General Electric Australia

EXCAVATOR SUPPORT

Excavator Systems Training Program

Resource Material

General Information and Procedures

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

General Information and Procedures

Module Contents
• Section One - Commutation
• Section Two - Commutator Maintenance
• Section Three - Motor Troubleshooting
• Section Four - Commutator Film Building
• Section Five - Surface Rounding Brush
• Section Six - Commutator Stoning Information
• Section Seven - Cleaning of Electrical Winding in DC
Motors and Generators.
• Section Eight - Brush Maintenance
• Section Nine - Commutation Adjustment – Brush
Potential Measurement.
• Section Ten - Mechanical Aspects of Commutator
Maintenance.
• Section Eleven - Vibration Identification.
• Section Twelve - Troubleshooting a Commutating
Problem
• Section Thirteen - Armature Changeout Instruction.
• Section Fourteen - Selective Maintenance for Electrical
Rotating Equipment.
• Section Fifteen - Reliability Factors of Electrical Rotating
Equipment.
• Section Sixteen - C - Sheets

MAY 2009 Page 2 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Table of Figures
Figure 1 Commutation .......................................................................................................................... 6
Figure 2 Magnetic Flux Distortions .................................................................................................. 7
Figure 3 Addition of Inter-poles ........................................................................................................ 7
Figure 4 Effects of Commutating poles ......................................................................................... 8
Figure 5 Pole-face windings ............................................................................................................... 9
Figure 6 Equaliser Coils.......................................................................................................................10
Figure 7 Brush polarity........................................................................................................................13
Figure 8 Current flow through the brush ....................................................................................14
Figure 9 Commutation ........................................................................................................................17
Figure 10 Commutating Pole Location ........................................................................................18
Figure 11 Equaliser Coils ....................................................................................................................19
Figure 12 Commutator construction............................................................................................20
Figure 13 Commutator cross section...........................................................................................21
Figure 14 Resurfaced Commutator ..............................................................................................22
Figure 15 Uniform Commutator Film ...........................................................................................23
Figure 16 Commutator Colour Pattern ........................................................................................26
Figure 17 Commutation colour markings ..................................................................................27
Figure 18 Bar corner etching ...........................................................................................................28
Figure 19 Burned bars ........................................................................................................................29
Figure 20 Copper Drag .......................................................................................................................30
Figure 21 Commutator Banding.....................................................................................................31
Figure 22 Commutator out of round ............................................................................................32
Figure 23 High bars .............................................................................................................................. 34
Figure 24 High mica ............................................................................................................................. 35
Figure 25 Flashover damage ...........................................................................................................36
Figure 26 Dial indicator ......................................................................................................................39
Figure 27 Fine grain sandpaper on shaped holder ...............................................................41
Figure 28 Common undercutting mistakes...............................................................................42
Figure 29 Raking Commutator Slots.............................................................................................43
Figure 30 Air Curing a Commutator..............................................................................................44
Figure 31 Misalignment & eccentricity of shaft or coupling ..............................................52
Figure 32 Shunting brush instalation ...........................................................................................76
Figure 33 Detecting shaft currents ...............................................................................................76
Figure 34 Canvas wiper ......................................................................................................................87
Figure 35 Low Spot ...............................................................................................................................94
Figure 36 High Spot .............................................................................................................................. 95
Figure 37 V Type holder ......................................................................................................................96
Figure 38 Rounded brush edges ....................................................................................................97
Figure 39 Typical brush potential curves for a DC motor ................................................ 111

MAY 2009 Page 3 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section One

General Information

MAY 2009 Page 4 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

GENERAL INFORMATION

SUCCESSFUL COMMUTATION

Successful commutation has been defined as “that which does not result in
accumulative injury to commutator and brushes which will prevent the machine
from meeting the required performance without undue maintenance. Absence of
visible sparkling is not essential to successful commutation”. (“Test Code for Direct
– Current Machines,” IEEE No. 113, December 1962).

Spark may be defined as a transient current flow through a gas such that a
steady-state condition is never reached, such as during a lightning bolt, whereas
as arc exists long enough to reach a steady-state condition, as may occur in
electrical equipment after as insulation failure.

Although both arcing and sparking may occur on a given machine, this article
generally uses the term “spark” to represent either phenomenon – particularly
when injury to the commutator is involved.

CURRENT FLOW

A study of the current flow through the brushes and armature windings of a DC
machine shows that the current from the commutator divides as it enters the
windings. After flowing through the windings it recombines at a commutator
segment and leaves through the outgoing brush, as shown by Figure 1.

Also, it is shown that the current flows in one direction when the coil is on one side
of the brush, and the current flows in the opposite direction when the coil gets to
the other side of the brush. Therefore, the current in the coil must reverse in the
split second it takes for the commutator segment to pass under the brush.

Hence another definition of commutation is “the successful reversal of current in a

coil under short circuit by a brush”.

MAY 2009 Page 5 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

NORMAL LOAD

+ -

COIL CURRENT
REVERSES
UNDER BRUSH
(NO ARC)

- +
Figure 1 Commutation

However, if the current doesn’t reverse in time, the coil will come out from under
the brush with the current still flowing in the original direction. The meeting point
with the current in the other path (called the “neutral point”) will no longer be
under the brush. This moving of the “neutral point” crowds the current to one
edge of the brush, and sparking ensues.

The greater the current, the harder it is to achieve a complete reversal of current
in the coil as the commutator segment races under the brush.

MACHINE DESIGN

As the armature current increases with load, the magnetic flux from the armature
cause a distortion of the main field flux, as shown by Figure 2, such that the
effective flux in the commutating zone is no longer zero. Various techniques may
be used to minimize the several effects of the distorted main field flux.

MAY 2009 Page 6 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

S N

NO LOAD NEUTRAL
FULL LOAD NEUTRAL

NO LOAD FIELD FORM

FULL LOAD FIELD FORM

Figure 2 Magnetic Flux Distortions

COMMUTATING POLES

The effects of the main field flux distortion on commutation can be minimized by
adding commutating poles (inter-poles) to the machines, as shown by Figure 3,
which is based on the simplified concept of Fig. 1.

COMMUTATING
POLE
GEN

MAIN POLE

BRUSHES

Figure 3 Addition of Inter-poles

MAY 2009 Page 7 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

(In actual practice, the construction of the machine is such that the brushes are in
line with the main poles, rather than in line with the commutating poles. The
active coil-sides are, however, positioned as shown by Figure 3).

The flux from these poles is approximately proportional to load current, and not
only does the commutating pole flux cancel the flux in the commutating zone
resulting from the distorted main field flux, but also it may provide a small amount
of flux that generates a small “negative” voltage to help force the required current
reversal. These effects are shown by Figure 4.

S N

NEUTRAL AT ALL
LOADS

NO LOAD FIELD FORM

FULL LOAD FIELD FORM

Figure 4 Effects of Commutating poles

NOTE: The polarity of the commutating pole is the same as the next succeeding
pole in the direction of rotation for a generator, and the same as the last
preceding pole for a motor.

POLE FACE WINDINGS

Reference to Figure 4 discloses that although commutating poles correct the flux
distortion problem in the commutation zone, the peak distorted flux is higher than
the peak no-load flux. As a result of the distorted flux, the generated bar-to-bar
voltages are not uniform.

It is possible to reduce the peak voltage that would otherwise be generated from
the distorted main field flux by using compensating pole-face windings as shown
by Figure 5.

MAY 2009 Page 8 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

S N

NEUTRAL AT ALL LOADS

NO LOAD FORM

NO LOAD FIELD FORM

FULL LOAD FIELD FORM

Figure 5 Pole-face windings

Pole-face windings carry current that, like the commutating pole coil current, is
proportional to load current. By restoring the main field flux to its designed form,
a higher average voltage per armature coil becomes feasible, and certain
necessary “crowded designs” can be quite successfully used.

The primary purpose, then, of the pole-face winding originally was to obtain a
more uniform bar-to-bar voltage for design purposes. It has been observed,
however, that the more uniform bar-to-bar voltages thus obtained improve the
commutation capability of the machine, and, of course, also reduces the
possibility of flash-over caused by inter-bar arcs. Consequently, large machines
are usually equipped with pole-face windings.

EQUALIZER CONNECTIONS

The flux per pole is never exactly the same for all poles because of unavoidable
irregularities. Consequently, the voltages in the parallel circuits of multiple or lap
armature windings will not all be alike. (the number of parallel circuits is
dependent on the number of pairs of poles). Hence there will be a circulating
current when the circuits are connected in parallel. Even a small voltage
difference would cause large circulating currents, because the armature coil
resistance is relatively low.

If this circulating current were allowed to pass through the commutator into the
brushes and complete its circuit through the bus connections between brush-
holders of like polarity, it would upset commutation and cause sparking at the
brushes. Equalizer coils are installed to minimize this problem. The equalizer coils
connect commutator segments of the same potential (i.e., segments at double the
brush spacing interval), as illustrated by Figure 6.

MAY 2009 Page 9 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

N S N S N FIELD POLES

ARMATURE COILS

EQUALISER COILS

+ - + - + - CARBON BRUSHES

BRUSH HOLDER BUS RINGS

+ -

Figure 6 Equaliser Coils

The circulating current passes through the equalizer coils, rather than through the
commutator segments and into the brushes. Happily, the circulating current
through the equalizer coils produces a magnetomomotive force of such a
direction that it tends to equalize the fluxes of several poles. Consequently, the
actual circulating current in the equalizer coils is relatively small.

With the series or wave winding type of armature, there are two parallel paths
through the armature, each path armature conductors in series with each other.
The voltage generated in either half of this parallel circuit adds up to the terminal
voltage of the machine.

With this type of winding, no equalizer coils are required.

BRUSH SPAN

Brushes used on most DC machines span more than one commutator bar. This
practice aids commutation in the following manner.

A coil undergoing commutation is magnetically coupled to the adjacent coil by the

mutual inductances of the winding. Providing good brush to bar contact is
maintained, the mutual inductance between coil sides can be increased by the
mutual inductances of the winding. Providing good brush to bar contact is
maintained, the mutual inductance between coil sides can be increased by
increasing the number of bars spanned by the brush. The magnetic coupling
between adjacent coils is particularly strong if the coils line in the same slot, and
much weaker if the coils are in adjacent slots.

The energy that is not commutated in the first coil is transferred, at least in part, to
the short-circuited second coil by induction, and then dissipated as I2R in the
second coil after the arc is extinguished.

Increasing the brush span is sometimes regarded as increasing the time available
for the commutation process (current reversal) to occur. It is not necessary to
increase the actual width of the brush if it is desired to increase the effective

MAY 2009 Page 10 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

brush span. Alternate brush-holders can be shimmed out from the brush-holder
support (circumferential stagger). The shims may range from 1/8 inch to ¼ inch in
thickness.

TRANSIENT RESPONSE

Machines that commutate satisfactorily under steady-state load conditions may

spark quite noticeably under conditions of rapidly changing load. For a given
machine, the maximum rate of rise of armature current, consistent with as
acceptable commutation margin, is dependent on the time lag between the
armature current and the commutating pole flux.

Eddy currents in the commutating pole or magnetic frame, saturation effects in

the various magnetic structures, the amount of field forcing applied, and the
effect (if any) of the main field flux on the commutating field “net” flux resulting
from inductive coupling all affect the ability of the machine to accommodate
transients successfully.

Most commutating field poles of larger machines are laminated, but of the
required rate of rise of armature current expected in a given application exceeds
the commutating ability of a properly adjusted solid frame machine, consideration
should be given either to large solid frame machine, or to a laminated frame
machine.

The use of a rectifier type power supply to permit operation of a DC motor directly
from an AC source may affect commutation. The current supplied by the rectifier
has a “ripple” current superimposed on the direct current. The magnitude of the
ripple current depends on the type of rectifier circuitry employed, and the degree
of phase-back at the operating point. Because of the time lag between the
instantaneous armature current and the commutating pole flux, the motor may
spark at the brushes. Fortunately, such sparking is usually less damaging than
sparking of a similar visual intensity when pure DC is used.

While small machines can operate acceptably from power supplies having
relatively large ripple currents, larger machines usually require power supplies
having low ripple currents. Small and medium machines may eventually be coded
to indicate the type of power supply from which they are designed to operate.

FUNCTION OF THE BRUSH

The brush serves to carry the short circuit current during commutating from one
bar to the other-hence the resistivity of the brush is important. Additionally, the
brush carries the current flow. The brush, therefore, functions as a sliding contact
with the commutator. How the brush accomplishes its functions is a complex
phenomenon not yet fully understood. However, a review of the information
generally available suggests the several conclusions may be drawn.

MAY 2009 Page 11 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATOR FILM

Operation of a DC machine with current passing through the brushes eventually

establishes a film on the commutator. The smooth polished appearance and
“feel” of a successfully performing commutator is not primarily the result of an
abrasive polishing of the copper commutator bars by the carbon brushes, but is
rather the result of the film which is superimposed on the commutator. A typical
film id very thin (perhaps only 1 x 10-5cm), and appears to consist of two distinct
layers of materials. The layer adjacent to the commutator id an extremely thin
layer of copper oxide, on top of which is a thicker layer of carbonaceous materials
perhaps as much as 10 times as thick as the oxide layer. The carbonaceous layer
consists of carbon, copper particles, compounds derived from other materials in
the brush (e.g., treated brushes) plush compounds derived from the surrounding
atmosphere, such as air borne abrasive materials and gaseous contaminants.

Additionally, a thin invisible moisture layer exists between the visible commutator
film and the brush when the machine is in operation. This invisible film, which is
formed from the water vapor present in the atmosphere, provides the lubricating
medium between the brush and the visible commutator film.

SLIDING CONTACT CURRENT FLOW

It is generally accepted that in most contact applications, the current does not
flow through the entire apparent area of contact, but rather flows through several
parallel paths, each of which has a very small area.

Current flow through the resistive commutator film apparently is in harmony with
the general case, and appears to be in the form of perhaps 5 to 20 parallel paths
per brush. The number and locations of these paths under the brush constantly
change.

The number of the conducting paths or spots existing at any given time appears
to be the result of a balance reached between three factors:

• The tendency of the brush and commutator surface to oxidize.

• The tendency of the conducting spots to “form” under the electrical forces
present.
• The effect of the abrasive or scouring action of the brush on the two prior
tendencies.

Additionally, the respective areas of a given number of conducting spots existing

at any given time appear to vary more or less in proportion to the current flow
through the spots. This “self-regulating” action tends to maintain an
approximately constant voltage drop. Thus the usual 0.5 to 2.0 volts drop for a
given brush is essentially independent of current magnitude.

MAY 2009 Page 12 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

At the voltages used on DC machines, current flow is often pictured in terms of

parallel lines of current more or less uniformly distributed across the
homogeneous conductor cross-section. At interfaces, however, such as the
brush-commutator sliding contact, the lines converge, or are “constricted” as they
pass through the small conducting spots.

The “constriction resistance” of the copper commutator bar is extremely small,

whereas the constriction resistance of the carbon / graphite brush near the
commutator is very high with respect to the normal resistance through the body
of the brush. (Field measurements on one machine indicated that the voltage
drop due to constriction resistance in the brush was 2000 millivolts, whereas the
voltage drop through the body of the brush was only 3 millivolts).

As mentioned previously, the conducting spots through the visible commutator

film are separated from the brush when the commutator is in motion by a very
thin moisture film, or layer. A generally accepted theory explains current
conduction through the moisture layer by the complex “tunnel effect” mechanism,
which has essentially metallic resistance characteristics.

These observations on the nature of current flow at the brush-commutator

interface are illustrated by Figure 8.

POLARITY

A brush is called an anodic brush when the current flow is from the brush to the
commutator, and a cathodic brush when the current flow is from the commutator
to the brush, as illustrated by Figure 7.

Figure 7 Brush polarity

MAY 2009 Page 13 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

For non-metallic brushes, the effect of the electrical forces is to transfer carbon
from the anode brush to the commutator, and to transfer copper from the
commutator to the cathodic brush. What is seen on the commutator, then, is the
net effect, or resultant of these two tendencies.

Provided excessive sparking does not occur, the anode brush generally wears
faster than does the cathodic brush - approximately twice as fast when they are
operated on separate tracks, as is the case for slip rings on synchronous
machines.

Note: these generalizations do not necessarily hold for metal-graphite brushes.

TEMPERATURE

Although the temperature of the current paths through the commutator film may
be quite high, the heat is quickly absorbed and dissipated by the surrounding
materials.

The average temperature of the brushes is somewhat higher than the average
temperature of the commutator.

Much of the I2R heat developed by the current flowing through the constriction
resistance of the brush is dissipated by the copper commutator. Usually, the
friction between the brush face and the commutator increases to a point with
temperature, and then falls off appreciable when temperature is further
increased. At some later point, the friction again increases with temperature. For
this reason, a brush which performs well under normal load may chatter at light
loads as a result of the increased friction experienced at the lower operating
temperature at the brush face.

