questions, multiple choice questions. This assessment covers the contents from sections 1 to 9 in the student resource package.
Theory Test 1:
Summary of Contents: Delivery & Assessment Details: Section No: 1 Section No: 2 Section No: 3 Section No: 4 Section No: 5 Section No: 6 Section No: 7 Section No: 8 Section No: 9 Three Phase Electrical Systems: Common Motor Information: Three Phase Induction Motors: Three Phase D.O. L. Motor Starter: Three Phase Motor Protection: Split Phase, motors Starters and Overloads: Capacitor, Shaded Pole & Synchronous Motors: Series Universal Motors: Servicing Motors and auxiliary equipment:
Page No 1 4 9 17 26 35 41 50 57 60 64 70
This package is designed as a self paced package with all relevant information and references contained. At the end of each section there are a number of review questions which require responses. (Answers to Review Questions page 64).
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Delivery:
Competence in this training program can be achieved through either a formal education setting by completing the attached student resource package or in the workplace environment.
Prerequisite:
The following resource packages or equivalent is a prerequisite: Occupational Health & Safety (7793T) Refrigeration Electrical 1 & 2.(NRE 1 & 2) Refrigeration Electrical Wiring (NREW)
Recognition of Prior Learning: The student/ candidate may be granted recognition of prior learning if the evidence presented is authentic, sufficient and valid which covers the content as laid out in this package.
Competency: Upon successful completion of the Occupational Health & Safety (7793T), Refrigeration the: Electrical 1& 2 (NRE 1&2), Refrigeration Electrical Wiring (NREW) and Three Phase / Single Phase Motors & Circuits training programs you will be assessed against the following competencies: UTE NES208EA: Disconnect & Reconnect fixed wired electrical equipment (up to 1000Volts). UTE NES 209EA: Attach flexible cords and plugs to electrical equipment connected to 240 volt supply UTE NES 210EA: Attach flexible cords and plugs to electrical equipment connected to a supply up 1000 volts AC ( Three phase 415) UTE NES106EA: Install electrical/electronic apparatus and associated circuits, refrigeration and air conditioning. UTE NES 206EA Maintain and repair electrical/electronic apparatus and associated circuits, refrigeration and air conditioning. UTE NES505EA Locate and rectify faults in electrical equipment intended to operate off fixed wired supply up to 415 volts A.C.
Suggested Resources: Jenneson, JR., 1995, Electrical Principles for Electrical Trades, McGraw Hill, Sydney. Australian Refrigeration and Air Conditioning Volume 1 & 2.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Section No: 1
Three Phase Electrical Production: Revision Three phase voltage is produced with a device called an alternator. The alternator has three sets of windings, mechanically fixed 120 electrical degrees to each other which when passed (rotated) through a fixed magnetic field will produce an Electromotive Force that is proportional to the strength of the magnetic field and the speed that the windings pass through the field. The current available from the alternator is limited by the cross sectional area (size) of the conductor in the alternators windings. Because there are separate voltages, each one can be used as a single phase power source provided a neutral connection is available.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Types of three phase connections: References: * ARAC page 14.7. * J.R. Jenneson chapter: 11, Page 218 221. Electrical Principles For The Electrical Trades There are two ways three phase can be connected to form a working system; Star (Y) Delta ( )
Star connection (Y) Sometimes referred to as the WYE system for electric motors. The star connection is formed, by connecting three similar ends of the windings together as shown in Fig.1. Either the start or the finish ends of the windings can be used but not dissimilar ends. Note: the common connecting point is called the star point.
Fig 1 Star Systems; This is the way three phase is delivered to the consumer. The delivery system is referred to as a four wire system because there are the three phase cables and the neutral. The three actives (lines) usually referred to as phase A. B. or C. they have a colour code of Red, White and Blue and the neutral is Black. The voltage between these three actives is called the Line Voltage and the current flowing through the lines is referred to as the Line Current.
The Line Voltage is not equal to the Phase Voltage because two windings are connected in series with two Line Voltages. Line Voltage (V line) = 415volts Phase Voltage (Vp) = 240volts Formula:
Vline 415V
Vp
Vp
Vp 240volts
The line current equals the phase current. Where: I line = line current I p = phase current Formula:
Iline Ip
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Delta connection () The windings of a three phase alternator can also be connected in delta as shown below. The delta connection forms a closed loop with dissimilar ends joined together with the line cables joined at these junctions. (fig 2)
Fig 2 In a Delta connection, each phase winding is connected across two line voltages and therefore the line voltage equals the phase voltage. Vline Vp The line current in a delta connection is a combination of the phase currents. If the phase currents are all equal, then the line current is equal to;
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Electrical Power: The amount of power consumed by a three phase load is determine by using the following formula: P = 3 x V x I x pf Where: P = power in watts or kilowatts (w or kW) 3 = 1.732 V = voltage in volts I = current in amperes pf = power factor (0 to 1) A 415 volt three phase motor draws 6.5 amperes with a power factor of 0.84. Determine the total power consumed. P = 3 x V x I x pf
Example:
Note: the power consumed is measured and charged as a kilowatt hour kWHr Example: If the above motor operates for 24 hours and the cost per kWHr is 12 cents determine the total cost of operation over 24 hours.
Service Points.
Remember to check the voltage on all three phases, 415 volts between phases, and 240 volts to earth. When testing the supply always check at a non-load point. i.e. at the input terminals of the contactor. The supply voltage should not be below 5% of the rated voltage. Check for continuity of supply at the terminals of the device it is powering. i.e. the motor terminal block. It must be the same at no load and full load, and within 5% of the rate voltage on the nameplate of the device it is supplying. Symptoms of low voltage supply. Motor overheating. Extra noisy motor. Motor fails to start. Overload tripping when motor not loaded. Causes of low voltage Dirty contacts, or loose terminals. Supply from the electrical authority. Overload building wiring. Always tong amp test at least two of the three phases although it is best to tong all three. They should be the same value and no greater than the Full Load Amps on the nameplate of the device it is supplying. Set the meg-ohmmeter to 1000V when testing three phase motors. 1. A reading less than 2Mohms indicates a burnt out motor. 2. A reading less than 25Mohms indicates moisture in the motor. 3. A reading greater than 25Mohms generally indicates no short to earth, but remember a motor starts with infinity resistance so anything less means it is wearing out.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Review Questions Section No: 1 Q.1 List the two methods of connecting a three phase systems?
Q.2
Can a single phase motor be connected into a three phase electrical supply system and are there any additional requirements:
Q.3
What is the line and phase voltage of a three phase delta system?
