FAULT DIAGNOSIS AND MAINTENANCE OF DC MACHINES

A DC machine can either be a motor or a generator. The construction is similar for both.

Construction of a DC machine

A DC machines has two major parts, a stator (stationery part) and a rotor (rotating part). There
are two windings i.e. the field winding arranged in the stator and the armature winding arranged
in the rotor.

Yoke/frame- provides protection of the inner parts from outer environments and provides
mechanical support of the inner parts of the device.
Pole core- consists of the pole shoe and field windings rests on the pole shoe. The pole shoe with
field windings is inserted into the slots of the pole core. When field winding is energized, the
pole gives magnetic flux.

Armature core- consists of the armature windings which rest on the slots of the core.

Commutator- is used for collection of current from the armature winding and the brush collects
current from the commutator.

For smooth operation, bearings are used .A fan is employed to remove heat generated during the
operation of a machine.

In a DC generator, the shaft (which holds the armature windings) is rotated by means of a prime
mover and the armature windings cut across the magnetic field produced by the field windings
and an EMF is induced in the armature windings. It is tapped through the commutator and brush.

In a DC motor, a DC supply is given to the armature windings. Current therefore flows in a coil
placed in a magnetic field and therefore a force is experienced causing the shaft to rotate.

Common faults in a DC machine

a. Short Circuit- It is a problem in an electrical circuit where two or more wires that are not
supposed to come in contact come in to contact. This results to a high amount of current
to flow in the circuit destroying components, melting insulations and burning coils.
b. Open circuit- This is where no current flows. An open circuit in a machine winding
causes current not to flow and machine fails to operate.
c. Speed Vibration- this is the un-uniform rotating speed of a machine. It is caused by poor
installation of a machine on the ground, loose nuts and bolts and misalignment of the
armature and yoke during assembling.
d. Burnt coil windings- Most common fault in DC machines. This is caused by over-heating
of the machine or overloading of the machine causing a high current to flow from the
supply which makes the windings overheat.
e. Mechanical noise- caused by the wear and tear of the ball bearing of the machine in the
shaft, poor installation and misalignment of the armature and yoke of the machine.
Causes of motor failure

a. Low insulation resistance- with continuous use, the resistance level of a motor decreases
which is likely to lead to a short circuit.
b. Overheating- overheating leads to the deterioration of the motor winding insulation.
Overheating can be as a result of the environment, failed fan or a short circuit in the
windings.
c. Electrical overload- This is where a motor draws too much current than its capacity.
There are devices such as CBs that prevent excess current to flow into the motor.
d. Moisture- it leads to rusting and corrosion of rotors, shafts and bearings. It is important to
keep a motor dry.
e. Dirt- Dirt and dust affects the insulation of the windings when it accumulates. It also
blocks the motor cooling fan which could lead to overheating.
f. Poor installation- leads to vibration during motor operation and could damage internal
devices of the motor or misalign the rotor and yoke.

Procedure for locating faults in DC machines

1. Visual inspection of the machine- this helps in looking out for signs of smoke, wear and
tear and loose parts.
2. Checking power supply- It is the checking of the voltage from the supply of the machine.
Voltmeter is used to measure voltage and a continuity test is conducted for the power
supply cables from the supply to the motor and the control system.
3. Continuity test- done at the winding terminals to help detect any open circuit in the
windings.
4. Insulation resistance test- used to detect any short circuits between the windings or the
windings and the frame. A continuity tester is used between the armature windings and
field windings. Continuity between the two windings or low resistance between the
shows that there could be a short circuit.
5. Grounding of the Machine- From the previous tests, a fault is likely to have been
identified. The machine is then grounded for repair and maintenance.

Dismantling and assembling of motors

Dismantling

 First remove the pulley of the motor on the shaft, remove the fan cover and then open the
fan which is screwed on the shaft of motor for cooling purposes.
 Open the nuts/bolts or screws of the end covers of the motor using a spanner or screw
drivers.
 Two screw drivers are inserted in motor cover and apply a little pressure internally as a
result the cover of the motor is easily opened.
  After that, the rotor of the motor will easily come out.
 The bearings of the motor are dipped in kerosene oil and grease applied to the bearings.
 Clean the stator carefully

Assembling

 The end cover of the motor is screwed with the yoke

 Enter the rotor of the motor in stator
 Fit the rotor in exact position in stator and screw the front cover of the motor.
 The cooling fan is then screwed on the shaft.
 Tighten the cover of the cooling fan with the yoke of the motor.

Inspection and maintenance of motors

Electric motor maintenance aims to prevent critical breakdowns rather than repairing them.

It includes:-

1. Perform a visual inspection to assess the general condition of the motor. Check for
cracks, broken welds, and missing parts.
2. Perform the following tests on the stator windings:- Insulation resistance (IR),
Polarization index (PI) and winding resistance (Terminal to terminal resistance).
3. Rotate the rotor manually and check for any defects in the bearings and shafts.
4. Run the rotor at no load. Measure and record currents vibration, bearing temperatures and
temperature rise.
5. Measure and record the motor end play (radial and axial movement of the rotor in the
bearing)
6. Dismantle the motor and remove the rotor.

Stator works

7. Clean the windings using low pressure steam if they are contaminated with dust, oil or
grease.
8. Dry the stator in an oven at a temperature of 1050C for about 6 hours.
9. Take the IR and PI tests which should improve.
10. Inspect the motor cable insulation for cracks, overheating and brittleness.
11. Inspect the stator insulation for cracks, brittleness and puffing.
12. Inspect the slot wedge and bracing system in the stator for looseness.
13. Inspect the laminations in the stator core for looseness, damage due to rotor rubbing,
localized overheating and blockage of the vent ducts

Rotor works

14. If there is dust, grease or oil contamination on the rotor, clean it with low pressure steam.
 15. Inspect the rotor laminations for looseness, cracks and damage due to rubbing with the
stator and localized overheating.
16. Inspect the rotor shaft fans of the motor for cracks. If there are signs of cracks, perform
dye penetrant and UV light inspection.
17. Inspect the bars and end rings of the rotor for cracks, looseness a and localized
overheating. If there are signs of cracks, perform the manual rotation test as well as dye
penetrant and ultraviolet light inspection.
18. Inspect the rotor shaft for cracks.
19. Mount the rotor on a lathe and measure the eccentricity of the shaft

Bearings

20. Inspect the bearings for cracks, wear etc. replace where necessary.

Functional Tests performed after repair of DC machines.

1. Load test- A load is connected to the motor and varied while observing characteristics
such as speed, efficiency and temperature rise. It is used to determine the rating of the
machine. When a machine is running, then some energy is lost as heat and too much heat
affects the insulation of the machine. Therefore the load is set at a value that can operate
within the temperature limit.
2. No load test- supply is provided to a machine but no load is connected. This test is used
to determine the no load losses i.e. core losses, friction and windage losses.
3. Open circuit test- used to determine the open circuit characteristics or magnetizing
characteristics of a DC machine. The armature windings are left as an open circuit and
not connected to any load. It gives the mmf and excitation current needed to generate a
certain voltage on no load at a fixed speed.
4. Short circuit test- it is done to determine the voltage drop across the armature at any load
current. The Armature windings are short circuited with an ammeter to measure the short
circuit current.
5. Speed/rotation test- used to determine speed and direction of rotation of the machine.
6. Insulation resistance test- it is done to determine the resistance of the insulation and
prevent short circuit from happening.

Safety precautions when dealing with DC Machines

 Use of correct tools

 Avoid loss of parts
 Use correct test instruments
 Personal safety- gloves, safety boots etc