Graphite Graphite Graphite Brush

Moisture Moisture Moisture Invisible film of moisture

Film Film Film Visable Film of copper oxides, carbons and

contaminants

Copper Copper Commutator bar

Current Flow Current Flow

Copper “conducting spots” The conducting spots are formed on and

through visible film are part of the copper commutator bar

Figure 8 Current flow through the brush

The friction characteristics of certain brush materials increase with temperature.
Brushes using these materials may chatter when the temperature exceeds 150 C
irrespective of load, although higher loadings naturally aggravate the condition.

MAY 2009 Page 14 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Two

Commutator Maintenance

MAY 2009 Page 15 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATOR MAINTENANCE

INTRODUCTION

The commutator is vital part of every DC motor and generator; therefore, it

deserves the very best of care. The fact that a commutator usually begs for
maintenance by showing signs of trouble before it actually occurs, is a big help to
the maintainer. If you are able to recognize these signs and know what to do, you
can often correct the trouble before it becomes serious.

The more you know about how a commutator is made and what it does, the
better you can maintain it.

FUNCTION

A commutator has three functions:

1. It provides the required sliding electric contact between the fixed brush
head and the moving armature.
2. It acts as a reversing switch. As the armature coils pass the brushes, the
commutator switches them out of one circuit into another. This means
that all the coils have current flowing through them in the right direction at
all times.
3. It also brings to the brush surface the voltage of each armature coil in the
circuit. These voltages add up bar by bar between brushes. As a result, the
total operating voltage of the machine appears at the brushes.

COMMUTATION

In studying the current flow through the brushes and armature windings of a DC
machine, we find that it divides as it enters the windings from the commutator.
After flowing through the windings, it reunites and leaves through the outgoing
brush.

Look at each coil as it passes under the brush (see Figure 9). Note that the current
flows in one direction when the coil is on one side of the brush and in the opposite
direction when it gets to the other side; so the current must reverse in the split
second it takes for the coil to pass under the brush. This is called commutation.

Commutation is defined as the successful reversal of current in a coil under short

circuit by a brush.

MAY 2009 Page 16 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

NORMAL LOAD

+ -

COIL CURRENT
REVERSES
UNDER BRUSH
(NO ARC)

- +
Figure 9 Commutation
What happens if the current doesn’t reverse in time? The coil will come out from
under the brush with the current still flowing in the old direction. The meeting
point with the current in the other path (called the “neutral point”) will no longer be
under the brush. This moving of the “neutral point” crowds the current to one
edge of the brush. Then it breaks out over the surface of the commutator in a
spark to reach this shifted point.

The greater the current, the harder it is to achieve a complete reversal of current
as the coil races under the brush. Some machines have inter-poles (or
commutating poles) to speed up this current reversal and keep the “neutral point”
under the brush. These are smaller poles located between the main poles in the
generator or motor frame (see Figure 10). The polarity is the same as the next
pole in the direction of rotation for a generator and the same as the last preceding
pole for a motor. They do no work outside of helping with the commutating job.
The magnetism of these poles builds up a voltage in the armature coils as they
pass through the zone covered by brush contact. This voltage speeds up the
current reversal to complete it before the coil leaves the brush contact.

MAY 2009 Page 17 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATING
POLE
GEN

MAIN POLE

BRUSHES

Figure 10 Commutating Pole Location

These poles are designed to do a good commutating job up to, and even beyond,
full load. When, however, a very sudden overpowering current flows through the
windings, the magnetism in the iron cannot build up quickly enough. It is like
suddenly turning on the garden hose, it take a few second to fill before water
comes out the nozzle. This means there is not enough voltage to reverse the
current in time and sparking results. Besides, you can force only so much
magnetism through a piece of iron. Then it becomes filled up or “saturated”. It is
like trying to force more water through the hose than it can handle. Hence, there
is a limit to the help the poles can give in reversing the current in the coil. When
the current gets so heavy that this help is not enough, you have more load than
the machine can handle and sparking results.

EQUALIZER COILS

Multiple or Lap Winding

Since the flux per pole is never exactly the same for all poles, the voltage in the
parallel circuits (the number of such circuits depending on the number of poles)
will not all be alike. This will result in a circulating current, since the circuits are in
parallel. Even a small voltage change would cause large circulating currents,
because resistance is relatively low (see Figure 11).

MAY 2009 Page 18 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

N S N S N FIELD POLES

ARMATURE COILS

EQUALISER COILS

+ - + - + - CARBON BRUSHES

BRUSH HOLDER BUS RINGS

+ -

Figure 11 Equaliser Coils

If this circulating current were allowed to pass through the commutator into the
brushes and complete its circuit through the brush-holder connecting bus rings, it
would upset commutation and result in sparking at the brushes. To avoid this,
equalizer coils are used to connect commutator segment of the same potential
(I.e. segment at double the brush spacing intervals) the circulating current then
passes through these equalizer coils instead of through the commutator, into the
brushes. This circulating current produces a magnetomotive force in such a
direction that it tends to bring the fluxes of several poles into equality. Hence, the
net circulating current is reduced to a relatively small value.

Series or Wave winding

In this type of winding there are two parallel paths through the armature, each
path consisting of one-half of all of the armature conductors in series with each
other. The voltage generated in either half of this parallel circuit adds up to the
terminal voltage of the machine.

With this type of winding, no equalizer coils are required.

MAY 2009 Page 19 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

CONSTRUCTION

Figure 12 Commutator construction

A commutator is made up of alternate copper segments and mica sections (see

Figure 12). The copper segments are often called “bars” and the mica sections are
usually called “ side mica”. The side mica separates the bars electrically and is
undercut below the surface of the bars to prevent interference with the sliding
action of the brushes on the commutator surface. The bars are wedge shape to
form a cylinder when assembled. They are clamped between a steel shell and a
cap held together with bolts or ring nuts. Mica cones prevent the shell and cap
from short circuiting or grounding the bars. A string band is applied over the
commutator cone to protect the mica. Each bar has a riser to form the
connection with the armature coils.

MAY 2009 Page 20 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

5 8 8 6
3

2
1

1 Commutator Shell 5 Cone Insulation

2 Commutator Cap 6 Cone Insulation

3 Commutator Segment 7 Cap Screw, Hex socket

4 Shell Insulation 8 Seal

Figure 13 Commutator cross section

Arch-Bound Commutator

An arch-bound commutator exerts pressure on the 30-degree surface of the

copper segments only (see Figure 13). This pressure is supported by the segments
pressing against each other around the complete periphery, as the name “arch-
bound” implies. An actual clearance (usually 1/16 inch) exists between the 3 or 6-
degree surface of the copper segments and the mica cone covering the steel
clamping ring. This clearance is sealed at the openings to prevent the entrance of
carbon dust that could short circuit or ground the bars.

The arch-bound type of construction produces a commutator that is less subject

to roughening of the brush surface from heat shock. Also, it is less critical to
machining tolerances and mica shrinkage variations, since it does not require the
critical balance of pressure between the 3 and 30-degree surfaces, as does the
“Vee-bound” commutator.

MAY 2009 Page 21 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Processing

A very considerable effort is made in manufacturing a commutator to see that it is

stable when completed. Stable means:

1. Commutator brush surface will not roughen up at high speed.

2. Commutator brush surface will not roughen up when heated or, if smooth
while hot, will not roughen up when cooled.
3. Commutator brush surface will not roughen up due to movement of the
bars after having been in service for a period of time.

To produce a stable commutator, a number of high-temperature bakes and

tightenings are applied, both to the ring of copper and mica segments before they
are bored, and also to the assembled commutator. The baking temperatures
exceed any that the commutator may encounter in normal service.

A large number of transportation commutators are seasoned in spin stands, after

they have been assembled on armatures and the armatures wound. In the spin
stands, the commutators are subjected to repeated cycles of heating and cooling
while running at speeds approximately 20 percent over maximum operating
speeds. A common cycle is to heat temperature to 160 C in one hour, hold this
temperature for ½ hour, and cool to room temperature in ½ hour – all at high
speed. This cycle is repeated a number of times to obtain desired results.

COMMUTATOR SURFACE CONDITION

No commutator can work as it should unless the brushes make good electric
contact. This requires a smooth, polished, cylindrical surface that runs true with
its center. When you realize the tremendous speeds at which this surface must
slide under the brushes, you can see why it must be as smooth and true as
possible.

Figure 14 Resurfaced Commutator

MAY 2009 Page 22 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Remember that the commutator is not one solid piece. It is made up of many
copper bars and mica sections clamped between steel parts. All of these
materials react differently to temperature changes (expanding and contracting at
different rates). This means that forces are set up which tend to shift the parts.
Also, the parts tend to shift during operation because of centrifugal action. In
spite of all that can be done in an attempt to maintain a perfect commutator
surface, small variations are usually present. Brushes, being forced against the
surface by spring pressure, will follow these variations if they are not too sudden.

It is the maintainer’s job to spot a surface that is heading for trouble and correct it
before failure occurs. Knowledge of various surface conditions and how they
effect commutation will be helpful. Let’s examine a number of these surface
conditions.

SURFACE FILM

The successful operation of all DC machines depends on establishing a good

commutator surface film. Thin film of carbon, graphite, copper oxide and water
vapor is deposited on the commutator by electrochemical action. It is formed by
the wiping action of the brush against the commutator and by the normal current
flow between the brush and the commutator.

The fact that a commutator surface is never absolutely smooth, although it may
feel so to the touch and look so to the eye, enables the film to stick. Normally, on
a new or reconditioned commutator, the brush begins to establish its
characteristic film as soon as current flows. It may take several hours or several
days to complete a good film – after which the main job is to maintain this film.

Temperature, atmosphere and grade of brush used all affect this film. If the film is
damaged electrically or mechanically, both brush and commutator wear is
accelerated.

Figure 15 Uniform Commutator Film

MAY 2009 Page 23 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

A sliding contact such as a carbon brush, is very sensitive to even the slightest
variation in the atmosphere. Acid or base contamination, dust, and oils react with
the brush and commutator surface to cause distributing conditions. Even normal
changes in humidity cause noticeable changes in contact drop and friction of
brush. These variations may result in the formation of irregular patterns on the
commutator surface.

Chemical contamination probably causes the greatest disturbance, since

formation of materials other than copper oxide is usually harmful. Abrasive dust
wears away the film, while other types of suspended particles react with the
vaporized copper to form nonconductive films. Many organic materials are just as
harmful as chemical contaminants.

Oil vapors have a decided effect on film condition. Not only does the oil introduce
an insulating surface, it also prevents bonding of film on the commutator and
causes a torn or mottled film surface. It will also promote rapid metal transfer
and, eventually, threading.

Some brushes lay down a heavier film than others depending on brush grade.
Some brushes require greater current densities to established and maintain a
satisfactory film than other grades. The manufacturer of the machine chooses a
brush depending on the machine application. Use the recommended brush
grade, once established.

The importance of the commutator surface film cannot be overemphasized. With

this film established and properly maintained, good brush performance (reduced
brush and commutator wear) and satisfactory commutation (no destructive
sparking) is assured. Changes in color from copper to deep brown or chocolate
should give no cause for worry, as long as the surface is smooth and polished
(glossy appearance). See fig.6.

MAY 2009 Page 24 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MAY 2009 Page 25 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COLOUR PATTERN

This term indicates only that the color of commutator bars is not uniform and a
definite pattern exists, almost always related to coil position in the slots; that is, to
the number of conductors per slot. In itself, this condition is not a sign of damage.
The color pattern may show up in several sequences (see Figure 16 and Figure 17).
As long as there is a definite patter around the whole commutator, do not be
concerned.

Figure 16 Commutator Colour Pattern

A check for surface damage should be made at regular commutator inspection

periods. If no damage exists, no further action is required.

MARKING, ETCHING AND FLAT SPOTS

The following conditions all indicated discoloration and / or etching of

commutator bars – but in varying degrees.

Some of the possible causes of etching and discoloration are:

1. Excessive loads on the machine.

2. Electrical adjustment off; such as, wrong shims behind commutating poles
or wrong inter-pole gap.
3. Wrong brush grade.
4. Uneven or rough commutator surface.
5. Contaminated atmosphere.
6. Incorrect brush spacing.
7. Incorrect brush shift.

MAY 2009 Page 26 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

The best way to overcome these conditions is to determine the cause and make
the necessary corrections. If damage has not progress too far, it may clear itself
up once the cause has been eliminated. Some resurfacing of the commutator
may be necessary but it should be done sparingly.

MARKING

Figure 17 Commutation colour markings

This condition is an opaque darkened surface or black deposit on the bars, usually
at their trailing edge, with no etching or corrosion of copper underneath.

Check for this condition quickly by using a common pencil eraser to remove the
deposit; then examine the copper surface for roughness or pitting. If none is seen,
the condition is marking, which can readily be removed with a canvas cloth. See
Figure 17.

BAR SURFACE ETCHING

This condition gives the appearance of severe marking, and a pencil eraser
uncovers pitting, eroded, or burned bar surfaces. Such a condition results from
arching between the brush and the copper segments and the etching is usually
visible with the naked eye when the marking is removed. See Figure 18 and Figure
19.

The term burned bars is sometimes used to indicate bar surface etching. This
merely represents an advanced stage of etching.

MAY 2009 Page 27 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

BAR CORNER ETCHING

This condition reveals that the corner of the bar may be eroded off, leaving a
chamfered corner but little or no evidence of marking or bar surface etching.

Bar corner etching may best be discovered by holding a light at such an angle
that light reflected from a chamfered corner can be seen with the eyes.

Figure 18 Bar corner etching

MAY 2009 Page 28 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

FLAT SPOTS

If etching is not corrected and progresses too far, flat spots will develop. Flat spot
may also result from mechanical causes, such as the pound from a loose bearing.
As a rule, however, flat spots result from failure to correct some faulty condition,
which is first indicated by burned bars. See Figure 19.

Figure 19 Burned bars

THREADING

This is a surface defect running around the commutator crosswise to the bars.
Threading shows up as narrow, circumferential lines or grooves cut into the
surface by abrasive action.

In light threading, these lines may just be apparent where the surface film or color
is disturbed or different. In heavy threading, a rippled surface can be felt if you
rub a fingernail along the bar surface from one end to the other (see figs.13 and
14).

The brush face wears to fit these grooves. When the commutator shifts, due to
end play, the brush is lifted out of these grooves. The contact between the brush
and commutator surface is then disturbed, sparking occurs, and poor operation
may result.

MAY 2009 Page 29 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Possible causes of threading are:

1. Low current density in brush (machine is not heavily loaded).

2. Abrasive dirt or other foreign material imbedded in bottom of brush.
3. Mica flakes or copper imbedded in brush face
4. Wrong brush grade.
Remedy: Resurface by hand stoning, grinding, or turning.

COPPER DRAG

Under certain conditions, copper is pulled over the edge of commutator bars. This
shows up as small flakes or feathers of metal that appear mainly on the trailing
edge of the commutator bars. The bar surface may also have an appearance
which suggests that the copper has flowed or been peened toward the trailing
edge. This condition is called copper drag or feathering and should not be
confused with bar corner etching. See Figure 18 and Figure 19.

Figure 20 Copper Drag

Copper drag is caused by copper, which is being rubbed back onto the
commutator as a layer of copper oxide, and contaminants, and does not bond
firmly to the commutator surface. As a result, the next brush that passes over this
surface will shove a small flake of this material into the commutator slot. This
decreases the distance between bars. An arc formed at a brush is then more
easily carried over to the adjacent set of brushes. This may result in a flashover.

MAY 2009 Page 30 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Possible causes of copper drag are:

1. Contaminated atmosphere.
2. Copper imbedded in brush face.
3. Hard spot in brush.
4. Wrong grade of brush.
5. Excessive vibration.

Remedy: A temporary solution is to clean the commutator occasionally with

a light brush seater stone. If drag has progressed too far, the edges
of the bars will have to cleaned, and the mica grooves cleaned out.

BANDING

This is a surface defect in the form of band around the commutator in which the
surface film has been partially or completely removed. These bands may be quite
narrow (not to be confused with threading) or they may extend over a sizeable
percentage of a brush path. They are readily visible to the eye. See Figure 21.

Figure 21 Commutator Banding

MAY 2009 Page 31 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Possible causes of banding are:

1. Too heavy brush film (film rolls up).

2. One wrong brush.
3. Hard spot in brush.

Remedy: This condition can be corrected by resurfacing after the cause has
been discovered and corrected.