Q.4
A three phase delta supply draws a phase current of 5 amperes from a 415, volt 50 HZ power supply. Determine following in the space provided: line voltage phase voltage line current phase current:
Q.5
A star connected 415 volt three phase motor draws a phase current of 3.6 amperes. Determine the following: in the space provided: line voltage phase voltage line current phase current:
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Introduction
The induction motor gets its name from the fact that the current that causes the magnetism in the rotor is induced it is not drawn directly from the supply
Construction.
Stator The stator is the magnetic field producing stationary part of the motor and is made up of laminated steel punchings with slots cut to accept the windings. The slots are insulated with thick paper type insulation (leatheroid), which acts to prevent the windings conductors from rubbing against the steel laminations as the magnetic flux cause everything to vibrate. Each lamination has a build up of oxidized metal on one side so that when they are placed together the oxidized surface will create an area of high reluctance for the Stator is for an Hermetic compressor. magnetism produced by the stator windings, this then gives each lamination its own magnetic field, as opposed to a solid steel block having one magnetic field.
Windings; The windings are made from varnish insulated copper wire, which is wound as coil sets, the number of coils in each set is determined by the number of magnetic poles in the motor. Single and three phase motors have different numbers of coils for the same number of poles.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Rotor / Shaft
The rotor is also made from laminated steel punchings for the same reasons as that of the stator. The rotor is designed to fit neatly in the stator so that the air gap between it and the stator is kept to a minimum. The closer they are together, the greater is the magnetic attraction, because air gap has a higher magnetic reluctance. The holes that accommodate the conductors are often skewed across the curved surface of the rotor to help with the inductive process during starting. It also helps reduce the magnetic humming noise. The shaft and rotor are supported by ballrace bearings mounted in the endplates.
Types of Rotors
Squirrel Cage; gets its name from the shape that the rotor conductors form without the laminations. The rotor conductors are mainly made from solid aluminium which is cast into the laminations when it is manufactured although there are some made from solid copper. The only insulation between the rotor conductors and the laminations is the oxide on the aluminium that comes from the casting. Insulation is not necessary because the induced voltage on the rotor is very low, but the current is very high to produce the required magnetism. The rotor bars are short circuited together so that the induced EMF has a circuit in which the current can flow. The rotor has low resistance that allows high starting current, to create the starting torque. They are available in a number of designs that provide different starting torque characteristics by having different widths for diameter and closeness of the rotor to the stator. Advantages of a squirrel cage motor include: simplicity and rugged construction No sparking contacts in the motor so they can be used in explosive atmosphere (provided; the appropriate enclosure is used). Wide range of shaft speeds (when used with electronic frequency controllers).
Disadvantages of squirrel cage motor include: Relatively poor starting torque Fixed characteristics.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Wire Wound (slip rings); (normally three phase), has a rotor winding the same as the stator, except that one end of the coil windings are connected in star, and the other ends are brought out through slip rings and brushes to an external circuit, where equal but variable resistance is connected to the rotor windings. The resistance is decreases as the speed increases. This limits the starting current, increasing the starting torque. They are not used much in refrigeration industry because of their cost and their complex control.
Synchronous Motor; is not an induction motor and it is not the power tool motor. It has a stator the same as the induction motor but the rotor is wire wound with each individual coil leads attached to a segment of a commutator. Now the rotor is now referred to as an armature. Both the stator and the rotor are supplied with A.C., and because of the way the windings are connected to the commutator on the rotor the A.C. is converted to D.C. for the rotor windings which will create a constant position magnetic field on the rotor. The constant position magnetic field reacts directly against the rotating magnetic field. This combination causes the shaft to rotate at synchronous speed, and has its strongest torque at synchronous speed. Sometimes used to correct power factor as it causes the current to lead the voltage, other than that not used in HVAC&R industry. Small Synchronous Motors, however small synchronous are used extensively in the industry for timer motors because they keep accurate time, and small modulating motor systems. They use permanent magnets in the rotor instead of the DC supplied magnetic field.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Frames
The frame (motor housing), carries the stator and is also the mounting for the end shields (end plates), that house the bearings. It is also the means of sercuring the motor to what it is driving.
Drip proof
Hose proof types they are designed to prevent the entry of forced water. Flame proof, meaning any burnout will be contained within the frame enclosure.
Whenever you are servicing an electric motor, check that all the mounting bolts are secure and that there are no cracks in the frame or its mountings. Electric motors must be held down firmly, for they develop large amounts of torque which strains the mounting points, and will twist the frame if it is not secure.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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4. Single Phase Motor Starting Relays 5. Single Phase Motor Overloads 6. Servicing of all the equipment.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Nameplate Information
Power
This is the rated shaft power, not the electrical input. The electrical input should be more and the difference between the two is regarded as losses for electric motors. The losses can be either electrical or mechanical and cause heat.
Supply Voltage
Single phase motors have a supply of 240V. Three phase motors will be supplied with 415V, make sure that the motor has its internal connection arranged to accept the voltage (star or delta), it will be on the nameplate. Always check motor voltage before energizing it.
Supply Frequency
Should be 50 hertz (cycles/sec). (60Hz USA motors)
Motor Current
Full Load Amps (FLA), is the maximum current that the motor is designed to draw at full load while maintaining its rated speed. Starting Current.(not on nameplate), this can be from 3 to 9 times the FLA, and is something that should be kept to a minimum. eg. If a motor has a FLA rating of 10 amps, and is started fully loaded it can draw 90 amps to start. If this motor was to start at your house the lights would dim until the motor reached running status. Locked Rotor Current (LRC on hermetic compressors nameplates) is the current that the motor draws if the rotor is locked by a too heavy load. eg. a compressor seize.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Motor Speed
Rev/min. (Shaft rotation on nameplate) is the speed that the shaft should turn at, even when fully loaded. Rotational speed of the electric motor is controlled by the number of poles built into the stator and the percentage of slip needed to maintain rotoation.
The voltage intensity has nothing to do with the rotational speed of the motor, but it does have a lot to do with the ability of the motor to turn the load.
Both three phase and single phase 4 pole motors have the synchronous speed of 1500 rev/min,
Shaft Speed
The speed the shaft travels at is the rated speed on the nameplate of the motor. The difference in speed between synchronous and shaft (actual) speed is referred to as slip and is expressed as a percentage in calculations, usually around 4%.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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e.g. A 4 pole motor (syn 1500 revs/min), has a rated shaft speed of 1440 revs/min, calculate the percentage of slip? ( 1500 - 1440) 100 slip = x = 1500 1 60 x 1500 1 100 = 4%
Another calculation that can be used when referring to motors is how to calculate the actual motor speed when the % of slip is given. If the motor was running 4% slow it means it is running at 96% of synchronous the 96% can be converted to a decimal (0.96) to make the calculation easier.
Service information.
An electric motor must turn at its rated speed. If the speed isnt maintained the motor will have less inductive reactance meaning, less impedance which will allow more current to flow causing the motor to overheat, tripping the overload or burning out the motors stator windings.