ECCENTRICITY (OUT OF ROUND)

Although a commutator surface is smooth, it can be running off center. It is then

said to be eccentric (or out of round). This is a common fault and is usually the
easiest of all surface variations for the brushes to follow. They simply rise and fall
in the holders with each revolution. However, as speed goes up, this eccentric
motion becomes faster. Finally, the brushes begin to break contact and gradually
burn the commutator surface. As this continues, the burning causes still further
surface destruction. See Figure 22.

Commutator
Centre

Bearing
Centre

Figure 22 Commutator out of round

Possible causes of eccentricity are:

1. Bent shaft.
2. Bearings not running true.
3. Commutator machined on bad shaft centers.
4. Distortion caused by wide temperature changes and high speed.
5. An offset coupling in single bearing traction generators.

MAY 2009 Page 32 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Remedy: Resurface the commutator using a rigidly-mounted grinding fixture.

If the armature is out of the frame, turn the commutator in a lathe
(on its own bearings if possible). If too badly out of round, replace
the commutator.

Note: A hand stone will not correct this condition.

SURFACE BREAKS

Sometimes a sharp step or break occurs on a commutator surface. This may be

caused by a bump or blow to the commutator. Though the change in surface
level may be very small, not even a heavy spring load will keep the brush in
contact with the depressed surface. The brush may “ski – jump” from the higher
level or, if rotation is reversed, the step strikes the brushes and “kicks” them away
from the surface. At high speed this “kick” may be hard enough to shatter the
brushes. See Figure 22.

Brush Breaks
Brush Bounces

Possible causes of surface breaks are:

1. Bump due to bad handling.

2. Foreign object (such as a tool) striking the surface.
3. Brush holder allowed to drop on commutator.

Remedy: Resurface with rigidly mounted fixture.

MAY 2009 Page 33 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

HIGH BARS

Figure 23 High bars

If a motor is held at standstill while the power in on, the commutator bars under
the brushes will be overheated. These bars will expand and rise above the others.
The high bars kick the brushes and arcing and burning occurs. This makes the
commutator surface even worse. If this condition is allowed to go uncorrected,
the brushes will finally shatter and a flashover will result (see Figure 23).

In severe cases, the temperature may get high enough to anneal the copper. The
binder may even be burned out of the mice. Flakes of mica will shift from the
pressure areas and lessen the clamping action on the hot bars. A commutator in
this condition is very troublesome. The soft bars wear differently than the hard
ones next to them and because they are loose, they will lift at high speed.

If you suspect annealed bars, check them by comparing their hardness with that
of adjacent bars. This can be done by the use of scleroscope or by some
equivalent means. Annealed bars can often be spotted by their discoloration,
especially at the ends where the brushes do not slide.

A quick check for loosened bars can be made by tapping each one gently with a
light hammer. At the same time, feel for vibration between bars with the finger
tips.

MAY 2009 Page 34 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

HIGH MICA

MICA PROPERLY UNDERCUT

HIGH MICA – COPPER WORN DOWN

FEATHER EDGE MICA – INCORRECTLY CUT

Figure 24 High mica
Mica is extremely hard on brushes when high or feather-edge. High or feather-
edge refers to the height relationship between the mica surface and commutator-
bar surface. High mica comes from normal electrical or mechanical wear and
subsequent failure to undercut mica after resurfacing where an appreciable
amount of copper has been removed. As the softer copper wears down, the mica
“rises” to stand flush or level with the bar surface. Feather-edge mica comes from
incompletely trimming high mica by leaving rough or “feather” edges of mica level
with the commutator bar surface or actually protruding above it (see Figure 24).

Mica in this condition steps up electrical wear on the bars, which in turn, exposes
fresh mica to beat the brushes faster. This vicious circle of wear has just one
solution: Prevent or eliminate high mica. The methods to be used will be
discussed immediately after resurfacing procedures have been discussed.

MAY 2009 Page 35 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

FLASHOVER DAMAGE

Any of the commutator defects discussed act like a break in a highway pavement.
At first, it is hardly noticeable, but if it is not cared for, it becomes progressively
worse, until the road must be closed. So, a commutator does not fail suddenly. It
gives warning in time for the trouble to be corrected. Bouncing or shattered
brushes, bad over loads, or dirt between commutator segments will cause arcing
at the contact surface. When these arcs become severe enough, they will change
the surrounding air into conductive gas and bridge the segments. This permits
the power to spill over between brushes in a burst of flame hot enough to melt
metal. This flashover is the commutator’s final protest against abuse. Evidence
that machine has flashed over is found in copper splattering on the surface and
ends of the commutator bars. Often these are also found on the brush holders,
the surrounding insulation, and nearby parts of the steel frame as shown in Figure
25.

If a flashover occurs, clean the commutator, the brush holders, the string band,
etc. Examine brush faces and replace damaged brushes.

Figure 25 Flashover damage

MAY 2009 Page 36 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

OTHER FACTORS AFFECTING COMMUTATION

We have already seen that the second duty of a commutator is to act as a

reversing switch. Just as mechanical defects on the commutator surface interfere
with proper brush contact, so electrical defects in the machine will interfere with
proper switching action. Some of the more common electrical defects are:

1. Wrong location of brushes on the commutator.

2. Winding defects in either the armature or the field windings. The defects
may be short-circuited turns, grounds, open circuits, or high resistance
connections.
3. Reversed main or commutating-field coils.
4. Use of improper shims under pole pieces.
5. Exchange of magnetic for nonmagnetic pole piece bolts, or vice versa.
6. Nonmagnetic instead of magnetic bands, or vice versa.

All these defect will cause sparking at the brushes and may result in overheating.
You are most likely to find them after a hasty emergency repair job on the
equipment.

Anything that breaks the connection between a commutator bar and its armature
coil will affect commutation. A break will occur when the when the commutator
becomes hot enough to melt the solder and allow the ends of the coils to lift out of
the riser slots. Such heating may be caused by overloads or lack of cooling air.
Hence, solder throwing warns the maintainer to check blowers, belts, air ducts
and covers, to be sure that the machine is getting enough cooling air. Look for
silver-colored spatter on the field-coil connections, the frame, etc.

A connection not properly soldered, or one that has thrown solder, may oxidize
rather than lift out of the risers. When this happens, local heating will cause a
blackened or burned area on the riser at the poor connection. Look for discolored
bars when making inspections.

Molten solder can cause serious damage. It not only can cause the leads to lift,
but it can also short-circuit the armature coils by collecting under the insulation.
Molten solder can also allow a coil to open up to produce burning at the edges of
adjacent commutator bars.

An open circuit in an armature winding can also occur from a conductor being
broken due to bad handling or vibration. Then the current cannot get through the
winding. An arc is drawn as the segments, to which the broken coil is connected,
move away from each brush. This burns the copper away on both sides of the
mica segments and makes a deep trench. At high speed and voltage this arc may
carry over between brush holders.

MAY 2009 Page 37 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATOR INSULATION

The purpose of insulation is to prevent leakage of the electric current. If leakage

occurs across a small area of insulation, it may cause sufficient heat to carbonize
the surface. This lowers the resistance enough to cause a breakdown.

Since each pair of commutator bars has the voltage of one armature coil between
them, if the side mica is bridged by any conducting material, the bars will be short
circuited. The current flowing across this small area will heat the mica and cause
it to carbonize and glow at that spot. At high speed and voltage this hot spot will
form a ring of fire around the commutator and may cause a flashover.

Another cause of short circuits is damage to the commutator, resulting from

accident. Loose objects such as small bolts, nuts, and washers may fall unnoticed
into an air duct or a commutator chamber. If such material lodges between a
brush holder and the commutator, it will do extensive damage and put the
equipment out of service.

Not only must the bars be insulated from each other, but the whole commutator
must also be insulated from ground. This insulation has to withstand the full
operating voltage of the machine. It consists of relatively long creepage surfaces
next to the commutator. The string band is one example. When these surfaces
become coated with dirt or moisture, there is leakage of current to ground. When
this leakage becomes great enough, the insulation breaks down and a ground
results. Such failures can be prevented, by keeping the string band clean.

A flashover may strike across the string band and do varying amounts of damage.
If the band is only smoke damage, it can be cleaned with a cloth and a solvent. If
the paint is burned, it can be cleaned with sandpaper and repaired. Be careful not
to cut through the string band. If it is seriously damaged, a new band must be
applied. This is a repair job for the work shop.

By watching for warning signs, an alert maintainer will be able to correct trouble
before costly failure results. A good job of preventive maintenance will pay big
dividends in increased equipment availability and decreased repair bills.

MAY 2009 Page 38 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

INSPECTION AND TEST

Visual inspection of a commutator will detect the majority of defects mentioned.

To learn more, you must feel, listen, or measure. If a traction motor is out of the
truck, if the wheels are jacked clear of the rails, or if a drop-pit table is lowered,
you can run the motor and feel or hear a rough commutator. A generator and its
auxiliaries may be checked while the engine is idling.

A distinct click can be heard as each brush goes over a step in the commutator
surface or the brushes will chatter as the rough spots disturb them. Hold a fiber
or wooden stick (something insulated), about the size of a long pencil, lightly on
the brush or on the spring right over it. This will give you the feel of the brush as it
rides the commutator. The bad spots can be felt clearly as they go by. Check
traction motors when turning in both directions, as there is sometimes a
difference in the degree of roughness.

The most accurate way to check a commutator surface is with a dial indicator
(capable of reading 1/10 of one mil) as shown in Figure 26. Clamp the indicator to
the machine frame so that the indicator tip touches the spring directly over the
brush. Be sure the brush is free to move in the holder. See that the spring
pressure is strong enough to hold the brush against the commutator surface.

Figure 26 Dial indicator

Mark the starting position and turn the armature slowly but steadily. This is not
always easy to do. The brushes may rock or tilt and lose the zero dial setting. If
the turning is opposite to the direction in which the motor was last run, the
brushes may chatter as the bar edges go by. Fit the brush in, or reverse the
direction, to get a steady reading. If the machine is to be turned with voltage on it,

MAY 2009 Page 39 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

the tip of the indicator should be insulated from the brush, otherwise serous
damage to the indicator will be caused by current passing through it to ground. A
rubber or fiber tip will be adequate. Watch the indicator for sudden swings.
These quick dips in the surface upset brush contact the most.

RESURFACE THE COMMUTATOR

Commutator troubles may often be corrected by resurfacing. This is the name

given to any process that restores a true, cylindrical, polished surface to the
commutator. This may be done with a machine in place or on a machine
removed from the locomotive (or car).

POLISHING

If the commutator surface is merely smudged, you can clean it by polishing with
canvas. When this is not sufficient, or if the commutator is slightly rough, crocus
sloth, fine (4/0) sandpaper, or 400 A Triemite* paper may be used. This should be
mounted on a wooden block curved to fit the surface of the commutator.

CAUTION:

NEVER USE EMERY CLOTH ON A COMMUTATOR. THE ABRASIVE PARTICLES NOT

ONLY SCRATCH THE SURFACE, BUT THEY ARE CONDUCTIVE AND LODGE BETWEEN
COMMUTATOR SEGMENTS. THIS LEADS TO SHORT CIRCUITS.

*Reg. Trade-mark of Minnesota Mining 7 Mfg. Co.

STONING

If the commutator surface is mildly grooved, etched, or burned, and only a small
amount of copper has to be removed to correct the defect, a hand stone is most
suitable. The stone should have a surface curved to fit the commutator. Also, it
should be long enough to bridge the defect to be removed otherwise the stone
will ride in and out of the defect and do nothing to correct it. The length of the
stone will usually be limited by the space between brush holders. If this is not
enough space, a brush, holder should be removed to make room for a large stone
(see Figure 27).

MAY 2009 Page 40 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Figure 27 Fine grain sandpaper on shaped holder

NOTE: Hand stoning will not correct an out of-round commutator.

When a greater amount of copper is to be removed, or the defect is too large to

be bridged by the stone, use a grinding fixture mounted on the frame of the
machine to hold the stone(s). this fixture has a movable carriage for passing the
stones back and forth across the commutator. A feeding device regulates the
position of the stone so that it cuts down the high spots on the surface. A vacuum
attachment is also available t pick up the copper and abrasive dust.

Stoning with a grinding fixture is faster and requires less skill than hand stoning. It
also has the advantage that it will correct a commutator that is out-of-round (see
Figure 22).

TURNING

If a commutator is badly worn or burned, the resurfacing operation can be

speeded by turning. A tungsten-carbide tipped lathe tool should be used because
the speed may burn a tool-steel tip. Remove only enough copper to give a
uniform surface. This cut should be followed by a coarse stoning and a finish
polish.

At times it may be necessary to remove the armature and turning the

commutator in a lathe. When this is done, the armature should be supported on
its own bearings if possible. If it cannot be supported on its own bearings, it must
be held in lathe centers. Be sure they are true with respect to the bearing seats or
you will end up with an out-of-round commutator.

UNDERCUTTING

After a commutator has been resurfaced, check the depth of the undercutting if
necessary, it should be done carefully with a proper tool of correct size. The tool
must have a sharp edge to cut the mica freely. A dull blade or saw produces small
cracks in the mica into which dirt or moisture may find its way and break down
the insulation between segments.

MAY 2009 Page 41 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Some common mistakes are shown in Figure 28. Avoid these mistakes. Be sure
that no fins of mica project for they will spoil the brush contact on an otherwise
good surface.

A MICA PROPERLY UNDERCUT

B UNDERCUTTING TOOL TO NARROW, LEAVING FIN AT ONE SIDE OF SLOT
C UNDERCUTTING TOOL TO NARROW, LEAVING FIN AT BOTH SIDES OF SLOT
D SLOT IMPROPERLY INDEXED, PART OF BAR CUT AWAY AND FIN OF MICA LEFT
E TOOL TOO WIDE. PART OF BAR CUT AWAY
F UNDRCUTTING TOO SHALLOW. SERVICE LIFE SHORTENS BEFIRE NEXT UNDERCUTTING
G UNDERCUTTING TOO DEEP. POCKET COLLECTS CARBON AND COPPER DUST, SHORT-CIRCUITING BARS

Figure 28 Common undercutting mistakes

A section of a hacksaw blade secured in a home made holder of one kind or
another cuts a satisfactory slot for small equipment provided a sharp blade id
used and kept parallel to the sides of the slots. Do not let the blade lean or
wobble. Saw lightly until the mica is down to the required depth (given under
MAINTENANCE DATA in individual instructions).

For an occasional undercutting job you may want to use a hand slotter and
scraper with a tool steel bit. Draw this tool lightly through the commutator slots.
The same tool also cleans slots, smoothes burrs, and removes mica fins if you
have undercut the commutator with powered undercutters.

Power tools range from the hand-held lightweight under-cutters (reciprocating file
or circular saw) with built-in small motors, through the flexible shaft stationary
motor models to heavy, king size-size units able to support an entire armature
assembly. All of these tools, except the reciprocating file, employ small circular
saws for U slotting. Where there is a big volume of undercutting to be done, many
shops prefer these motor-driven rotary-type cutters for their speed and quality of
work. Built-in slot guides and depth gages help to position the cutting wheel or
saw for accurate, uniform cuts. It is easy to learn the technique. Follow
suggestions supplied by the tool manufacturers, make a few practice passes over

MAY 2009 Page 42 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

a scrap commutator to get the “feel” of the tool, and you are ready to do your own
undercutting.

RAKING AND BRUSHING SLOTS

Resurfacing usually leaves particles and slivers of copper hanging in the bar
edges or lodged in the undercut. These must be removed before the machine is
placed in service or the particles may shift and bridge the side mica and cause a
flashover. A stiff brush, fiberboard, or a special engraving tool may be used for
this job.

Figure 29 Raking Commutator Slots

MAY 2009 Page 43 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

If the brush is used, use one with stiff nylon bristles. A new paint brush or stencil
brush with bristles cut short for added stiffness will be satisfactory.

Another method of removing copper fins is to rake the slots with a piece of
fiberboard, approximately the same thickness as the slots.

If stoning has produced considerable dragging of copper from the edges of the
bars, it may be necessary to use an engraving tool to remove the copper fins and
ragged edges. Such a tool can easily be made by grinding a 60 Degree “V” into
the point of a short-handled screw driver. Use the tool to drag out the slots with
the point inserted in the slot so the sides of the “V” are cutting the edge of the
baron each side of the slot. Do not chamfer the edges. If the tool is ground as an
engraving tool, it will remove ragged fins and break the sharp edges of the bars.

If the slots have raked with fiberboard or an engraving tool, it may be necessary to
sand the commutator with a very fine sandpaper to remove small pieces of
copper sticking up from the edges of the bars.

AIR CURING THE COMMUTATOR

After raking and brushing between bars, blow out the commutator with clean, dry
compressed air to remove all traces of dust.

The job may have to be checked by operation the machine at no load. Start with
low voltage. Sweep a strong jet of compresses air back and forth longitudinally
across the commutator surface midway between the brush holders. The voltage
and the air stream act together to disturb and burn loose any copper particle
remaining in the slots. When sparking under air jet stops, increase the voltage
another step. Repeat this procedure until top voltage is reached.