Terminal Block
All electrical connections made to a motor must be completed in the motors terminal block. Flexible conduit and multi-strand conductor must be used (preferably flexible conductor). The conduit must be secured by an approved fitting or in the case of flexible cable to a small fan motor an approved gripping type grommet. The earthing connection must only be made at the terminal marked as the earth.
All electric motors must be earthed at the earth terminal in the terminal block.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Construction
They have three separate sets of coil windings placed 120 E apart in the stator. Each winding is connected to two sequential phases, (see diagram below). They have squirrel cage rotors.
o
Operation
Because of the winding configuration, and the nature of three phase supply, as power is supplied to the motor having two magnetic poles (3000 rev/min synchronous), only one set of coils will have maximum magnetic strength, another set of coils will have a rising magnetic field, and the other a falling. As this is happening the rotor is being affected by all three magnetic fluxes which are moving at different angles through the rotor conductors inducing three currents and three magnetic fields which react with the stator fields producing a very strong starting torque. The magnetic fields of the stator appear to rotate around the stator, but actually they only grow stronger and weaker in sequential order around the stator windings.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Three phase motors made here in Australia are designed to operate from our 415 volts 50 Hz four wire system. The neutral is needed for single phase motors and control circuits. Some motors are imported from overseas and may not be suitable for our supply, so check the nameplate information before you make the connections. They may need a transformer to be supplied separately, or have a transformer as part of package. Some imported motor have lower voltage and 60Hz frequencies and must be connected in star.
Connection
There are two ways to connect the coil windings of three phase motor so that 415 volts can be applied to them. They are; Star or Delta. Some three phase motors can be connected in either Star or Delta. These motors will have six terminals in their terminal block and their nameplate will indicate that they can be wired to 415V. They will have terminal bridging links to connect the
ends of the coil windings together so that they can be configured to either star or delta. When the motor is connected in Delta will draw more current from the supply then when it is connected in Star. The lines are then connected to each set of windings at the motor terminals.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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If the motor has only three terminals it is internally connected in either Star or Delta and should just have the lines connected to the terminals. (Check the nameplate for voltage rating). Most motors used in refrigeration and A/C will be connected internally in Star and there will be three terminals for the connections.
Reversal of three phase induction motors: Since the rotor follows the rotational magnetic force (RMF), to reverse the direction of a three phase induction motor you must reverse the direction of the RMF. The directional change can be achieved by changing the phase sequence (swapping two supply lead connections).
Reguardless if the motor has six terminals or three the reversal procedure is the same.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Practical Exercise Three Phase Motor Connections Aim: To test the supply of a three phase system and to draw a sketch of the component layout needed to supply power to a three motor. Electrical training boards in workshop. 415 volt power supply Isolation switch Fuses or circuit breaker D.O.L. motor contactor 240 volt control circuit ON/OFF control switch Overload Three phase motor Note: drawing to be done on attached page. Complete a risk assessment of the task. On completion of circuit diagram check with you teacher/mentor and proceed test a power circuit and a motor wired in Star and there Delta:
Equipment: Procedure:
Electrical meters: Megohm-meter Multi-meter Tong ammeter Record Results: Delta: Resistances across each winding: 1 Star: 2 3
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Review Questions Section No: 2 Q.1 When testing a three phase motor the tong tester is placed: (a) (b) (c) (d) Q.2 across the active or neutral cables between any phase and earth cables around any two phase cables around any one phase cables.
The stator core is laminated to: (a) (b) (c) (d) improve starting torque provide silent running reduce eddy current loss reduce hysteresis loss.
Q.3
Rotor bars are usually made from: (a) (b) (c) (d) steel or copper copper or aluminium carbon or copper. steel or aluminium.
Q.4
Slip speed is the difference between: (a) (b) (c) (d) standstill and rotor speed rotor and stalling speed Synchronous speed and rotor speed Synchronous speed and standstill speed.
Q.5
A typical three phase stator winding would be expected to have a resistance of: (a) 10 to 100 ohms (b) 100 to 1000 ohms (c) greater than 1 megohm (d) almost zero ohms. On completion of an insulation test between each of the phase windings and earth a three phase induction motor would pass if all test results were: (a) (b) (c) (d) less than 2 ohms between 10 kilohms and 1 megohm The greater the better. between 2 ohms and 100 ohms.
Q.6
Q.7
The rotor windings of a wound rotor induction motor is usually connected in: (a) (b) (c) (d) delta series parallel star.
Q.8
To reverse the direction of rotation of a three phase squirrel cage motor you would: (a) (b) (c) (d) interchange any two supply lead connections replace the squirrel cage rotor with a wound rotor change the delta connected stator winding to star remove the rotor and reverse end for end.
Q.9
At what speed is the RMF produced by the stator winding rotate at?
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Q.10
Q.11
Briefly explain why the rotor speed of an induction motor is always less that the speed of the stator RMF:
Q.12
A three phase 415 volt, 50 HZ, 4 pole induction motor operates with a 4% slip. Determine the synchronous speed and the actual rotor speed:
Q.13
From the details below determine the voltages for a three phase power supply between: Any two lines: = Any line and earth: = Any line and neutral: = Earth and neutral: =
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Q.14
The diagrams below (fig 1 & 2) represent a schematic layout of the motor windings for a six terminal three phase motor. Complete the diagram from the three phase supply (L1, L2, and L3) to include the phase windings for both a star and delta connections.
Star Y
L1
L2 L2
L3
A1
B1
C1
B2
C2
A2
Fig. 1 Delta
L1 L2 L2 L3
A1
B1
C1
B2
C2
A2
Fig. 2
Q.15
Indicate on the diagram below the main components of the squirrel cage induction motor:
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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The operating characteristics of an induction motor are that current and torque conditions are considerably different during the starting sequence and then running conditions. In the refrigeration industry, the compressor motor is the largest single load that has to be switched by the control circuit. The control circuit can not directly handle the large starting currents or switch the 3 phase for the motors, so it operates a contactor or intiates a starter sequence that is in the power circuit.
Contactors
A Contactor is multi-poled device for repeated establishing and interrupting an electrical circuit with a large current draw, and a Starter is an electric controller for accelerating a motor from rest to normal speed. (Starters control is covered in greater detail in Systems Control).
The contactor has an electromagnetic coil that moves an armature which closes the contact points. The magnetic coil can have a different voltage ratings to the motors, some typical voltages are 24V, 240V, and 415V. (24V is common on Air conditioning systems because untrained operators tend to fiddle with the controller adjustment). The physical size of the coil will not relate to the voltage rating. The control circuit is connected to terminals A1 and A2 on the contactor
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Contactor Rating
The contact points are rated for different types of load. ie. The e.g. 40amps resistive same contactor will be rated for resistive load (heater bank), and inductive load (motor). 15 amps inductive The rating is done this way because the heater will have a constant current draw whereas the motor has a very high starting current. Contactors normally have three main sets of poles so that the three phase supply can be switched on/off to a three phase motor. The pole connections are marked by numbers, 1 through to 6. Odd numbers on top evens on the bottom. There can be other contact points on the contactor these are referred to as the auxiliaries, which can be used as part of an interlock system, or used to energized some other auxiliary piece of equipment, (eg. A contactor for fan motor or water pumps).