This process is called air curing. It can be done easily with a generator by blocking
open the power contactors and increasing the speed a notch at a time. In order to
check a motor commutator at full voltage, you must arrange to have the field
separately excited. This is necessary to keep the motor from running away at load
and full voltage.

Figure 30 Air Curing a Commutator

MAY 2009 Page 44 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

SAFETY PRECAUTIONS

When working on commutators, always wear goggles and gloves protection

against flying particles and possible flashover when air curing. A respirator should
also be worn during stoning operations to avoid breathing abrasive dust.

Stoning a commutator with the brushes in place will wear the brushes away very
rapidly and cause carbon dust to deposit on insulation. Brushes that are hard-to-
reach should be removed before the engine is started if you are working on an
engine driven generator. After cranking, the rest of the brushes should be taken
out. In the case of motors, the good brushes should be removed, and worn
brushes substituted. Usually one brush in each holder is enough to run the motor
light.

MAY 2009 Page 45 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MAY 2009 Page 46 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Three

Motor Troubleshooting

MAY 2009 Page 47 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MOTOR TROUBLESHOOTING

INTRODUCTION

Motor trouble may be either mechanical or electrical in nature. These two

categories may be further subdivided into several general problem types. The
discussion that follows outlines the various problems, and discusses their
characteristic and causes. The order of presentation is not necessarily related to
the seriousness or frequency of occurrence of the trouble.

VIBRATION

Excessive vibration is one of the more frequent problems on motor installations.

There are many possible causes, some of which are listed below. It should be
noted at the outset that the motor is not the only possible cause of vibration.

CAUSE OF VIBRATION

Misalignment and eccentricity of shaft or coupling

Faulty bearings
Mounting Unstable or not level
Excessive Motor Unbalance
Excessive Driven equipment Unbalance
Open Bars in Motor Rotor
Uneven Motor Air Gap
System Resonance
Pump Shaft Resonance
Hydraulic Conditions in Pumping System
Up-thrust on Vertical Motors Not Designed or Properly Adjusted
Operation of Spring Loaded Spherical Roller
Bearings with Insufficient Thrust load

Motor are carefully balanced at the factory, and each motor is run for a balance
check as part of its final test. This balance check is made with the motor mounted
on a resilient mount in accordance with NEMA Standard MG 1-12. 05 and MG 1-
12. 06 (which are quoted below for easy reference), or on a special mount giving
similar result.

MAY 2009 Page 48 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MG 1-12. 05 DYNAMIC BALANCE OF MOTOR

The balance for integral-horsepower alternating current and direct-current

motors built in a 143 and larger frame, when measured in accordance with MG 1-
12. 06, shall be as follows:

Speed, Rpm* Maximum Amplitude, Inches#

3000-4000, incl 0.001

1500-2999, incl 0.0015

1000-1499, incl 0.002

999 and below 0.0025

*For alternating-current motors, use the highest synchronous speed. For direct-
current motors, use the highest rated speed. For series and universal motors, use
the operating speed.

#Amplitude as used in this paragraph means total peak-to-peak displacement.

MG 1-12.06 METHOD OF MEASURING DYNAMIC BALANCE

A. Place the motor on an elastic mounting so proportioned that the up and

down natural frequency shall be at least as low as 25 percent of the test
speed of the motor, to accomplish this it is required that the elastic
mounting be deflected downwards at least by the amounts shown in the
following table due to the weight of the motor. When a flexible pad is used,
the compression should in no case be more than 50 percent the original
thickness of the flexible pad; otherwise, the supports may be too stiff.

Rpm Compression Inches

900 1

1800 1/4

3600 1/16

7200 1/64

NOTE: The required deflection is inversely proportional to the speed squared.

MAY 2009 Page 49 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

B. The Amplitude of vibration shall be measured on the bearing housing, in

any direction, with the axis of the shaft in the normal position. With the
motor operating at no load, it shall be balanced with one half a standard
key in the key-seat; that is, a key of full length flush with the top of the key-
seat. An alternating-current motor shall be operated with rated voltage
and frequency applied and a direct-current motor shall be operated from a
ripple-free power supply.

It is understood that a reliable vibration indicator will be employed.

RECOMMENDED PROCEDURE IF MOTOR VIBRATION IS EXCESSIVE

The procedures outlined in this section are intended as a general guide for the
logical and effective investigation of motor vibration with reasonable expense. It
is recognized that these procedures are general and that it may not be possible to
follow them exactly at all times. However, it is imperative that we avoid the
expense of vibration investigations that are meaningless because vibration is not
accurately measured, or because the motor mounting conditions are not
acceptable. Likewise we must avoid unnecessary moving or disassembly of the
motor.

Do not go out to make a vibration investigation without proper equipment.

Suggested equipment is listed below:

• I.R.D. Vibration Analyzer for measurement of vibration peak to peak

amplitude, vibration frequency and location of unbalance.

• Light-beam Vibrometer for measurement of vibration peak to peak

amplitude if IRD meter not available.

• Frahm Reed Tachometer for determining critical frequency. (Rough check

only).

• Vibrator for making mechanical resonance curves.

• Tachometer.

• Rubber pads for resilient mounting of the motor during tests.

• Dial indicator.

MAY 2009 Page 50 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

VIBRATION CHECK OF MOTORS

Check motor and driven equipment for obvious causes of vibration. Be sure that
there are no loose or missing part or keys. If motor is installed, be sure its support
is secure and flat.

Run motor as found at rated voltage and frequency and measure vibration with
reliable instrument. If vibration falls within limits outlined above, the motor meets
normal standards. End-play of motors with spherical roller thrust bearings must
be set to zero for this check.

Check for system resonance at or near the operating speed of the motor. If
resonance occurs near operating speed, a system resonance problem exists. See
discussion of system resonance.

If cause of vibration is still not-pointed, motor should be uncoupled from the

driven equipment and vibration measured. If motor vibration was probably
caused by misalignment or unbalance in the driven equipment.

In order to be sure that motor parts are not causing the trouble, motor and
coupling parts should be checked with a dial indicator to be sure that they are not
eccentric.

MISALIGNMENT & ECCENTRICITY OF SHIFT OR COUPLING

Misalignment of the shafts of motor and load can cause vibrating forces. The
misalignment may be divided into four classes:

1. Crank action – due to shaft coupling.

2. Out of square coupling face – due to shaft coupling.
3. Angular – due to fit of motor to intermediate base.
4. Offset – due to fit of motor to intermediate base.

MAY 2009 Page 51 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

ANGULAR OFFSET

CRANK ACTION OUT OF SQUARE

COUPLING FACE

Figure 31 Misalignment & eccentricity of shaft or coupling

Figure 31 illustrates these misalignments before the shaft are coupled. Bringing
the coupling faces together will bend the shafts in various ways.

The relative importance of the alignments will depend upon the forces required to
retain the shaft in the bearing. (The force producing shaft flexure). For a given
allowable force and shaft size misalignment will be proportional to the ratio of
coupling to bearing distance and the diameter of the ratio of coupling to bearing
distance and the diameter of the coupling (or base flange). In solid shaft motors
the ratio is frequently about 3, so that the offset and crank action tolerances can
be three times the angular or out of square coupling face tolerances. In hollow
shaft motors, the ratio is frequently 10 to 15, so that the misalignment forces are
usually negligible for any reasonable values of misalignment. Crank action
misalignment could be considered the more important in that the vibrating force
produced is at twice operating speed and therefore cannot be compensated for
by field balancing. The vibrating force due to out of square coupling faces is at
operating speed, and sometimes can be compensated for by field balancing. The
vibrating force due to out of square coupling faces is at operating speed, and
sometimes can be compensated for by rebalancing after installation.

MAY 2009 Page 52 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

DEFECTIVE BEARINGS

Vibration may be caused by bearings with damaged balls or rollers; such bearing
will also be noisy and this type of trouble should be easily detected.

Vibration can also be caused by bearings that are loose on the motor shaft or in
the bearing seat. This looseness may allow the axis of rotation to shift and cause
unbalance or misalignment. This can usually be detected only by inspection and
measurement of the parts after the motor is disassembled. Bearings that are out
of tolerance should be replaced, and other parts either replaced or brought to size
with metal spraying or chrome plating; either of these methods can give
satisfactory results, but only if the process is closely controlled with laboratory-like
precision.

MOUNTING UNSTABLE OR NOT FLAT

Rotating machinery, motors and driven equipment alike, must be securely

mounted on a firm, flat foundation. Even a well balanced machine has some
remaining unbalance – absolute perfection is seldom obtained – and if the
mounting allows the machine to wobble or teeter, this small amount of unbalance
can cause objectionable vibration.

If the mounting surface is not flat, shims should be used to support the machine
uniformly, or the mounting re-surfaced.

MOTOR UNBALANCE

Motor vibration can, of course, be caused by motor unbalance. Motors should be

well balanced when they are shipped from the factory but errors can occur. If a
motor is unbalanced, check for obvious external causes before disassembly. Be
sure a half-key is use if checking with coupling removed. Check also to be sure
that there are no loose parts.

DRIVEN EQUIPMENT UNBALANCE

The driven equipment can cause vibration of both itself and the motor. This
possible cause of vibration should be checked along with alignment if the motor
runs smoothly when the load is disconnected.

If the driven machine is gear or belt driven, it will run at a different speed than the
motor and vibration caused by the load will be a different frequency than
vibration caused by the motor. This fact can be useful in locating the cause of
vibration; various vibration meters are available which indicate the frequency of
the vibration as well as its amplitude.

MAY 2009 Page 53 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Inspection of the load machine may reveal some loose or missing part or an
accumulation of dirt or the material being processed on the rotating parts. Since
pump rotors are enclosed, it is usually not possible to check them without
disassembly.

OPEN ROTOR BARS

A large number of open bars in a motor rotor may cause enough magnetic
unbalance to cause excessive motor vibration. Open bars can be detected by one
of the test outlined later in this section.

UNEVEN AIR – GAP

Radial magnetic forces resulting from a badly uneven air-gap in a motor with a
spherical roller thrust bearing may cause the rotor to pull over. The bearing loses
its radial stability even though properly adjusted and loaded, if the radial magnetic
pull is strong enough.

The air-gap must usually be checked by measuring size and concentricity of the
various parts when the motor is disassembled.

SYSTEM RESONANCE

Resonance should be recognized as a system problem.

System resonance is more often encountered with vertical pump motors than
with horizontal motors; hence, vertical motors will be used as a basis for the
following discussion, although the same principles apply to horizontal motors.

A vertical motor and the pump base or support on which it is mounted can be
considered as a vertical reed or cantilever beam, anchored at the lower end to an
infinite mass and free to move at the top end. If such a reed or beam is plucked at
the top end, it will vibrate at its natural or resonant frequency just as a reed in a
Frahm tachometer. This natural frequency is an inherent property of the system
or assembly rather than of any individual component.

If the system resonant frequency (CPM) is numerically close to the operating speed
of the motor and pump (RPM), excessive vibration will probably occur even though
the equipment is well balanced. Evan a small amount of unbalance in the motor
or driven equipment will cause the system to vibrate at operating speed, and the
magnitude of this vibration for a given amount of unbalance is greatly amplified if
the resonant frequency approaches operating speed.

MAY 2009 Page 54 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

CORRECTIVE MEASURES FOR SYSTEMS FOUND TO BE RESONANT AT OR NEAR

OPERATING SPEED.

Systems found to be resonant at a speed too close to operating speed can

sometimes be made to operate successfully by field modifications, either
stiffening the system or making it more flexible. Sometimes braces or stiffeners
can be installed, sections can be cut out of some support member, or the motor or
pump mounted on shims.

Stable, continued operation of a motor and its load at a low vibration level can be
obtained only when the system resonant speed is well removed from operating
speed.

Balance refinement is not a desirable permanent solution for excessive vibration

caused by system resonance. While vibration of the motor and pump running
close to the system resonant speed or frequency can be reduced by precision
balancing at the installation, it may prove impossible to balancing at the
installation, it may prove impossible to balance the equipment well enough to
reduce vibration to unacceptable level. Furthermore, a bearing replacement, a
shift in alignment, wear of the pump, or some other change in the components
may destroy the precision balance and, thus, allow excessive vibration to occur
again. It is also possible that the resonant speed will be shifted closer to operating
speed by a change in foundation bolt tension or some similar change.

PUMP SHAFT RESONANCE

Long pump shafts must be supported at intervals. If support bearings are too far
apart, the shaft may vibrates excessively, and may even become resonant.

The required spacing is, of course, a function of the operating speed and pump
shaft diameter. On vertical hollow shaft motor installations the pump shaft is
supported at the top of the motor but usually not at the bottom of the motor; this
may require a pump shaft bearing close to the base of the motor.

HYDRAULIC CONDITIONS IN PUMPING SYSTEM

If hydraulic conditions are such that cavitation occurs in the pump, the flow of
liquid through pump pulsates, and this pulsative flow may cause vibration of the
pump, motor or piping.

Excessive high water velocities at the pump intake will result in vortexes and
turbulence, with vibration the end result. Velocities over 1 foot per second, and
sharps changes in flow direction at the pump intake may cause trouble. Pumps
mounted with their bowls and intake in a pit or sump are most likely to run into
trouble of this nature, especially when several pumps are pumping from one pit.

MAY 2009 Page 55 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

UP – THRUST ON VERTICAL MOTORS NOT DESIGNED & PROPERLY ADJUSTED

FOR UP-THRUST

Both angular contact ball bearings and spherical roller bearings lose their radial
stability if they are operated without down-thrust load, or if up thrust is imposed.
If the bearings lose their radial stability, they allow the top end of the motor shaft
to gyrate with resultant vibration and possible rotor or shaft rubs. Instructions for
adjusting end-play are also given in the instruction book furnished with each
motor requiring this adjustment.

SPRING LOADED SPHERICAL ROLLER THRUST BEARING MOTORS WITHOUT

THRUST LOAD

Motors with this type of bearing may vibrate excessively even though well
balanced if they are operated without thrust load. The lower race of the bearing is
lifted out of its normal seat by the springs if no thrust load is imposed on the
motor, and this may shift the axis of rotation slightly and cause vibration. If the
motor is to be run for a balance check without thrust load, the end-play must be
set to zero to simulated normal operating conditions. Be sure to reset the end
play to the normal amount after completion of tests.

OPEN ROTOR BARS

Open bars in a squirrel-cage rotor may cause noise, line current pulsations,
vibration, poor torque characteristic, low operating speed and over-heating. Cast
aluminum rotor windings may have original casting defects, or the bars or end-
rings may crack or melt if the rotor is stalled. Copper bar rotors may develop an
open bar if the braze cracks at the joint between an end-ring and a bar.

Motors with a large number of open bars can usually be detected by a growling
noise at start, a noise at operating speed that pulsates at slip frequency, and line
current pulsations. (Slip frequency is the frequency is the frequency at which a
given point on the rotor slips past the rotating magnetic poles created by the
stator winding. For example in a four pole 60 cycle motor running at 1750 RPM,
the slip frequency would be 4 x (1800 – 1750) = 200 CPM).

To check for open bars, the motor should be energized with single-phase power
on one winding; the applied voltage should be selected to obtain about rated full
load current in the winding. (About 23% rated voltage) Connect an ammeter in
the line, and read maximum and minimum current as the rotor is turned slowly by
hand through several complete revolutions. Be sure that the rotor is turned slowly
enough that the meter inertia does not mask the current variations. The ratio of
maximum to minimum current is a measure of the uniformity of the rotor and
serves as a good check for open bars. If maximum current / minimum current is
greater than 1.05, the rotor should be replaced.

MAY 2009 Page 56 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

If the motor is disassembled, the rotor can be checked with a growler. It is

recommended that the single-phase test described above be used also however.

Repair to cast aluminum rotors with open bars are no feasible, and it is necessary
to replace the rotor. Copper bar rotors can usually be repaired by re-brazing the
joints.

STATOR WINDING FAILURES

Stator winding failures may be of any of the following types:

• Turn-to-turn. • Overload & High Ambient

• Phase-to-phase • Ambient chemical Deterioration
• Grounds • Mechanical Coil damage
• Single-phasing • Ambient Abrasives
• Rotor-rub. • Part Winding Start Motor failures
• Corona. • High Voltage Surge

TYPE OF FAILURES & IDENTIFYING CHARACTERISTICS

TURN – TO – TURN

Definition: Failures involving a short between turns of an individual coil. The

shorted turns are in effect the same as a transformer secondary shorted across
its terminals, and destructive high current flows in these shorted turns.

Identifying Characteristics: Roasting throughout the entire length of the

individual coil, caused by the high current in the shorted turns. Reminder of stator
coils relatively undamaged.