Auxillary contacts have very low current ratings and should not be used to switch inductive loads. They are numbered 13 - 14 for normally open contacts and 21 - 22 for normally closed contacts.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Motor Starters
There are a number of three phase motor starters used within the refrigeration, air conditioning and electrical industries and they are as follows: Note: further reference: ARAC, page 14.11 14.19 D.O.L. (Direct on Line) Reduce Voltage star- delta starter primary resistance starter secondary resistance starter auto-transformer starter part winding starters. Electronic (soft- start) starter. Note: reduced voltage and electronic soft starters will be covered in more detail in another student resource package. All reduced voltage starters require the motor to be unloaded to start.
Direct on Line Starter (D.O.L.) The basic D.O.L. motor starter, consist of a contactor with a thermal overload relay that will trip in the event of an overload condition. The D.O.L. starter has the added feature in that it can be operated by manual or automatic control devices.
A simple ON/OFF control switch is all that is needed to energize the contactor coil via the overload. This will create the electromagnetism that causes the contactors armature to pull in and close the three Line contacts and switch any auxiliaries on the contactor. D.O.L. motor starter uses its three line contacts to simultaneously energize the motor winding. The windings receive full line voltage so they will draw up to eight times their running current.
Control Circuit Cycling Devices: A number of control devices can be used to stop and start a three phase motor control circuit utilising a D.O.L. starter. These devices can be stand alone or used as part of the other circuits: Switches like, Thermostats, Pressure Controls. Relays with Latching circuit Other contactors with Interlocking circuit. Advantages of D.O.L. motor starters: Fail safe operation of the control circuit Simple operation Low initial cost Remote stop and start features of control. Disadvantages of D.O.L. motor starters: No current limiting ability, therefore maximum current occurs at start.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Interlocking circuits: Interlocking uses the auxiliary contacts on contactors to automatically bring in other components, or stop them if a fault appears in another circuit.
The interlocking circuit represents the control circuit for a refrigerated coolroom operating with a three phase evaporator, condenser fan motor and compressor drive motor. Note: The diagram interlocking compressor drive motor in a refrigerated coolroom. The compressor drive motor contactor will be energised when the evaporator fan motor contactor is energised via EF/1. The normally closed auxiliary (EF/2), will indicate fan failure.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Practical Exercise Three Phase D.O.L. Motor Starter Aim: To construct an electrical wiring circuit diagram for a three phase exhaust fan motor in accordance with the following details: 415 volt power circuit Isolation switch / fuses etc D.O.L. contactor Star connection. Control circuit consists of: STOP/START switching and overload protection for the fan motor.
Note:
Complete circuit diagram on the page provided below. Read the procedure completely. Complete a risk assessment for the task. On completion of your circuit diagram proceed to electrical workshop and hard wire on three phase training boards, using the correct meters tools and safety procedures. Test run on completion of connection and check current and voltages under supervision of your teacher or mentor.
Procedure:
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Practical Exercise Three Phase Motor Connections Aim: To draw a complete wiring diagram for a three phase motor for star and then delta in accordance with the following details: Procedure: Electrical training boards in workshop. 415 volt power supply Isolation switch Fuses or circuit breaker D.O.L. motor contactor 240 volt control circuit ON/OFF control switch Overload Three phase motor. Condenser fan to be energized via contactors N/O auxiliary. Note: drawing to be done on attached page. On completion of circuit diagram check with you teacher/mentor and proceed to: Isolate the power supply and proceed to connect the motor circuit (STAR). Electrical meters: Megohm-meter Multi-meter Tong-ammeter Record Results: Star: Resistances across each winding: 1 Line voltage: Phase voltage: Current: 2 3 2 3 Test the motor windings resistances and record. Switch the power supply on and measure the operating voltages, current and record results. Reverse the direction of the motor.
Delta: Resistances across each winding: 1 Line voltage: Phase voltage: Current:
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Review Questions Section No: 3 Q.1 Describe the operation of a DOL motor starter:
Q.2
Q.3
What is the major advantage of a D.O.L. contactor over an isolation control switch?
Q.4
List three types of motor starters used to operate three phase induction motors:
Q.5
Draw an electrical control circuit for D.O.L. contactor controlled by a start / stop switch. (space provided on the next page).
Q.6
With the aid of the above circuit diagram, explain how the control circuit operates:
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
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Section No: 5
Always have the current rating of the overload matching the FLA of the motor it is protecting.
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Overloads for three phase motors will either be; 1. Current sensing 2. Heat detecting.
Magnetic Overload The magnetic overload is current sensing, and will only operate if the current flow through it exceeds its rating. They are normally only wired in series to two of the phases and operate a set of contacts in series with the control circuit. They have fixed ratings and are found on imported package air conditioning systems.
Heat sensing
These devices are usually embeded in the motor windings when it is manufactured. They are connected in series with the control circuit supplying the contactor coil and open circuit if the motor windings temperature exceeds their rating. The new types are made from semi-conductor material,(thermistor), while the older types used bimetal strips that were manufactured as a set of contacts. Both embeded types are non-adjustable, and the motor has to cool down before they will reset automatically.
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Setting and re-setting overloads: Only thermal overload relays can be adjusted and the correct setting must be made to the motor specifications. Set at motor full load amperes. If the setting is to low nuisance tripping may occur. A motor may burn out due to a high setting. This is particularly relevant for modern motors because their design efficiency has increased along with operating temperatures.
Under Voltage and Over Voltage Relays: The under voltage relay will respond to low voltage on the control and motor circuit and the effects of under voltage are as follows: Relays and contactors will not operate correctly. Sensing devices do not respond as required. Increase in temperature of motor windings dur to the lack of inductance with will allow more current to flow. The over voltage relay responds to over voltage on the control and motor circuit and the effects of over voltage are as follows: Increase power consumption in the control circuit. Sensing and controlling devices operating incorrectly. Increase in motor temperature because more current will be push by the higher voltage.. Electronic motor protection relays: The electronic motor protection relays offer the ultimate protection functions by incorporating thermal, magnetic and voltage protection.
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Isolation Switch:
The AS/NZS 3000 requires that every circuit and apparatus has a point of isolation. In the event of electrical or mechanical hazard, the circuit between the motor supply and its associated control circuit must be capable of being isolated through the installation of an approved isolation switch. A licensed refrigeration mechanic is allowed to repair and replace up to the isolation switch, but not the switch itself.