PHASE – TO – PHASE

Definition: Failure involving a short between coils of different phases.

Identifying Characteristics: Burned areas on coils of two adjacent phase groups

and burns in the sheet of material used as insulation between the two groups of
coils. This generally occurs in the end turns of the winding.

GROUNDS

Definition: Failures involving a short between any part of the stator winding and
the stator punchings or other parts of motor at ground potential.

MAY 2009 Page 57 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Identifying Characteristics: A hole in the coil insulation at the point of the ground.
This may be very small, or, if large fault current existed before the motor was
tripped off the line, the holes may be large. Stator lamination will also be melted
at the ground if fault current was large. Damage is confined to the area around
the ground, even on the coil involved. Adjacent coils may be damages by the fault
current also.

SINGLE – PHASING

Definition: Failures caused by accidental application of single-phase power to

polyphase motors. The most frequent cause is the loss of one fuse in a power
system having fuses in all three lines, but not having overload device in all three
lines. If the motor is running under load and one line is opened, the motor will try
to keep running on single-phase power. The motor torque is reduced, and the
motor will continue to run only if torque required by the load is less than the
single-phase maximum torque develop by the motor. If single-phase power is
applied to a polyphase motor at standstill, the motor will not start and locked-
rotor current will flow in the energized phase.

Identifying Characteristics: Note that, if one line supplying a Delta connected

motor is opened, all 3 phases of the motor remain energized with single phase
power. If one line is opened while the motor is running, the motor phase
connected directly to the other two lines will be uniformly roasted, while the other
two motor phases may be not damaged.

If one line supplying a Wye connected motor is opened, two motor phases remain
energized and will be burned, while one motor phases has no current flow.

If the motor stall or if single-phase power is applied to a motor at standstill, two

motor phases will be burned out and one left undamaged on Wye connected
motors; on Delta connected motors all three motor phases will be burned out but
one phase should be more severely damage than the other two.

“ROTOR – RUB”

Definition: Failures caused by heat generated by friction between rotor and stator
core.

Identifying Characteristics: Localized burning or charring of the stator coil

insulation in the area of the rub. Stator punchings will be polished and sometimes
blued from the friction heat. Slot wedges usually charred in the area of the rub.

CORONA

Definition: Stator coil failure caused by Corona attack on the coil insulation to
ground.

MAY 2009 Page 58 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Identifying Characteristics: Small pin-point holes burned through the coil

insulation. These may be crater-like when examined under a magnifying glass.
This damage will appear where there are air spaces next to the coil, particularly at
the edges of inside core air ducts.

HIGH VOLTAGE SURGE

Definition: Stator coil failures caused by exposure of the motor to high transient
over-voltages. These may be voltage surges causes caused by system
disturbances, arcing grounds on system or lightning.

Identifying Characteristics: Holes or breaks in the coil insulation. Usually appears

in a terminal coil or group. May appear as Corona damage or severe localized
burning.

OVERLOAD & HIGH AMBIENT

Definition: Failure caused by overloading the motor or operating it in a high

ambient temperature, with resultant winding temperature so high that the
winding fails. This type of failure can also result from operating on a duty cycle,
which exceeds the thermal capacity of the winding. A severely over-heated motor
may also develop a turn-to-turn or phase-to-phase failure as its final or specific
point of failure.

Identifying Characteristics: Charring, discoloration or embrittlement of the

insulation throughout the entire stator winding. Turn-to-turn or phase-to-phase
failures may develop as pointed out above. However, if the entire winding
appears to have been over-heated, load or ambient temperature at time of failure
should be investigated and cited as the true cause of failure if this is justified.

AMBIENT CHEMICAL DETERIORATION

Definition: Failure caused by damage to stator coils by chemicals which are

carried into the motor by the ventilating air or drip into the motor as liquids.

Motor used in paper mills and chemical plants are often exposed to vapors or
liquids which, cause insulation deterioration by chemical action. The “black-
liquor” widely associated with the paper industry is definitely harmful to many
types of stator insulation.

Identifying Characteristics: Ambient chemical deterioration of stator insulation

may lead to a ground or turn-to turn failure as the end result, but chemical
deterioration should be cited as the primary cause of failure of this is evident. An
accumulation of the offending material is usually found on the stator windings.
Sample can be collected and sent to the motor plant for analysis.

MAY 2009 Page 59 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MECHANICAL COIL DAMAGE

Definition: Failures caused by mechanical damage to the stator coils. Turn-to-

turn, phase-to-phase or ground failures may be the end result, but mechanical
coil damage should be cited as the prime cause of failure if this is evident. This
type of failure is especially like to occur on DDO motors.

Identifying Characteristics: Cuts or dents in the coils caused by hammer, screw

driver, or some other tool. Damage can also be inflicted by dropping something
into the motor or by interference between the winding and the air deflectors or
end shields.

AMBIENT ABRASIVES

Definition: Failure caused by damage to the stator windings by continual “sand-

blasting” by abrasives in the ambient air. This might occur in motors used in a
cement mill.

Identifying Characteristics: Worn spots on the stator windings, where the

insulation has been abraded away.

PART WINDING START MOTORS

Definition: Part winding start motors sometimes fail because the motor control
device or starter does not properly energize all of the motor windings. If only part
of the motor windings are energized, and the control does not energize the
remaining part of the motor after a few seconds, that part of the motor which is
energized will burn out.

Identifying Characteristics: Those parts of the winding energized will be burned

out and the remaining groups of coils will be OK. Correlation between the motor
and control can be established by examination.

MAY 2009 Page 60 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

STATOR WINDING REPAIRS & MAINTENANCE

REPAIRS FOR RANDOM WOUND STATORS

Individually coils in this type of motor cannot be removed and replaced. If the turn
insulation on the wire itself is damage, it is necessary to strip out the entire
winding and rewind the motor. Grounds and phase-to-phase shorts usually
damage the turn insulation and thus require a rewind.

Connection may sometimes be repaired or modified (e.g. To make a 220V motor

suitable for 440V by field modification) but this is at best a risky venture because
of possible damage to wire insulation and is not recommended. If such work is to
be done, heat winding and keep it between 90°C and 100°C during all work. Then
re-tube or reinsulated all disturbed wires or damaged insulation. Finally treat with
varnish as recommended by the manufacturer and bake at 150°C for 2½ hours.

REPAIRS FOR FORM WOUND STATORS

In the older design of Class A & B, sealed & Non sealed & Varnished Cambric Coils,
damage Form Wound coils can generally be removed and replace on an
individual basis as required. It is also possible to reconnect and re insulate the
connections desired. If one or two coils are damage, it is sometimes possible to
open up the connection and by-pass these coils as a temporary measure until
new coils can be obtained; this, of course, cause unbalanced currents in the motor
and imposes abnormally high voltage on some of the coils, and should not be
done indiscriminately. Consultation with the manufacturer is recommended if
coils are to be by-passed.

Form wound stators of this category are varnish treated after coils are inserted
and connected. This varnish treatment makes a better motor but at the same
time makes coil removal somewhat difficult. However coils can be lifted and
removed by heating the stator punchings and coils to 90°C - 100°C, and holding
the parts at this temperature while coils are being removed. Use thermometers
on the stator core and maintain the temperature carefully in order to avoid coil
damage. It is recommended that the stator be heated in an oven or with heat
lamps rather than by applying single phase power to the winding, since there is
danger of getting part of the winding too hot if power is applied to the windings.

In newer design the Form Wound coils are often Vacuum Pressure Impregnated
(VPI) with an epos varnish after the coils are set in place. This treatment, while
markedly reducing the incidence of coil failures, makes removal of an individual
coil extremely difficult.

MAY 2009 Page 61 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MOTOR OVER HEATING

Induction motors may over-heat for many different reasons, some of which are
discussed below. Modern motors pack more HP in a given frame and operate
close to their rated temperature rise, and hence, may be hotter to the touch than
some old motors. Do not regard a motor as overheated just because it feels hot –
use thermometer.

OVER – LOADING

Over-loading is a common cause of over-heating. Check the motor line voltage

and current against the rated values on the nameplate and reduce the load as
required. If the load cannot be reduced, you must accept the over-heating and
expect reduced motor life.

SEVERE DUTY CYCLES

Severe duty cycle may cause over-heating. At start, an induction motor draws
about 600% to 700% of rated current, and high currents and losses persist
through most of the acceleration period. During this same time the motor speed
is below normal, and its ability to dissipate the heat losses is reduced. Repetitive
starts and long accelerations of high inertia loads may thus cause the motor to
over-heat, even though it is not over-loaded once it reaches normal speed.

If the duty cycle appears to be causing the motor to over-heat, some

modifications can possibly be made in the equipment, or some change made in
the operation to make the duty cycle less severe. It is sometimes feasible to install
a small blower to help cool the motor.

HIGH AMBIENT TEMPERATURE

High ambient temperatures may cause a motor to over-heat. Motors are

normally rated on the basis of a 40°C ambient. If the motor is in an enclosure,
which is not well ventilated, the heat losses of the motor may raise the ambient
temperature in the enclosure.

DIRT IN MOTOR

Accumulations of dirt in motor ventilating passages decrease the air flow in the
motor and cause over-heating. Clearing instructions are given in the instruction
book shipped with each motor.

MAY 2009 Page 62 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

ABNORMAL APPLIED VOLTAGE.

Abnormal line voltage will cause motor over-heating. Line voltage at the motor
terminals at all normal loads should be carefully checked any time a motor over-
heats. Recording voltmeters should be used if there is any possibility of the line
voltage changing significantly; be alert for possible voltage changes on different
work shifts or at different times of the day. Line voltage should be corrected as
required, by changing transformer taps, improving the distribution system, or
other means.

UNBALANCED LINE VOLTAGE

NEMA Standard MG 1-14-34 is quoted here in its entirety to give an overall

statement of the effect of unbalanced voltage on induction motors; over heating
is discussed in paragraph C of this NEMA Standard.

MG 1-14-34 Effect of Unbalanced Voltages on the Performance of Polyphase

induction Motors.

When line voltages applied to a polyphase induction motor are not exactly the
same, unbalanced currents will flow in the stator winding, the magnitude
depending upon the amount of unbalance. A small amount of voltage unbalance
may increase the current an excessive amount.

To avoid possible damage to the motor or depreciation in operation

characteristics, the supplier of power should be notified of such unbalance in
order that the situation can be corrected.

While the voltages should be evenly balanced as closely as can be read on the
usually available commercial voltmeter, it is recommended that any voltage
unbalance at the motor terminals not exceed 1 percent.

Effect on Performance – General

The effect of unbalanced voltages on polyphase induction motors is equivalent to

the introduction of a “negative sequence voltage” having a rotation opposite to
that occurring with balanced voltages. This negative sequence voltage produces
in the air gap a flux rotating against the rotation of the rotor, tending to produce
high currents. A small negative sequence voltage may produce in the windings
currents considerably in excess of those present under balanced voltage
conditions.

MAY 2009 Page 63 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Unbalance Defined

The voltage unbalance (or negative sequence voltage) in percent may be defined
as follows:

Percent Maximum voltage deviation

Voltage = 100 X from average voltage______
Unbalance Average voltage

EXAMPLE: With voltages of 220, 215 and 210, the average is 215, the maximum
deviation from the average is 5, and the percent unbalance = 100 X 5_ = 2.3
percent. 215

Temperature Rise and Load Carrying Capacity

A relatively small unbalance in voltage will cause a considerable increase in

temperature rise. In phase with the highest current, the percentage increase in
temperature rise will be approximately two times the square of the percentage
voltage unbalance. The increase in losses and, consequently, the increase in
average heating of the whole winding will be slightly lower than the winding with
the highest current.

To illustrate the severity of this condition, an approximately 3.5 percent voltage

unbalance will cause an approximately 25 percent increase in temperature rise.

Torques

The locked-rotor torque and breakdown torque are decreased when the voltage is
unbalanced. If the voltage unbalance should be extremely severe, the torque
might not be adequate for the application.

Full-Load Speed

The full-load speed is reduced slightly when the motor operates at unbalanced
voltages.

Currents

The locked-rotor current will be unbalance to the same degree that the voltages
are unbalanced but the locked-rotor KVA will increase only slightly.

The currents at normal operating speed with unbalanced voltages will be greatly
unbalanced in the order of approximately 6 to 10 times the voltage unbalance.
This introduces a complex problem in selecting the proper overload protective
devices, particularly since devices selected for one set of unbalanced conditions
may be inadequate for a different set of unbalanced voltages. Increasing the size
of the overload protection against heating from overload and from single-phase
operation is lost.

MAY 2009 Page 64 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

ROTOR RUBS

Rotor rubs may cause over-heating by friction and by increasing the load on the
motor. These can often be detected by listening carefully to the motor. If the
motor is disassembled, polished and discolored, areas on the rotor and stator
laminations will point to any rubbing; the slot wedges may be charred if rubbing
has been severe.

INCORRECT CONNECTION OF MOTOR LEADS

Incorrect lead connections may cause a motor to over-heat. Be sure the motor is
connected according to the connection nameplate or diagram furnished with the
motor.

BALL AND ROLLER BEARING FAILURES

All ball and roller bearings are subject to metal fatigue and will eventually wear
out even though they are correctly applied, installed, and maintained. This is
simply a case of fair wear and tear.

Fatigue failures are characterized by flaking-away of the bearing races along the
ball path, and flaking-away of the balls or rollers. Fatigue is a gradual process,
and usually is made apparent in its early stages by an increase in the operating
noise level of the bearing.

Usual causes are listed below and discussed in following sections:

Lubricant improper, contaminated or deteriorate.

Excessive thrust or radial loading.
Shaft currents.
False-brinelling during shipment.
Pre-loading & improper end-play adjustment.
Rusting during storage.
Misalignment of motor & load or of the motor bearing alone.
Incorrect bearing type.

MAY 2009 Page 65 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

IMPROPER OR CONTAMINATED OR DETERIORATED LUBRICANTS

Oil Lubricated Bearings

Oil, which becomes contaminated with dirt, metal, dust or chips or other abrasive
material may cause bearings to wear and fail prematurely, or to be noisy. Great
care should be used to avoid contaminating the oil, or contaminating the oil
reservoir if the motor is disassembled. The reservoir should be thoroughly cleaned
and flushed if it has been contaminated.

Oil used for motors should be of proper viscosity, with oxidation and corrosion
inhibitors, as recommended in the manufacturer’s Instruction Book provided with
each motor. If improper oil is used, or if oil is not changed often enough, the oil
itself will oxidize and become acid. Oil with the wrong viscosity may cause the
bearing to over-heat or may not provide proper lubrication.

Oxidized oil is characterized by darkening and sludge formation, and causes the
bearings to over heat. If the oil becomes acid, the bearings are corroded.

Grease Lubricated Bearings

Comments made in the preceding section concerning bearing or oil

contamination by foreign materials are also applicable to grease lubricated
bearings.

Grease recommendations are given in the Instruction Book furnished with each
motor. Special lubricant instructions are found on the motor nameplate.
Operation with deteriorated grease may result in bearing failures; the grease
should be examined in all cases of premature bearing failure.

EXCESSIVE LOADING

The life of ball and roller bearing is radically shortened if they are overloaded. This
type of failure will appear as fatigue failure normally, and the bearing load should
be investigated in all cases of premature bearing failure.

SHAFT CURRENT

Irregularities in the motor winding and punchings may set up circulating currents
which flow along the shaft, through on bearing, through the stator and thence
back to the shaft through the other bearing. This current, if large enough, may
damage the bearings. The bearings usually become noisy, and small darkened
spots appear on the bearing balls. The races often have darkened bands around
them, made up of a large number of lines across the ball track parallel to the shaft
axis.

MAY 2009 Page 66 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Methods for detecting and eliminating motor shaft current are discussed later in
this section.

FALSE BRINNELING

This type of damage is most common on roller bearings but does occur on ball
bearings. Axial vibration encountered during motor shipment with rotor resting in
one position may cause the bearing rollers to wear or “fret” the races at the
contact points. These minute axial grooves across the rollers path in the bearing
races will make the bearing noisy. Bearings which are too noisy to be acceptable
must be replaced. This type of damage may occur in motors having a ball bearing
at one end of the motor and a roller bearing at the other end.

Motors subject to false-brinnelling damage should be specially crated before

shipment, with the rotor blocked to prevent axial vibration.

PRELOADING

Motor having spherical roller or ball bearing at both ends of the motor may suffer
bearing damage by “preloading” or loading one bearing against the other, if the
motor end-play is incorrectly adjusted or if motor part are not correctly machined
and assembled.