Motor Timer Protection: (lock out timers) Timers can be used to protect three phase motors against the problems associated from short cycling. These problems include: Increased heating of protective devices. Increase in temperature of the motor Extra stress placed on the motor. Control contacts, both power and control, have increased operation which will result in lowering the life span Coupling between motor and load is subjected to increased stress.
Note: To become competent in motor fault finding it is essential that you have on the job training guided by a licensed mentor in the workplace.
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Review Questions Section No: 4 Q.1 List four problems that are associated with excessive current flow in a three phase induction motor:
Q.2
Q.3
Q.4
List two main considerations that need to be taken into account when setting overloads:
Q.5
Q.6
List two problems associated with under voltage in a three phase motor circuit:
Q.7
List two problems associated with over voltage in a three phase motor circuit:
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Q.8
Electronic motor protection relays offer three protective functions. What are they?
Q.9
Q.10
Timers can be used to protect three phase motors against the problems associated from short cycling. List three of these problems:
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Symbol
Applications: anything that doesn't require the motor to start loaded; Domestic compressor (equalize or the off cycle) Fans, Load comes with speed increase. Pumps, the same as above
If a split phase motor is designed for two speeds it will have three windings; One will be the start winding so it will have the highest resistance. The second highest resistance will be the slower of the two speeds, because the there needs to be more poles for the slower the motor, therefore more copper windings, more resistance. The third winding should have the lowest resistance. This means less copper windings for fewer poles.
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Reverse Rotation
Reverse connection of either (but not both) starting or running windings connections are swapped around.
Even though both terminal links are moved it only changes the point that the A.C. is first applied to one winding.
Characteristics of a split phase motor: The run winding by itself does not develop starting torque. The start winding, working with the run winding, is needed to develop starting torque. Starting currents are around five to seven times the rated motor current. The starting current is not damaging because it decreases as soon as the motor accelerates. Because of the high starting current the starting torque developed is around 1.5 to 2 times the rated full load torque.
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Split Phase Motors in Sealed compressor: The signal phase hermetic motor/compressor unit is used in both refrigeration and air conditioning systems consists of a compressor with a drive shaft connected to the rotor of the motor which is hung on springs that are attached to an internal frame. The whole unit is fitted into a two piece pressed metal housing, called the dome and hermetically sealed by welding the two parts together Note: the electrical motor terminal connections are as follows: start winding connects between S and C run winding between R and C C is common to both windings.
Correct electrical terminal identification: There are three terminal connections on a hermetically sealed motor compressor and are as follows: Common (C), Start (S) and Run (R). To identify the correct terminal connection the following procedure applies. The highest resistance reading is between the start and run terminals The middle resistance reading is between the start and common terminals. The lowest resistance reading is between the run and common terminals. Testing and fault finding: The insulation resistance between the motor frame and all windings and active conductors must be greater than 30 meg-ohm. Remember when it was new its resistance started out so high it could not be measured (infinite). Damage to start windings could be due to one of the following: Starting device not opening because of a sticking centrifugal switch or a malfunction of the current sensing device (current coil / solid state relay). Frequent stop / start Excessive load on the motor Incorrect winding connections Low supply voltage.
Possible causes of non-starting are as follows: Loss of supply voltage Overload reset button needs to be reset Open circuit in either winding Locked rotor Faulty relay Excessive load on compressor motor (Trips out on overload) operates on a single phase supply. low starting torque and high slip on heavy load. output ratings are: 250 watts 1.5kW.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Hermetic Compressor
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Practical Exercise Split Phase Motor Aim: With the aid of the ohms scale of a multi-meter and meg-ohm meter determine the motor winding resistances and check for earth leakage on a split phase sealed motor compressor.
Procedure:
After obtaining the results place the appropriate resistance readings across each winding connection and indicate the Common (C), Start (S) and Run (R) terminals on the diagram below.
Recorded results:
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Operation When the motor is at rest the springs hold the flyweight in, which keeps the rotating element pushing against the switch closing the contacts. As the motor accelerates from rest centrifugal force starts to be exerted by the flyweights against the springs, when the rotor speed reaches about 75% of its rated speed the centrifugal action will overcome the spring tension allowing the rotating element to release the N/C switch opening its contacts disconnecting the start winding from the power supply. Different speed motors have different tension spring. e.g. A 2880 rev / min motor will have springs with a greater tension than a motor which operate at a speed of 960 rev/min. Advantages If the speed of the motor decreases (because of increased load etc.), the centrifugal action will also decrease allowing the switch to reset energizing the start winding. This gives the motor extra torque to try to get back up to speed again. Disadvantages Cannot be used on hermetic compressors because the flash from the arcing contacts will burn the refrigerant. (The refrigerant vapour is used to cool the windings of the sealed unit compressors). Applications Motors that drive open compressors, pumps, fans or any application where the motor is air cooled.
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Operation. When the motor is energized it initially draws Locked Rotor Current, which is sufficient to energize the relay coil lifting the armature closing the N/O contacts connecting the start winding circuit to the supply, which starts the motors rotation. As the motor builds up to its rated speed the increasing inductive reactance within the motor reduces the current flow through the run windings and the relay coil. At about 75% of the motors rated speed the current flow should be insufficient to hold the relay closed, opening the start winding circuit. Disadvantages Current coil relays are designed to suit individual motors because the LRC and running currents are critical to the operation of the relay. Current coil relays need to be mounted the correct way up, as they rely on gravity to complete the disconnecting process. Advantage As with the centrifugal switch, if the motor slows for load reasons, the current draw will increase and some current coil relays will pull their start winding back into the circuit.
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Potential Coil Relay. A potential coil (voltage coil) is used for the magnetic force needed to move the armature of the relay. The contacts in this relay are normally closed (N/C), and open only when sufficient back EMF is generated in the auxiliary winding. The high voltage produced in the auxiliary winding is a result of the transformer action
between adjacent coils. Operation. At the instant of start up both the main and auxiliary windings are connected to the supply, as the rotational speed builds up so does the induced EMF in the auxiliary winding. The potential relays coil is connected in parallel across the auxiliary winding, and responds to the voltage flowing in that winding. At about 75% of the motors rated speed the induced EMF in the auxiliary winding is around 350 to 400 volts, which is the voltage needed to energizes the coil opening the N/C contacts that are in series with the auxiliary winding. The motor continues to induce the high voltage in the auxiliary winding holding the coil energized. Current flow in the potential coil is restricted by the high resistance of the small CSA conductor of the potential coil. Potential coil relays are used with high torque, capacitor start motors, because the contacts are closed at start up and only opening as the motor reaches its running speed therefore the current will be low which will reduce arcing at the contact points.
If Potential Coil Relays needs to be replaced, one of the same coil characteristics should be selected so that the pick up voltage (the voltage that is needed to make the relay work), will be available from the start winding, as the motor reaches 75% of its rated speed.
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Solid State Relay. (SSR) The solid state relay has no moving parts. It is a positive temperature co-efficient (PTC) thermistor that increases its resistance when heated by the start winding current passing through it.
Operation At start up the SSR is cold allowing sufficient current to flow to the start winding to energize it. Within milliseconds the current flowing through the SSR causes it to heat up increasing the resistance, reducing the current flowing to the start winding to milliamps. Although there is still a 240 volts potential on the start winding, the current flow through it is so small it produces very little magnetic effect in the windings, but produces enough heating effect in the SSR to maintain the resistance. Disadvantages The Solid State relay can be affected by other sources of heat, such as radiated heat from a discharge pipe and should be mounted away from any heat source. Be careful when handling Solid State relays, as they can get hot. This type of relay requires a cool down time between starts, and is not designed for operation on compressors that have a high number of starts per hour, such as commercial systems. Advantage Unlike the Current Coil and Potential Coil Relay, the SSR does not have to be exactly sized to suit the electrical characteristics of the motor. One relay can be used to control the start winding circuit for motors ranging in size from 0.25 kW to 0.37 kW.
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Heat Sensing
External Bi-metal thermostat overload. This type of overload is often referred to as a Klixon (brand name), because it clicks off when it reaches a predetermined temperature, and clicks on when the reset is pushed. This type of overload is fitted on the outside case of the motor, and it normally is accessible for resetting manually. # not used on hermetic motors.
These overloads automatic reset after they have cooled. They are fitted to the outside of Hermetic compressors in the terminal box next to the motor terminals. They must have good thermal contact with the body of the compressor. The adjustment screw should not be fiddled with.
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Review Questions Section No: 5 Q.1 Which of the windings is open circuited by the current sensing switch?
Q.2
Explain how you would reverse the direction of rotation of a split phase motor:
Q.3
Explain the operation of the following switching mechanisms on a split phase motor: Current coil relay:
Q.4
When energised, a split phase induction motor fails to start. List in point form the steps you would take to locate the fault:
Q.5
Describe the operation of a centrifugal switch when used on a split phase motor:
Q.6
When energised a split phase induction motor continually trips out on its thermal overload. List a least four possible faults that would cause this condition:
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Q.7
A 50 HZ two pole split phase induction motor operates on full speed with a 4% slip. Calculate the full load rotor speed:
Q.8
In the space below draw an electrical wiring diagram for a split phase compressor motor controlled by a thermostat, current coil relay and overload protection. Include on your drawing the motor windings and terminal connections.
Q.9
You are to replace the current coil relay with a solid state relay within the circuit above. Draw an appropriate electrical circuit diagram to meet the requirements for a solid state relay.
Q10.
After checking a hermetically sealed motor compressor the following resistances were measured between the terminals. Indicate the common (C), start (S) and run (R) terminals on the diagram below:
47 ohms
22 ohms
25 ohms
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Capacitors must be matched to the motor to obtain optimum starting torque. Manufacturers will specify the capacitor value required for a particular motor. Start capacitors can range from 40f to 180f. Start capacitors remain in the circuit for approximately three seconds and are limited on the number of starts per hour. This depends on the motor design. Increasing the starting torque with this type of motor is accompanied by an increase in starting current.
Application Small commercial compressors that will cycle loaded, i.e., high discharge pressure. Reverse rotation same as split phase motor.
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Symbol/Schematic
Characteristics: Starting relay required; Centrifugal switch or potential coil are normally used. Main and auxiliary windings. Running capacitor Starting capacitor. High starting torque. Capacitors must be matched to motor
Operation. Similar to C.S.I.R. motor with the exception that two capacitors are connected in parallel and then in series to the auxiliary terminal (winding). Once the motor reaches 75% of its rated speed the starting capacitor is switched out of the circuit leaving the running capacitor connected in series with the auxiliary winding. This arrangement gives a high starting torque (reduced phase angle) and good running torque. Application. Large single-phase compressors that starts loaded. e.g. low temps. Reverse rotation same as Split Phase motor.
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Characteristics: No starting relay required. On small fan motors both main and auxiliary windings can have the same resistance, but with compressors there is a difference in resistance. Picture of a Fan Deck motor assembly Capacitor 3 to 80MF Quiet electrical characteristics, i.e. won't upset T. V. at start up. Torque Low starting so, motor starts unloaded. Good running torque.
Operation At start up both windings are energized but having the capacitor in series with the auxiliary will cause its magnetic field to be less "out of phase" with the supply voltage. This will result in the rotor's magnetic field to misalign with the main windings magnetic field given the rotor its rotation. The capacitor and auxiliary winding remain energized during operation, giving the motor its good running torque. They are used on fans and pumps because with these devices the load increases with speed. They can all be used with compressors that unload on the off cycle. i.e. capillary systems Applications. Evaporator fans, condense pumps and compressors in residential. A/C. Reverse rotation - Connect active to other side of capacitor. Compressor motors should not be reversed.
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Service Points.
Capacitors have a limited life so always test the capacitor on a single phase motor before you replace the motor.
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Shaded pole
Symbol Characteristics Picture Low torque Can be stalled without damage therefore they do not have an overload. Has a single winding. No starting relay required.
Operation: The shading ring causes the defection in the magnetic flux, starting the rotor to turn. Uses/ Applications: -Small evaporator fans. -Non critical timers -Two position value/damper motors with spring return. Reverse rotation: Must be dismantled and rotor and shaft must be reversed in stator.
Synchronous Motors.
Symbol:
Characteristics: Single winding of high resistance. No starting winding or relay. Permanent magnets in rotor. No overload.
Operation. A.C. is applied to the stator winding creating a magnetic field across the rotor. Rotation happens because the rotor's permanent magnets will react to the stators electromagnetism. Synchronous motors are so named because they spin at synchronous speed, (e.g. 2 pole motor will have a shaft rotation of 3000 revs per minute). Application Timers (because they rotate at an exact speed). Small modulating motors. Reversing Rotation, is the same as the Shaded Pole motor in as much as the motor must be dismantled and the rotor reversed in the stator.
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2.
3.
Operation. The Series Universal Motor (Commutator Motor), is not an Induction motor, the current flowing in the armature (rotor) is not induced it is fed directly from the supply via a set of brushes and the commutator. The main magnetic field is set up by two field poles mounted on the stator. It remains in a constant position. The armature has overlapping coils wound on to it similar to an induction motors stator but each coils leads are connected to individual segments on the commutator. The commutator converts the AC to DC and because of the way the brushes are positioned, supplies the voltage only to the coil that is being affected by the field coils magnetic flux. This will position the armature magnetic field to give an alternating magnetic field reacting with a permanent magnetic field resulting in rotational. The Commutator motor can be supplied with either AC or DC voltage of the same intensity. e.g. 240V AC or 240V DC. Applications: Portable hand held tools Drills (240 and Battery) sanders jig saws routers grinders
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Review Questions Section No: 6, 7 and 8 Q.1 Name four methods used to switch the start/auxiliary winding of a split phase motor.