End-play of vertical motors with angular contact ball thrust bearings or spherical
roller thrust bearings must be properly adjusted in accordance with the limits
established by the manufacturer. On motors in which end-play is set by adjusting
the top shaft nut, the bearings can be preloaded if the shaft nut is tightened too
far. End-play of medium thrust motors is adjusted by installing shims above the
outer race of the guide bearing in the top end shield to limit end-play the desired
amount and, shield to limit end-play to the desired amount and, if the shims are
too thick, the bearings will be preloaded with a compressive force when the motor
is assembled.

RUSTING DURING STORAGE OR IDLE PERIODS

Moisture – either water or water vapor – may work its way into the bearing
housing during storage or idle periods, and rust the bearing. Preventative
maintenance is the answer to this problem.

New motors are shipped with oil drained out of the bearings, and, even the
bearing reservoirs are filled with the proper amount of oil, some parts of the
bearings are above the oil level. The bearings are coated with a film of oil when
the motors are run during final testing at the factory; this film will normally provide
adequate protection for the bearings for about three months. Motors should be
turned over occasionally to reestablish an oil film on those bearings, which are
above the oil level.

MAY 2009 Page 67 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

It is possible to fill the oil reservoir above the normally level for added bearing
protection during idle periods, but be sure to drain the oil back to normal level
before running the motor. Maximum permissible oil levels should be obtained
from the motor manufacturer for specific motors involved if user wishes to use
this technique.

MISALIGNMENT

Misalignment of the driven equipment with respect to the motor or misalignment

of a motor bearing because of improper assembly or machining of the motor
parts can cause bearings to over-heat and eventually fail. If it is hard to rotate the
motor rotor, alignment should be checked.

INCORRECT BEARINGS

When replacing bearings it is possible to substitute an incorrect bearing. Some

motors require bearings with special large clearances to accommodate the
normal expansion, substituting a standard bearing will lead to overheating and
early failure.

SLEEVE AND PLATE BEARING FAILURES

Sleeve and plate bearings are oil-film bearings and not subject to metal fatigue
failure. Failures occur when the oil film between the runner and bearing shoes is
broken, allowing metal-to-metal contact with resulting galling and heating of the
metal surface.

The oil film may break down for various reasons, some of which are listed below:

a. Use of oil with too low a viscosity.

b. Used of oil that becomes too thin at normal bearing
temperatures.
c. Continued use of oil that has become contaminated, acid,
or oxidized.
d. Operation at excessive thrust loads. Note that plate type
bearings cannot carry much over-load, even for short
periods.

Bearings may be damage by rusting if they are not protected during storage
periods.

Some horizontal sleeve bearings depend upon oil rings to properly lubricate the
bearings and the bearing will fail if the oil-rings are stuck and do not rotate when
the motor is running.

MAY 2009 Page 68 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Water cooled bearings will fail if water flow is inadequate and permits the oil
temperature to increase, lowering the oil viscosity and allowing the oil film to
break.

If a bearing fails and the cause is not apparent from field investigation, a sample
of the oil in the motor at the time of failure, and a sample of unused oil of the type
normally used in the motor should be sent to the manufacturer for analysis. The
manufacturer should also be advised of the name and complete specification of
the oil. Investigation should also be made of the thrust load on the motor at the
time of failure. Any records of oil and bearing temperatures should also be
reviewed with the manufacturer.

MOTOR BEARING NOISY

Anti-friction bearings inherently make a certain amount of noise, and experience

is the best guide to recognition of normal noise levels. Bearing noise should in
general be a steady hum. It must be realize that some bearing types are
inherently more noisy than others; for example, cylindrical roller bearings are
more noisy than ball bearings of the same size.

Bearings may be excessively noisy for various reasons, some of which are listed
below and discussed in the following sections:

• Lack of lubrication.
• Contaminated lubricant.
• Lack of thrust load on angular-contact ball bearing.
• Bearing damage or beginning to fail.

INSUFFICIENT LUBRICATION

Grease lubricated bearings are more often noisy for this reason than oil lubricated
bearings, since it is easy to check the oil level. If lubrication is insufficient, the
bearing may develop a squealing noise. Grease lubricated bearings may be noisy
because there is not enough grease, or because the grease is dried out and no
longer can supply oil to the bearings. Lubrication should be checked if bearings
are noisy, and lubricant added if necessary. On grease lubricated bearings be
careful not to over-grease, this may quiet the bearing but at the same time cause
heating or grease leakage.

MAY 2009 Page 69 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

LUBRICANT CONTAMINATION

Foreign material such as metal particles or sand in the lubricant or bearing

reservoir may cause noise as it passes through the bearing. The lubricant should
be replaced if it is found to be contaminated. The bearing and reservoir should, of
course, be thoroughly cleaned and flushed before motor re-assembly and re-
lubrication.

Foreign material may have already damage the bearing, so that it will still be noisy
after it is cleaned and re-lubricated. Therefore, consideration should be given to
replacement of the bearing.

ANGULAR CONTACT BALL BEARING NOISE CAUSED BY LACK OF THRUST LOAD.

Angular contact ball bearings (normally used as thrust bearings) must have axial
thrust loading imposed in order to retain their radial stability. If motors with this
type bearing are operated without thrust, the bearing may be more noisy than
usual. Thus a motor with angular contact bearings may be more noisy when
running uncoupled from its load than it will be after it is put in service.

BEARING NOISE CAUSED BY BEARING DAMAGE OR BEARING FAILURE

Bearing will, of course, become noisy if parts are broken or rusted, or if the
bearings begin to fail from fatigue. Inspection of the bearings should in these
cases reveal the cause of the noise, and the bearings can be replaced.

BEARING OVER-HEATING

Grease lubricated bearings may over-heat for various reasons, some of which are
listed and discussed below. It must be recognized that bearing in some motors
normally run hot when they are fully loaded. Use a thermometer or thermocouple
to measure bearing temperature – NOT YOUR HAND. The outside of the bearing
housing may run as high as 50 C above ambient; in a 40C ambient this would
result in 90C or 194F total temperature, too hot to be comfortable to your hand. If
higher bearing temperatures are encountered, the motor manufacturer should be
consulted.

Usual cause of over-heating are listed below and discussed in the following
sections:

• Bearing over-greased.
• Grease deteriorated or dried out.
• Improper grease.
• Bearing over-loaded.
• Misalignment.
• Bearing pre-loaded.

MAY 2009 Page 70 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

OVER – GREASING

Bearings that are operated while over-greased heat up because of churning and
whipping of the excess grease. The balls are not able to establish a channel in the
grease.

Remove the grease relief plug from the bearing housing and run the motor to
allow it to purge out the excess grease, if this trouble is suspected.

GREASE DETERIORATION

Grease may deteriorate or dry out and fail to supply enough oil to the bearing for
proper lubrication. In such cases the old grease should be removed and the
bearing re-greased.

OVER – LOADING

Over-loading is a common cause of over-heating on vertical motor thrust

bearings and on the pulley-end bearing of belt connected motors. Loading should
be investigated and corrected if found to be excessive.

Belt tension on belt-drive installations should be kept as low as possible; it is better

to have the belts slip and squeal a little on peak loads and during acceleration of
heavy inertias, then to have bearing failures caused by excessive loading.

If vertical motor thrust bearings over-heat, the thrust imposed by the pump must
be checked with the pump builder, and checked against the thrust capacity of the
system can be changed to hold thrust within bounds, or it may be necessary to
modify the motor or pump.

MISALIGNMENT

Misalignment may cause either thrust or radial load components in a bearing, and
thus, cause over-heating. Careful realignment of the motor and its load is
required. Also the motor must be checked to be sure there is no internal
misalignment.

PRE-LOADING

Pre-loading imposes thrust loading on the bearing and may cause the bearing to
over-heat if pre-load is severe. Proper adjustment of motor end-play will relieve
this condition. Pre-loading and misalignment will make the motor hard to turn if
severe enough.

MAY 2009 Page 71 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

OIL LUBRICATED BEARINGS

Oil lubricated bearings, like grease lubricated bearings, may normally be expected
to be quite warm or hot when fully loaded. If bearing temperature is a problem,
measure the oil temperature with a thermometer to see if it is really excessive,
some bearings normally operate with about 60C oil temperature rise.

Usual causes of over-heating are:

• Bearing over-loaded.
• Bearing misalignment.
• Bearing preloaded.
• Improper oil.
• Insufficient oil.
• Deteriorated or contaminated oil.
• Insufficient water flow in oil cooling coils.

The first three of these have already been discussed.

IMPROPER OIL

Oil with wrong viscosity (too heavy) can cause bearing to over-heat. Replace with
recommended oil.

INSUFFICIENT OIL

If bearings are over-heating, check oil level to be sure it is at proper level.

DETERIORATED OR CONTAMINATED OIL

Most motor manufacturers recommend use of oils with oxidation and corrosion
inhibitors. Even these oils slowly deteriorate and must be replaced occasionally as
operating experience indicates. If operation is continued with oil that has
deteriorated or is contaminated with dust or other foreign matter, the bearings
will heat excessively. This, in turn, causes further deterioration of the oil and the
bearing temperature spirals upward.

The only cure for this type of trouble is the use of recommended oil, changed as
required.

Oil deterioration is indicated by a darkening of the oil and the formation of sludge
in the oil.

MAY 2009 Page 72 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

INSUFFICIENT WATER FLOW IN OIL COOLING COILS

Cooling water requirements are indicated on a nameplate attached to the motor.

These requirements must met in order to insure satisfactory oil temperatures.

OIL LEAKS

Oil leaks must be carefully and logically investigated if corrections are to be made
with reasonable effort and expense. It is recommended that an external
examination be made as outlined below, before a motor is disassembled or
removed from its installation.

First check the oil level to be sure that the motor has not been over-filled at any
time.

Check to see that proper oil is in the motor. Some oils with high detergent content
may foam excessively and leak over the oil sleeve.

By careful examination, try to determine the source of the leakage. Check for
cracked or porous castings, leaks at oil gages or other fittings.

If the leak cannot be found, clean the motor, run it for a short time, and then re-
examine the motor.

GREASE LEAKS

Grease leakage is usually caused by over-greasing. Investigate this possibility by

cleaning away the leakage and running the motor with grease relief pipes or plugs
open. This will allow excess grease to get out and stop leakage in many cases.
Improper grease may bleed its oil too rapidly or break down, with consequent
leakage. Some other possible causes of leakage are:

Missing gaskets.
Bearing covers not right.
Excessive clearance between parts (machining error or wear).
Cracked or damaged parts.

OIL DETERIORATION

Oil slowly oxidizes and may become acid during normal motor operation.
Oxidized oil may be recognized with sludge. Laboratory tests are required to
determine the acidity. Oxidation produces water-soluble acids and leads to
formation of water, and the combination of these acids and water leads to a
corrosive condition. Rust may result. Soluble oxidation product are converted to
insoluble products, by polymerization or condensation and the end products, by

MAY 2009 Page 73 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

polymerization or condensation and the end product is sludge which is a mixture

of metal soap and asphaltic residues.

Oil should be changed regularly, before it becomes badly oxidized or acid, since
the rate of deterioration becomes more rapid if the oil is kept in service.
Continued use of deteriorated oil will damage the motor bearings.

Deterioration is accelerated by high ambient temperatures, excessive bearing

loads, insufficient cooling water (on water cooled bearings) or any other condition
that caused the oil to run hotter than normal.

GREASE DETERIORATION

Motor bearing grease ages or deteriorates in normal service as its oil content is
depleted. The grease becomes hard and caked. Motors should be re-lubricated
regularly as service conditions require. Bearings may be damaged if operated
with deteriorated grease.

PROBLEMS ASSOCIATED WITH COUPLINGS

Problems with couplings generally fall into one of the following areas:

1. Excessive run out on rabbet fit.

2. Excessive run out on coupling face.
3. Offset misalignment between coupling halves.
4. Angular misalignment between coupling halves.
5. Poor fit between coupling and shaft.

Item 1, 2 and 5 may be caused by some defect in the motor shaft extension or in
the coupling, whereas item 3 and 4 are usually caused by improper line-up
between the motor and the driven equipment. Coupling run out, etc., is usually
discovered when dial indicator checks are made during installation; if not caught
and corrected at this stage, it may cause excessive vibration.

SHAFT BENT OR BROKEN

Usual symptoms of a bent shaft are excessive run out or vibration. Shaft run out
can be measured with a dial indicator at several places along the shaft as a check
to see if the shaft is bent.

If a motor shaft is bent, check for possible shipping damage or damage from
rough handling during installation. Check for signs of rubbing at the various shaft
seals, since a shaft can bend as a result of localized frictional heating. If the motor
is belt connected, check for excessive belt tension.

MAY 2009 Page 74 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Also make physical inspection of the installation of you arrive before the belts are
taken off, checking the shat deflection and checking the clearance around the
shaft deflection and checking the clearance around the shaft at the end-shield.

Repairs can sometimes be made in the field by a skilled mechanic by careful

application of heat. If this cannot be done, the shaft must be repaired in a service
shop or replaced.

BROKEN SHAFT

Motor shaft may be broken or cracked by damage in transit, mechanical abuse,

torsional fatigue or bending fatigue caused by excessive belt tension.

Torsional fatigue failure is indicated by a break along a plane at 45° from the shaft
axis. This type of failure may occur on direct connected motors driving pulsating
loads.

Bending fatigue failure is indicated by a break perpendicular to the shaft axis. This
type of failure is usually caused by excessive belt pull on belt drive applications.

Broken shaft must be replaced, but it is of equal importance to determine the

cause of failure and take steps to prevent repeated shaft failures.

SHAFT CURRENTS

Magnetic dissymmetry in a motor may cause current to flow through the stator
and end-shields, through one bearing, along the shaft, and then back to the stator
through the other bearing. This current may damage the bearings by producing
electric arcs that deteriorate the bearing races and balls.

Motor bearings that have been damaged by shaft currents become noisy, since
the electric arcs produce a characteristic rough “washboard” pattern on the metal
surfaces.

Shaft current damage to bearings can be prevented by installing a shunting brush

connected to the motor end-shield and riding or brushing against the shaft. A
brush arrangement that has been success fully used in the field is shown in Figure
32.

MAY 2009 Page 75 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

This is generally considered only a temporary measure, and is not generally

acceptable as a permanent solution. Permanent repair requires insulating one
bearing or re-working the motor to eliminate the voltage producing the shaft
currents.

1. Monel Disk Screwed Into End of Motor or Pump Shaft

2. Brush Holder & Bracket (98% Copper – 2% Graphite)
3. Steel Bar Bent Into Suitable Bracket
Figure 32 Shunting brush instalation
Shaft currents can be detected in the field by making check with a clip-on
ammeter and a volt-meter as show in Figure 33. The ammeter should be set on
the 0 to 5 or 0 to 10 ampere scale and the voltmeter should be a 0 to .5 or 1.0
voltmeter. As can be seen in Fig. 3, the measurements are not direct
measurements of the actual shaft current which is flowing, but they do give useful
indication. Also note that shaft current generally increases under load, so
measurements should be taken with the motor fully loaded.

Figure 33 Detecting shaft currents

MAY 2009 Page 76 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MOTOR NOISE

Motor noise of the several types listed below exists to some extent in most motors.
Types of noise, characteristics and solutions are as follows:

Bearing noise – discussed earlier

Noise caused by open rotor bars – discussed earlier

Magnetic noise – caused by vibration set up by electro-magnetic forces. Usually a

steady non-pulsating tone. May increase as voltage is increased. This type of
noise can be identified and separated from windage noise because it stops
immediately if the motor is de-energized, whereas windage noise decreases
gradually as the motor slows down.

Windage noise – caused by motor fans and other rotating parts. Generally low
frequency, but dependent on number of fan blades and motor speed. Rotor and
stator air ducts on some motors may produce a siren-like noise.

Generally there is not much that can be done in the field to reduce magnetic or
windage noise. Sometimes it is feasible to provide a sound deadening enclosure
around the motor although it is of course necessary to provide for adequate
ventilation & motor cooling.

SINGLE PHASE MOTOR CAPACITOR FAILURE

Single-phase capacitor motors are of two types capacitor start – capacitor run
and capacitor start only.

RUN CAPACITOR FAILURE

A parallel connected bank of Pyranol run capacitor is connected in series with the
auxiliary winding at all times on capacitor run motors. These capacitors give the
motor higher power factor, higher efficiency, higher maximum torque and higher
full load speed than the motor would have without the capacitors. Therefore,
failure of the run capacitors will detract from the performance of the motor, and
these capacitors should be checked of motor performance becomes poor or the
motor begins to overheat. Since these capacitors are connected in parallel with
each other, one capacitor can open-circuit with only a partial reduction in motor
performance, but if one capacitor is short circuited, the whole bank is made
ineffective.

While all run capacitors will eventually age and fail after several years of service,
premature failures should be relatively rare. Most failures will simply be internal
failures with no special external cause. High line voltage will increase the voltage
on the capacitors and shorten their life, and this may become a cause of

MAY 2009 Page 77 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

premature failure. Voltage on the run capacitors rises as the load or the motor
decreases, so that motors that are lightly loaded or that are driving pulsating
loads are most subject to run capacitor failure.

START CAPACITOR FAILURES

Motor starting capacitors are electrolytics suitable only for intermittent duty. They
are connected by the starting switch at standstill and removed from the circuit by
the switch when the motor reaches approximately 2/3 synchronous speed.

Many single-phase motors use a series-parallel bank of start capacitors. If a

capacitor failure occurs, all capacitors should be checked. If one of two series
connected capacitors develops an internal short, the second capacitor will be
over-voltaged and will fail; often the first capacitor will look OK, and if its failure is
not detected, it will cause failure of any replacement capacitor connected in series
with it. Detective capacitors should be replaced with capacitors with the same
mfd and voltage rating. See item “e” below.

Premature start capacitor failure may be caused by one of the following:

a. Internal defect.
b. Motor line voltage excessively high.
c. Motor subjected to excessively long or frequent starting duty. Starts
should in general be limited to not more than 15 starts per hour, with
acceleration period no longer than 3 seconds.
d. Failure of centrifugal mechanism or switch, thus leaving the start
capacitors energized when the motor is up to speed.
e. Use of capacitors with wrong voltage or microfarad rating. Capacitors
connected in series act as a voltage divider and both voltage rating
and microfarad rating must be properly chosen or one capacitor will be
subject to over-voltage. Substitution of 110 volt capacitors for 160 volt
capacitors is not permissible.
f. Motor stalled – thus leaving starting capacitors energized long enough
to burn them out.

SINGLE PHASE MOTOR START SWITCH & CENTRIFUGAL SWITCH – OPERATING

MECHANISM PROBLEMS

Most single phase motors use a switch operated by a centrifugal mechanism to

switch the start capacitors in and out. If the switch fails to connect the capacitors
in the circuit at standstill, the motor starting torque will be very low. If the switch
fails to disconnect the capacitors when the motor reaches about 2/3 synchronous
speed, the capacitors will be destroyed.

The centrifugal mechanism makes an audible click or snap when it operates, and
thick click can be heard by listening closely as the motor accelerates. If the switch

MAY 2009 Page 78 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

fails to disconnect the start capacitors, the motor will be very noisy when it
reaches full speed.

The start switch must interrupt a considerable current each time the motor starts,
and the contact will eventually deteriorate. Expected life is about 100,000 starts.
Inspection of switch contacts and replacement of the switch when required
should be a part of regular motor maintenance.

The external arm of the switch rides on the bakelite push collar of the centrifugal
switch operating mechanism during acceleration and deceleration below about
2/3 of synchronous speed. After long service, the rubbing surfaces will become
worn, and the switch and centrifugal mechanism should be replaced.

If the switch and mechanism do not function properly, they should be inspected to
be sure that no parts are binding or damaged. Check the motor shaft to be sure it
is not so dirty that it jams the centrifugal mechanism.

RUBS BETWEEN ROTOR AND STATOR PUNCHINGS

Rubs between rotor and stator may be caused by eccentric parts, a bent shaft,
excessive belt tension, or foreign material in air gap. If motor air gap is improper,
the rotor may be allowed to pull over and rub because of unbalanced magnetic
pull. Parts should be checked carefully if a rub occurs and corrected as required.

If the rub is severe, it may have generated enough frictional heat to damage the
stator slot wedges and stator coils. Examine these parts carefully to be sure that
they are all right. Also, severe rubs may generated enough heat to cause rotor
bars to crack; an open bar check is advisable.

COLLECTOR RING THREADING ON WOUND ROTOR MOTORS

Collector rings usually give long service, but under some adverse conditions may
“thread” and wear away rapidly.

Threading may be caused by two factors:

1. Extremely dirty or oil conditions around the rings, which prevents

formation of a suitable film on the rings. The source of the contamination
should be eliminated, and a regular maintenance program established to
keep the rings clean.
2. Operation of the motor at light loads for prolonged periods. This reduces
the brush current density below allowable levels, causing damage to the
rings.

Brushes are normally selected on the basis of full load operation. If the motor is
lightly loaded and the rings are threading, contact the motor manufacturer for

MAY 2009 Page 79 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

recommendations for a different brush material more suited to existing current

densities. Following is a guide indicating suitable brush material for various
conditions.

TABLE 1

Motor Type Current Density (Amps/Sq. In.) Brush Material (G.E.

Grade)

Open Drip-proof, TEFC 30 – 50 D

& TENV Motors 50 – 65 456
Except 2 Pole) 65 – 80 L4

Motor with External 20 – 40 D

Enclosed Collector 40 – 60 L4
Ring Housing

All Pole Motors All D

OPERATING CONDITIONS WHICH MAY CAUSE TROUBLE

Some operating conditions may be detrimental to motor performance and life.

You should be familiar with these conditions as an aid in diagnosing existing
troubles and in preventing trouble by recommending corrective measures.
Various detrimental conditions are discussed in the following sections.

IMPROPER POWER SUPPLY

Allowable voltage and frequency variation for successful motor operation for
general purpose motor operation in ambient 40°C or less at 3300 ft. or less are as
follows:

a. Voltage = Motor nameplate value plus or minus 10%.

b. Frequency = Motor nameplate value plus or minus 5%.
c. Combined voltage and frequency deviation may be as mush as
10% above or below nameplate values provided frequency does
not deviate more than 5%.

NOTE: Motors should operate successfully within above limits, but will not
necessarily meet performance guarantees.

MAY 2009 Page 80 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

APPLICATION OF SINGLE PHASE POWER TO THREE PHASE MOTOR

Accidental application of single-phase power to a 3-phase motor will generally

damage the stator winding. Stator winding damage can be prevented by use of
properly selected overload devices in all 3 lines.

Pump motors sometimes drive the pump backwards if single-phase power is

applied after a system power failure or disturbance. This can cause damage to
the motor and the pump.

MOTOR OVER-LOADED OR DUTY CYCLE TOO SEVERE

Motors can carry large overloads without immediate failure, but the overload
gradually takes its toll and shortens the life of the motor. Motors are sometimes
overloaded from the outset by being connected to a machine requiring more
horsepower than the motor rating. Motors are also subject overloading by
changes in materials or processor or changes in operating condition. For
example, changes in head or flow or pump impeller adjustment may overload a
pump motor.

If it is desired to determine the motor load and check its performance, the
following data should be obtained and forwarded to the manufacturer.

1. Voltage at motor terminals (all 3 Phases).

2. Line current (all 3 phases).
3. Watts input to the motor.
4. Motor speed (measure slip with strobotach if possible to get accurate
speed).

Motor can be over-loaded in effect by imposing duty cycle that is too severe. A
cycle involving a large number of starts and stops may cause over heating even
though the actual HP requirements are not excessive. On cycle in which the
motor output HP varies during the cycle, it is necessary to calculate an equivalent
steady state HP to determine whether the motor is over-loaded. Data for
evaluation of the duty cycle should be obtained if the cycle appears to be
overheating the motor.

VENTILATION INADEQUATE OR EXCESSIVE AMBIENT TEMPERATURE

Most motors are designed to operate in an ambient temperature not exceeding

40°C or 140°F. Operation in higher ambients shortens the motor insulation life. At
altitudes above 3300 feet, the cooling ability of the air is decreased and the
normal allowable ambient for 40°C motors is as follows:

MAY 2009 Page 81 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Ambient Temp. Maximum

altitude
Degrees C Feet

40 3300
30 6600
20 9900

Motor must be installed so that there is adequate ventilation around the motor
and so that the heat losses of the motor can be dissipated without raising the
ambient temperature around the motor above allowable limits. Furthermore,
installations should be checked to be sure that nothing causes the warm air
coming out the motor to be re-circulated back into the motor.

EXCESSIVE EXTERNAL THRUST IMPOSED ON MOTOR BEARINGS

Pumps and fans may impose axial thrust on motor bearings. While motor
bearings are often designed to carry this external thrust load, trouble can arise if
motors are misapplied or if thrust conditions change. Pump thrust changes with
flow and head, and motors with bearings adequate for all anticipated conditions
should be selected.

OPERATION OF MOTORS ON UNGROUNDED POWER DISTRIBUTION SYSTEM OR

SYSTEM WITH INADEQUATE SURGE AND LIGHTNING PROTECTION

Operation of motors on ungrounded or inadequate protected systems subjects

them to possible stator winding failure caused by transient over-voltages. An
arcing ground on an ungrounded system can build up transient over-voltage and
damage all the motors on that system.

IMPROPER MOTOR OVERLOAD PROTECTION

A motor without adequate overload protection is operating on borrowed time.

The overload protective device must protect the motor if it is stalled as well as
protect it from operation and overheating at continuous overloads exceeding its
service factor. Three-phase control devices which have heaters or relays in all 3
motor leads are greatly superior to devices with only 2 heaters, since they prevent
damage to the motor by “single-phasing”.

Ambient compensated control devices are desirable if ambient temperature at

motor differs greatly from ambient at control device.

MAY 2009 Page 82 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Motor users should be cautioned against installing oversized heaters in control

devices. Regular inspection and maintenance of control devices will insure that
they are ready to protect the motor at all times.

EXCESSIVE BELT PULL ON BELT CONNECTED MOTORS

Motor shaft or bearing failures may result if excessive belt pull or tension exists.
Belt tension should be adjusted so that it is just enough to prevent serious slipping
during accelerations. Require belt tension increases the arc of contact between
belt and sheaves decreases; therefore, drive using sheaves of widely different
diameters, or sheaves located on a short center to center distant most likely to
cause trouble. Motor bearing loading is increasing by use of very wide sheaves
which in effect multiples the belt pull through lever action; the motor sheaves
should be located as close as possible to the motor bearing.

MAY 2009 Page 83 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MAY 2009 Page 84 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Four

Commutator Film Building

MAY 2009 Page 85 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATOR FILM BUILDING

INTRODUCTION

Generally a commutator on a DC machine will be covered by a carbon, copper,

oxide film. This film may vary in appearance from an even light tan to a mottled
surface, to a dark brown film and still give satisfactory performance. Sometime,
however, a machine will have difficulty forming a satisfactory film or if a film is
formed, it may be “stripped” off one or more brush tracks. When there is no film
present, the commutator may experience grooving and rapid brush wear. The
grooving can occur in a matter of hours and unless it is corrected, this condition
can severely shorten the life of the commutator.

A number of procedures have been tried to aid in the building and maintaining of
a commutator film. Although film building is not a science, there are procedures
that are felt to have some success. This report is written to review some of the
practices that people with field experience in filming problems feel are useful.

This discussion of field practices is being published for the convenience of our
users. Since the knowledge presently available about film building is not precise,
this paper should no be interpreted as a guaranteed “ how to “ manual. While we
hope that this report is useful, General Electric Company cannot warrant that any
of the processes reported herein will be successful on any specific case.

II. THINGS THAT CAUSE COMMUTATORS TO LOSE FILM

The three factors that have the most detrimental influence on film formation are:
1. Low moisture in the air.
This condition is found in hot, dry, areas and during cold weather. The
moisture content is determined by the air temperature and the relative
humidity. It is not relative humidity alone.

2. High brush temperature.

Brush temperature usually goes along with the temperature of the entire
machine.

3. Abrasives in the atmosphere (taconite and other abrasive dust).

III. METHODS OF BUILDING FILM

A. TREATED CANVAS

Recent trials have indicated that use of treated canvas obtained from General
Electric’s Carbon Products Department has been helpful in aiding film building
during low humidity periods and when brush temperature is high. The use of
treated canvas is felt to offer protection against film stripping when conditions are

MAY 2009 Page 86 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

bad and to aid in film building under most conditions. However, using treated
canvas will not help problems resulting from electrical misadjustment of the
machine.

A canvas wiper can be made by wrapping the canvas around and securely
fastening it to a wooden stick, (Figure 34). All tracks of the commutator should
then be wiped with the canvas on the leading side of each brush stud.

Figure 34 Canvas wiper

WARNING: HIGH VOLTAGE AND ROTATING PARTS CAN CAUSE SERIOUS OR

FATAL INJURY. TO PROTECT PERSONNEL FROM HARM DUE TO
ELECTRIC SHOCK, ROTATING PARTS AND FLYING DUST, THE
FOLLOWING SHOULD BE OBSERVED.

1. HIGH VOLTAGE WILL BE PRESENT: DO NOT CONTACT INTERNAL

PARTS OF THE MACHINE.
2. MAKE SURE THAT THERE ARE NO LOOSE ENDS OF CANVAS THAT
CAN CATCH ON ROTATING PARTS.
3. WORKMEN SHOULD WEAR GOGGLES AND RUBBER INSULATING
GLOVES AND STAND ON DRY PLANKING.
4. THE PERSON OPERATING THE CONTROLS SHOULD REMAIN AT
THE CONTROLS UNTIL ALL WORK IS COMPLETE.

B. ETHYLENE GLYCOL

A piece of cloth barely moistened (NOT WET) with ethylene glycol may be use to
wipe the commutator periodically to help prevent rapid brush wear. Some people
have found this method effective when the moisture content of the air is low. It
has been reported that brushes sometimes begin “singing” during cold weather
and that this is one indication that rapid brush wear and possible film stripping
are about to begin. Under these conditions, the ethylene glycol should be used. A
wiper can be made by wrapping a non-linting cloth around and securely fastening
it to a wooden stick (Figure 34). All tracks of the rotating commutator should then
be wiped on the leading side of each brush stud.

WARNING: HIGH VOLTAGE AND ROTATING PARTS CAN CAUSE SERIOUS OT

FATAL INJURY. TO PROTECT PERSONNEL FROM HARM DUE TO
ELECTRIC SHOCK AND ROTATING PARTS, OBSERVE THE FOLLOWING:

1. HIGH VOLTAGE WILL BE PRESENT: DO NOT CONTACT INTERNAL

PARTS OF THE MACHINE.

MAY 2009 Page 87 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

2. MAKE SURE THAT THERE ARE NO LOOSE ENDS OF CLOTH THAT

CAN CATCH ON ROTATING PARTS.
3. WORKMEN SHOULD WEAR GOGGLES AND RUBBER INSULATING
GLOVES AND STAND ON DRY PLANKING.
4. THE PERSONS OPERATING THE CONTROLS SHOULD REMAIN AT
THE CONTROLS UNTIL ALL WORK IS COMPLETED.

CAUTION: USE ONLY PURE ETHYLENE GLYCOL. ANTIFREEZE CONTAINING

ANTILEAK COMPOUNDS OR RUST INHIBITORS SHOULD NOT BE
USED.

MAY 2009 Page 88 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

C. SEATER STONE

If the film is stripping from some tracks of the commutator, the current
distribution between brushes may be unequal and the situation may get worse. In
this case, the film is usually cleaned from all tracks of the commutator with a
seater stone. Stoning should continue until all tracks are cleaned and appear
even. The machine should then be blown out with compressed air to remove as
mush of the dust as possible.

WARNING: HIGH VOLTAGE AND ROTATING PART CAN CAUSE SERIOUS OR FATAL
INJURY. TO PROTECT PERSONNEL FROM HARM DUE TO ELECTRIC
SHOCK, ROTATING PARTS AND FLYING DUST, OBSERVE THE
FOLLOWING:

1. WHEN USING THE SEATER STONE, THE MACHINE SHOULD BE

RUN WITHOUT VOLTAGE TO PREVENT FLASHOVER.
2. HIGH VOLTAGE MAY BE PRESENT: DO NOT CONTACT INTERNAL
PARTS OF THE MACHINE.
3. DO NOT USE A METAL FITTING ON THE END OF THE AIR HOSE.
USE AN EXTRA LENGTH OF HOSE BEYOND ANY SHUT-OFF VALVE.
4. WORKMEN SHOULD WEAR GOGGLES AND RUBBER INSULATING
GLOVES AND STAND ON DRY PLANKING.
5. THE PERSON OPERATING THE CONTROLS SHOULD REMAIN AT
THE CONTROLS UNTIL ALL WORK IS COMPLETE.

CAUTION: THE COMPRESSED AIR SHOULD BE FREE OF OIL MIST SINCE OIL CAN
CONTAMINATE THE COMMUTATOR.

MAY 2009 Page 89 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

D. COMPRESSED AIR

After the machine is initially blown out, the compressed air may be used to further
clean the machine and to help rebuild film on the bare commutator. The theory
behind the use of compressed air to build commutator film is that the air from the
compressor has a higher moisture content than the surrounding air. The
procedure to be used when using compressed air to build film is as follows:

1. Operate the DC motors for the motion (hoist, swing, etc.) corresponding to
the generator in question at about 20-25% rated speed (voltage) and direct
a jet of compressed air in the generator commutator surface. The hose
should be held between one and two inches from the commutator surface
and swept back and forth longitudinally in the direction of the mica.
2. Increase the DC motor speed (voltage) in steps of about 20%.