Q.2
Describe how would you change the direction of a shaded pole motor:
Q.3
Explain why a capacitor start motor can develop a greater starting torque than a split phase motor.
Q.4
Explain how you would change the direction of a permanently split capacitor motor:
Q.5
Q.6
Which of the following motors is best suited for a single phase evaporator fan motor? (a) (b) (c) (d) Series universal motor Permanently split capacitor motor Split phase motor. Capacitor start motor
Q.7
The single phase motor which is most suitable for a domestic refrigerator evaporator fan motor is the: (a) (b) (c) (d) Capacitor start motor Series universal motor Shaded pole motor Permanently split capacitor motor.
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Q.8
Which of the following motors would be best suited for a domestic refrigerator compressor? (a) (b) (c) (d) Shade pole motor Permanently split capacitor Capacitor start / capacitor run motor Split phase motor :
Q.9
List a least three desirable characteristics of a capacitor start / capacitor run motor
Q.10
Why would you use a capacitor start capacitor run motor in preference to a split phase motor compressor on a refrigeration system that has a TX valve as a refrigerant metering device?
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60
Megger the windings to earth, at least 1Mohm for open type motors and 30 Meg-ohms for hermetic. Remember when the motor was new it had a resistance that was so great it could not measured, (infinite). Do not megger a hermetic motor while it is under a vacuum, the risk of insulation damage is very high under vacuum conditions.* Overloads. Overloads are generally not serviceable, and if the fail they are replaced. Testing is limited to continuity check and checking of the mechanical action of the three phase overload relays, although you can purchase replacement bi-metal heaters for the larger three phase thermal overload relays. If the overload is tripping, and the motor current draw is within the FLA rating do not attempt to adjust three phase overload relay current setting, as the overload tripping mechanism has failed through age or other means, replace the overload completely. Always replace an overload with one of the same rating and calibration. Some overloads are buried in the windings, so if they fail it will be necessary to fit a replacement externally. Fitting an overload externally requires careful selection as the heat generated by the windings will take a lot longer to conduct to the frame of the motor where the replacement overload will have to be fitted. As a general rule if is better to replace the buried temperature sensing type with a current sensing device that is set to the FLA of the motor
Testing Capacitors Tests can be made for continuity which will indicate short circuits or open circuits. * On run capacitors disconnect the Bleed resistor from one terminal. Test 1. Set the ohmmeter to the Rx1 scale, and do a continuity check between the terminals, if there is a circuit the capacitor has a short circuit between the plates Test 2. Set the ohmmeter to the Rx10000 scale, do a continuity check. There should be an immediate indication of a short circuit, leave the meter connected and wait for the capacitor to charge up as the electrons (from the battery in the meter), flow onto the negative plate. The number of electrons flowing will reduce as the plate fills with electrons, which will be indicated on the ohmmeter as if the resistance of the capacitor is increasing. This is an indication that the capacitor is serviceable, and could be put back into operation. Test 3. Some capacitors have a metal case which can allow the outer wound plate to track to earth. A megohm meter is used to test for shorts to earth. Use the lowest voltage output of the megger to do this test. Connect one lead of the megger to one terminal, and the other lead to the case, operate megger, there should be a very high resistance to earth. Do the same of the other plates terminal. Do not megger between terminals as the dielectric between the plates is not designed to withstand the high DC voltage from a megger. To accurately test a capacitor use a capacitor analyser. Remember to reconnect the bleed resistor on run type capacitors. Symptoms of Faults Run Capacitors. An open circuit on the run capacitor connected to a PSC motor will effectively disconnected the auxiliary winding from the supply therefore the motor will not turn, it will just hum. An open circuit in the capacitor on a CSCR motor will reduce the running performance to about the value of a split phase motor. The starting relay may chatter, and the motor overload should begin to heat because of the excessive current flowing in the windings
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A short circuited capacitor on either a PSC or CSCR motor should cause excessive current flow. Start Capacitor. An open circuited capacitor on a CSIR motor will disconnect the start winding from the supply leaving the motor to hum. A short or open circuited capacitor on a CSCR motor will reduce the starting torque only. A short circuited capacitor on a CSIR motor normally reduces the starting torque to a point where it will not start to turn against a head pressure. Mechanical Testing Electric motors are used because they are reliable and rugged, they rarely suffer from mechanical failure other than bearing replacement. During routine servicing it is a good practise to check the mounting of a motor to ensure that it is held down firmly, and that the coupling to the compressor or fan is secure as well.
Another check that can be made on site is to feel for bearing movement. there should be no vertical play on the motor shaft, there can be horizontal slide of the shaft in and out of the end plates, but if you push it in it should spring back out, as there is a spring fitted to the back end bearing of some cheaper motors to ensure that the rotor lines up with the stator.
Be-careful of moving parts while you are doing this test. Place a long screw driver against the end plate of the motor and then cover the handle of the screwdriver with your ear you can hear if the bearings are making a grinding sound. If the bearing is making this sound it means that they will need replacement soon. This check generally can not be made on motors directly coupled to compressors, as the piston movement sound is transferred to the shaft and bearings.
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Starting Relays Centrifugal Switch. Centrifugal switches suffer from mechanical wear because the switching arm actually rubs against the rotating element. Over time the switching arm will break off, this requires switch replacement. This problem is indicated by the motor not starting to rotate combined with excessive current draw. Another mechanical problem that can occur is that the springs that hold the flyweight and determine the speed at which the switch will open circuit break. Symptom of this is that the motor will not start each time, and when it does it appears to be slow at getting away. ie. The starting torque is reduced because the start winding is removed from the circuit too early. What normally happens is that the motor will kick off but slow down immediately causing the centrifugal switch to reset and give the motor another kick along. This will continue to be repeated until the motor overload heats up and trips open. There is no electrical test for this you need to dismantle the motor and look. Remember replace the spring or the centrifugal switch with one of the same rating. Current Coil Relay. Because the conductor in the coil of the currents coil relay is so large in diameter not much can go wrong with it, other than mechanical breaks at the connection points. There are a few things that go wrong with the contacts. Burning is one which makes the contacts a high resistance point. This is indicated by the motor starting some times but not others. To check for this remove the relay from the motor, connect an ohmmeter between the pin connection points on the relay turn the relay upside down and check the ohm reading it should be a perfect circuit. Repeat this a few times, each time check the ohmmeter reading it should be the same. If there is any reading that is not a perfect circuit keep the relay upside down but shake it side ways to see if the reading will improve. Replace the relay if the readings are higher than 5 ohms. Another problem can be the contact points welding together. This is indicated by the motor starting but continuing to draw a high current and not getting up to full speed. This is checked the same way as before, except that when the relay is returned to the upright position the ohmmeter will continue to show a circuit. Replace the relay. It is critical to make sure the ohmmeter is working correctly for both of these tests. Potential Coil Relay. The potential coil relay has one set of normal close contacts wired in series with the start winding. The contacts are moved by the potential coil that is wired in parallel across the start winding. The potential coil needs about 380 volts to work. This is obtained via the step up transformer action between the run winding (primary) and the start winding (secondary). Faults. Start winding stays energized. Either the potential coil has burnt out or the switch contacts have welded together, use an ohmmeter to test the coil, and a screw driver to feel for the welded contacts. The coil should have a high resistance, you may have to adjust to a high range setting on the ohmmeter. Motor hums but will not start. Normally dirty contact points resulting in an open circuit to the start winding. The contacts can be cleaned on a lot of potential coil relays so open it up and clean them with a points file or fine wet and dry paper. Solid State Relay. The solid state relay is made from a Positive Temperature Co-efficient semi-conducting material which needs time to cool between starts. This is the biggest problem. If the relay hasnt cooled it will not allow a current to flow to the start winding therefore the motor will not rotate but it will hum and drop out on its overload. If short cycling of the motor is indicated turn off the machine for 15 minutes then re-start it checking the operation of the relay with an ammeter to the start winding. Other than short cycling of the device the motor is connect to not a lot can go wrong, as the are no moving parts. Some early relays developed an oxide between the semi-conductor and its holder causing an open circuit.
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Answers to Review Questions: Section No: 1 Q.1 Q.2 Q.3 Q.4 Star and Delta Yes a single phase motor can be connected to a three phase supply as long as a neutral is present. Phase voltage = 415 volts Line Voltage: Phase Voltage: Line Current: Line voltage = 415 volts.
Vline Vp Vp 415volts
Vl 415volts
Iline 3 Ip
Ip Iline 3
1.732 5
8.66amperes 5amperes
8.66 1.732
240volts
Il Ip 3.6amperes
Il 3.6amperes
Phase current
Section No: 2 Q.1 Q.2 Q.3 Q.4 Q.5 Q.6 Q.7 Q.8 Q.9 Q.10 Q.11 Q.12 (d) (c) (b) (c) (a) (c) (d) (a) Synchronous. Swap any two phase connections. because of the slip speed. Actual speed = 120 x 50 X 0.96 = 1440 rpm. 4
Q.13
any two lines = 415 volts. any line and earth = 240 volts. any line and neutral = 240 volts. earth and neutral = zero volts.
Q.14
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Star Y
L1
L2 L2
L3
A1
B1
C1
B2
C2
A2
Delta
L1
L2 L2
L3
A1
B1
C1
B2
C2
A2
Fig. 2
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Section No: 3 Q.1 The three contacts when closed supply the electrical power to three phase motor windings. An ON/OFF control switch when closed energises the contactor coil KI through the overload and thus creating an electromagnet causing the three contacts close. Coil, armature, electrical contacts. Can switch the three phase appliance on and off automatically and provides overload protection. Q.5 D.O.L. Star Delta Auto- transformer Primary Resistance Part Winding. Electronic Soft Start. Secondary resistance.
Section No: 4 Q.1 Mechanical load is greater than the electrical rating (kW) Rotor shaft locked Partial loss of supply voltage Reduction in supply phase voltages Winding insulation breakdown. Fuses, circuit breakers, thermal overload, magnetic overload. Thermal overload (bi-metal strip)Thermistors. Not to be set to low to prevent nuisance tripping Not to high causing motor burn out. A heater senses a rise in temperature on either one of the phases, this rise in temperature causes the bi-metal strips to warp and through a lever mechanism the overload switch is opened. Relays and contactors will not operate correctly. Sensing devices do not respond as required. Increase in temperature of motor windings.
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
Q.6
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Q.7 Q.8
Increase power consumption in the control circuit. Sensing and controlling devices operating incorrectly. Increase in motor temperature. Thermal Magnetic Voltage To isolate electrical circuit between the motor supply and or its associated control circuit in the event of electrical or mechanical hazards. Increased heating of protective devices Increase in temperature of the motor Extra stress placed on the motor Control contacts, both power and control, have increased operation which will result in lower life span. Coupling between motor and load is subjected to increased stress.
Q.9 Q.10
Section No: 5 Q.1 Q.2 Q.3a Q.3b Q.4 Q.5 Q.6 When the motor is at standstill the centrifugal switch is closed. Both start and run are energised. Centrifugal switch will open at approximately 75% full motor speed dropping the start winding out and leaving the run in. Locked rotor Open circuit in either winding Faulty relay Excessive load on motor trips out on overload. N = 120 x f P x slip N = 120 x 50 X 0.96 2 N = 2880 rpm Ensure correct voltage is present. Isolate power supply to motor. Check relay and overload operation. With the motor terminals disconnected check the winding resistance against the manufacturers specifications using an ohm meter or megger. Start Change either the start or run winding connections but not both.
Circuit energised causes a high rush or current through the relay coil. Relay contacts close and energises both start and run. As motor reaches full speed current falls and relay contacts to open. The start winding drops out and leaves the run winding in circuit. Voltage is applied to the motor. As the current flows through the SSR it causes the semi conductor to heat up. The semi conductor will reach a temperature where its resistance will change for very low to very high. This will reduce the current flow to a trickle maintaining the heat in the semi conductor.
Q.7
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
67
Q.8
R C S
O/L
Q.9
R C S
O/L
Q10
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
68
47 ohms
22 ohms
25 ohms
Section No: 6 Q.1 Q.2 Q.3 Q.4 Q.5 Q.6 Q.7 Q.8 Q.9 The contacts are normally closed energising both windings (aux & main). The contacts will open at approximately 75% full speed due the back EMF generated in the auxiliary winding. The auxiliary drops out and leaves the main in circuit. (b) (c) (d) Reduced noise and vibration. Improved motor efficiency and power factor. Current coil relay can be used on this type of motor. Because the refrigeration system would require a motor with high starting and running torques to compensate for varying loads. Split phase motor has both low starting and running torques. Speed sensing, current sensing or voltage sensing devices. Which include: centrifugal switch, current coil relay, solid state relay and potential coil relay. Dismantling and turning the stator end for end, relative to the rotor. The capacitor start motor has a start capacitor connected in series with the start winding. By switching the supply connection from one side of the capacitor to the other.
Q.10
NRE 8 Three Phase/Signal Phase Motors and Circuits Compiled by Bruce Davison, Greg Riach & Robert Baker
69