CAUTION: DURING THE GRADUAL INCREASE IN SPEED, PIN POINTS OF LIGHT

SPARKS MAY BE OBSERVED ON THE COMMUTATOR. DO NOT INCREASE THE SPEED
UNTIL THIS IS CLEARED UP BY WORKING THE AIR BACK AND FORTH.

3. If the sparks cannot be blown out, shut down, clean out the commutator
slots with a scraper or engraving tool to remove the dirt, copper whiskers,
etc. Then restart and proceed as before.
4. Continue air treatment until the film begins to rebuild.

MAY 2009 Page 90 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

E. OTHER CONSIDERATIONS:

1. Brush grade is also a factor in building and maintaining commutator

film. Choice of brush grade for a given application should be based on
recommendations of the machine manufacturer or a brush application
specialist. Different machine characteristics or different environments
may require different brush grades.
2. Another factor that can affect the commutator film is machine loading.
Motors or generators should not be run at light loads for extended
periods as this tends to wear away commutator film.
3. Correct electrical adjustment if the machine is important to obtaining
good commutation and will, therefore, affect the commutator film. The
brushes must be set on the correct position (usually electrical neutral)
and they must be equally spaced around the commutator. Air gaps
must be balance and the proper shims must be used with the
commutating poles.

MAY 2009 Page 91 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MAY 2009 Page 92 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Five

Surface Rounding Brush

MAY 2009 Page 93 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

SURFACE ROUNDING BRUSH

THE SRB, WHAT IT IS AND HOW IT WORKS!

The Surface Rounding Brush (SRB) is a tool developed to remove rough spots from
a commutator or collector surface while the machine is in operation. These rough
spots may occur because of one more of a variety of detrimental operating
conditions, such as machine over loading, bearing failure or improper mechanical
alignment, improper electrical adjustment, excessive vibration, or contaminants.
Properly applied, the SRB can be an effective maintenance tool in improving brush
operation and commutation while avoiding costly and inopportune downtime on
critical machine applications.

PRINCIPLE OF OPERATION

The SRB is constructed of brush carbon with a conductive abrasive insert located
at or near the center of the brush. The abrasive section is positioned so that when
a low spot on the commutator or collector is encountered by the SRB, the brush
will ride on the carbon portion of the assembly. As the SRB comes out of the hole
the abrasive section will hit the lip, reducing its magnitude. (See Figure 35.)

LOW SPOT
As SRB comes
Lead, trail
out of hole the
Edges prevent
insert hits the
insert from
lip reducing its
Deepening
magnitude.
the hole

T L T L

Rotation

Figure 35 Low Spot

When a high spot is contacted by the SRB, the concave shape of the brush riding
face causes the abrasive insert to bear on the high spot. (See Figure 36).

MAY 2009 Page 94 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Figure 36 High Spot

So the SRB has been designed to “ride through” leaving the low spots unaffected
while it hones down the high spots. This process, repeated with every revolution,
will eventually smooth the collector or commutator surface. Accelerating forces
acting on the brush due to the previously rough surface will be reduced and the
brushes will once again ride smoothly.

APPLICATION CRITERIA

The SRB is applied in place of the brushes of one brush arm. Select one that is
accessible and be sure there is no power on the machine! The SRB should be
considered a “temporary” tool. When it has done its job, it should be removed.
Remember the SRB is a cutting tool. Keep the commutator or collector under
surveillance while the SRB is applied.

The length of time necessary to remove material and smooth the collector surface
depends on:

• The distance traveled on the collecting surface.

• The pressure applied to SRB.
• The number of SRB’s used per path or track.

If removal rate is to be increased, increase the brush spring pressure and the
number of SRB’s as with any brush, when brush pressure is increased, the same
pressure should be maintained on all brushes. This will reduce the tendency of
selective action between brushes with different pressures.

Selective action is a term used to describe the tendency of brushes with different
spring pressure or carbon resistivity to carry more current than the others.
Selective action results in poor commutation.

MAY 2009 Page 95 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Use of the SRB in machines using smaller brushes (3/8 inch thick or less, in the
direction of rotation) is not recommended. These thinner brushes are not as
effective in holding the insert off the bottom of the hole. They also tend to chatter
when used in brush holders that operate in the stubbing direction (ration into
brush toe).

Where the “V” type brush holder is used on a machine, the SRB should be used
only in the part of the holder that operates in the trail direction for rotation (see
Figure 37).

Rotation

Figure 37 V Type holder

If the SRB has to be sanded to fit large face variations, be careful not to round off
the lead and trail edges. (see Figure 38). Doing so will allow the abrasive to follow
surface contour, thus worsening rather than lessening roughness.

MAY 2009 Page 96 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

INCORRECT CORRECT

Edges and radius

Rounded brush edges
maintained after sanding

Figure 38 Rounded brush edges

Other than regular monitoring of surface condition (see previous guidelines), the
SRB requires no special maintenance procedures. The fine abrasiveness of the
SRB insert develops wear particles that are extremely small. These particles tend
to oxidize quickly and there is little evidence of their presence around the
machine. The rate of metal removal is so low that the machine is not
contaminated with wear debris. Of course, regular preventive maintenance
practices, such as brush wear monitoring, lubrication checks and periodic
machine cleaning should be followed.

The SRB is also effective in controlling film resulting from either poor commutation
or excessive chemical contamination on slow-speed equipment. The abrasive
insert, when riding on a fairly uniform surface, will perform a scrubbing action,
cleaning up non-conductive film or burned spot from the commutator or collector
surface.

CONSTRUCTION CRITERIA

The carbon portion of the SRB is made from material that is similar in resistivity to
the carbon used on the machine. This maintains the same commutating ability
and reduces selectivity effects. The abrasive insert is made conductive to prevent
a break in the commutation patter under the brush.

The effectiveness of the SRB can also be altered by a base material with either too
high or too low a wear rate. For example, if the SRB is applied in a high strength
metal graphite base, the wear rate of the base material may be so low that the

MAY 2009 Page 97 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

SRB effectiveness is limited. Therefore, in this case it would be necessary to use a

lower strength SRB base material.

Often brushes are ordered with a fluted or pre-roughened brush face for ease of
fitting to the commutator or collector surface. In the case of the SRB, the brush
face should not be fluted. Removal of the abrasive insert material will reduce its
effectiveness.

LIMITATIONS

Carbon materials have mechanical limitations. If the machine is so rough that the
existing brushes are breaking up, up not expect that the SRB will perform any
better. Sometimes the ride can be improved by utilizing a rubber hardtop on the
brush to absorb some of the mechanical shock. In severe cases of roughness it
may be helpful to lightly stone the commutator to reduce the breakage and allow
the SRB to do its work.

The SRB, properly applied, can be a convenient and effective tool in your overall
commutator and collector maintenance program.

MAY 2009 Page 98 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Six

Commutator Stoning Information

MAY 2009 Page 99 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATOR STONING INFORMATION

STONING FIXTURE: Purchased from Martindale or Ideal.

ADAPTER PLATE: Allows fixture to mount to most GE motors with 4 brushes or

more per stud.

GRINDING STONES: Also available from Martindale or Ideal usually Medium and
Fine Grades.

SHOP VACUUM: For copper dust removal during stoning process.

STONING PROCEDURE:

1. REMOVE ALL BRUSH-HOLDERS FROM STUD THAT FIXTURE WILL BOLT TO.
Keep in mind that stoning is done in the trailing not stubbing direction.

2. REMOVE BRUSHES ON THE TRACKS TO BE STONED.

(Otherwise copper particle are imbedded in the brush face possibly causing
commutator grooving or the brushes would wear excessively anyway from
the grinding effect).

3. DISCONNECT AND INSULATE ELECTRICAL CABLES CONNECTED TO THE

BRUSH STUD THAT THE STONING FIXTURE WILL MOUNT TO.
(Be sure to secure in such manner so they will not come in contact with
rotating armature or stoning fixture as it moves back and forth).

4. SPEED: APPROXIMATELY 2400 SURFACE FEET PER MINUTE.

800 rpm for a 11.50 diameter commutator.
600 rpm for a 15.00 diameter commutator.
400 rpm for a 22.00 diameter commutator.

5. MOTOR ARMATURE VOLTS: 400 VOLTS MAXIMUM.

Machine should be run no load. Disconnecting the drive coupling or
removal of drive belts might be necessary.

6. START WITH “MEDIUM” STONE FOR INITIAL CLEANUP. SWITCH TO “FINE” FO

FINISHING. A HAND HELD RUBBER STONE CAN BE USED TO POLISH COMM.
HOWEVER, IS NOT REQUIRED.

7. ATTACH VACUUM NOZZLE OR HAVE SOMEONE HOLD VACUUM HOSE JUST

AFTER STONING FIXTURE.
This will prevent excessive conductive copper dust from being distributed
throughout the motor interior and especially prevent this dust from being
drawn into and behind the open risers.

MAY 2009 Page 100 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

8. ATTACH RISER GUARD IF POSSIBLE.

A riser guard of some sort should be used. Its main function is to prevent
the copper dust from being drawn into the open risers. This is a very
difficult area to clean even if the armature is removed. A second function
is to prevent the stone from hitting the risers while the armature is rotating.
Some designs will allow the use of duct tape attached from brush stud to
brush stud. Other will require a textolite or cardboard arrangement
securely attached to brush studs or possibly pole-face connectors.

9. MOUNT STONING FIXTURE TO BRUSH STUD.

Check to make sure its parallel to the commutator surface so the comm. Is
not stoned into a tapered shape.

10. SCARFING THE UNDERCUT SLOTS OF THE COMMUTATOR MIGHT BE

NECESSARY IF AND EXCESSIVE AMOUNT OF COPPER WAS REMOVED FROM
THE COMMUTATOR.

11. WHEN FINISHED VACUUM OUT THE MOTOR. CLEAN COMPRESSED AIR
MIGHT ALSO BE USED TO BLOW OUT MOTOR.

12. INSTALL BRUSHES AND RUN MOTOR. USE OF SANDPAPER AND BRUSH
SEATER STONE WILL BE NEEDED TO PROPERLY SEAT BRUSH TO
COMMUTATOR.
Seater stone does not remove copper.

13. AIR CURE THE COMMUTATOR.

Using low pressure, blow air on the comm. Surface while the machine is
running to remove any remaining copper particles that might be bridging
the mica segment or in the banding groove.

SAFETY: IT ISN’T POSSIBLE TO MENTION EVERY ITEM THAT COULD POSSIBLY

CAUSE SERIOUS INJURY WHILE PERFORMING THIS KIND OF REPAIR,
SO PLEASE READ THE FOLLOWING LIST OF ITEMS THAT QUICKLY
COME TO MIND BUT ALSO DON’T FORGET TO USE COMMON SENSE.

• HIGH VOLTAGE IS PRESENT, SOMETIMES EVEN WHEN THE MACHINE ISN’T

RUNNING. BE CONSTANTLY AWARE OF THIS.

• USE OF SAFETY GLASSES, FACE SHIELD, DUST MASK AND GLOVES IS A

MUST.

• LOOSE CLOTHING SHOULD NOT BE WORN. POSSIBLE ENTANGLEMENT

WITH ROTATING PARTS OR EVEN STATIONARY PARTS MIGHT RESULT.

MAY 2009 Page 101 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

• DISCONNECT POWER WHEN REMOVING OR INSTALLING BRUSH-HOLDER,

ELECTRICAL CABLES AND THE STONING FIXTURE ITSELF.

• TAKE NECESSARY STEPS TO LOCK-OUT THE DRIVE OR CONTROLS SINCE

THEY ARE USUALLY QUITE A DISTANCE AWAY FROM THE MACHINE AND
NOT IN VISUAL SIGHT.

SINCE VACUUMING WILL BE DONE DURING THE STONING PROCESS, MAKE SURE
THE VACUUM NOZZLE IS ATTACHED FIRMLY OR IF ANOTHER PERSON WILL HOLD
THE VACUUM HOSE, TAKE NECESSARY STEPS TO INSURE HOSE DOES NOT BECOME
ENTANGLED IN ROTATING PARTS. ALSO MAKE SURE HOSE IS NON-METALLIC.

MAY 2009 Page 102 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Seven

Cleaning of Electrical Windings in DC

Motors and Generators

MAY 2009 Page 103 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

CLEANING OF ELECTRICAL WINDINGS IN DC MOTORS AND GENERATORS

FOR FRAMES CD-180A THROUGH CD-8800

When harmful dirt accumulations are present, a variety of cleaning techniques

are available. The one selected for a particular machine will depend on:

1. The extent of the cleaning operation to be undertaken.

2. The particular machine involved.
3. The type of dirt to be removed

FIELD SERVICE CLEANING (ASSEMBLED MACHINES)

DRY DUST

Dry dirt, dust, or carbon should first be vacuumed without disturbing adjacent
areas or redistributing the contamination. Use a small nozzle or tube connected
to the vacuum cleaner to enter into narrow openings, as between commutator
risers. A soft brush on the vacuum nozzle will loosen and allow removal of dirt
more firmly attached.

After the initial cleaning with vacuum, high velocity air may be used to remove
remaining dust and dirt.

Warning: SAFETY GLASSES AND / OR OTHER PROTECTIVE EQUIPMENT SHOULD

BE USED TO PREVENT POSSIBLE EYE INJURY.

Great clouds of dust may fill the air during this operation so, where possible,
operate the machine at low speed to permit maximum dust removal. Also,
continue vacuum cleaning to prevent contamination of the machine or adjacent
equipment. Compressed air is to be clean and free from oil and water.

OILY DIRT

The presence of oil makes thorough, effective cleaning of machines in service

virtually impossible, and Service Shop conditioning is recommended. Oil on a
surface forms a “fly paper” which attracts and holds firmly any entrained dust.
Neither suction nor compressed air is effective, consequently only accessible
areas may be cleaned. First, removed as much of the dirt as possible by wiping
with clean, dry rags. For areas not readily accessible, a “shoe shine” technique
may be used. A clean rag is drawn through an opening by means of a hooked
wire. The rag is drawn alternately back and forth. This process is continued until
a clean cloth thus applied stays clean. The cloths should be changed frequently in
any wiping operation, otherwise the dirt or contamination picked up by the cloth
may simply be transferred to another, perhaps previously uncontaminated, area.

MAY 2009 Page 104 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

To simplify removal of oily dirt, solvents are commonly prescribed. No liquid

solvent as such is to be applied to any DC machine, solvent application should be
by a wiping rag barely moistened (not wet). Where dirt is heavy, repeated wipings
may be required. Liquid solvent can carry conducting contaminants (metal dust,
carbon, etc.) deep into hidden but critical areas to produce shorts and grounds,
thus causing machine failure. Without special testing equipment such as
“armature surge tester”, weakness that could result in shorts in the armature
cannot be exposed. Grounding weakness may be studied with the “megger”, but
even here acceptability of the test is questionable, because the megger does not
develop enough electrical energy to expose all of the weak grounding paths.

Warning: SOLVENTS MAY BE TOXIC OR FLAMMABLE. ADEQUATE VENTILATION

MUST BE PROVIDED TO MINIMIZE FIRE HAZARDS AND HEALTH
HAZARD CAUSED BY THE USE OF SOLVENTS FOR CLEANING
PURPOSES.

Warning: VOLTAGES. ELECTRIC SHOCK CAN CAUSE SERIOUS OR FATAL

INJURY.

ELECTRICAL CIRCUITS MUST BE DE-ENERGIZED PRIOR TO CLEANING

OR OTHER MAINTENANCE ACTIVITIES - GROUND ELECTRICAL
CIRCUITS PRIOR TO CLEANING OR MAINTENANCE TO DISCHARGE
CAPACITORS.

FREON TF (E. I. Dupont Co.) is the recommended solvent for cleaning because it is
nonflammable, has good solvency for grease and oil, is considered safe with most
varnishes and insulations, and has a low order of toxicity. Inhibited Methol
Chloroform is also acceptable. Carbon Tetrachloride is effective and
nonflammable, but it is very toxic in confined spaces with repeated usage and is
therefore not recommended. Toluene and Zylene and Stoddard Solvent
(hydrocarbon solvents) possess good solvency, but are not recommended since
they are flammable and attack varnishes quite readily. Steam cleaning is not
recommended because, as with liquid solvents, conducting contaminants may be
carried deep into inaccessible areas resulting in shorts and grounds.

CAUTION: CARBON BRUSH PERFORMANCE MAY BE RUINED BY ABSORBED

SOLVENTS, REMOVED BRUSHES PRIOR TO SOLVENT WIPING.

SERVICE SHOP CLEANING (DISASSEMBLED MACHINES)

The usual Service Shop practice calls for an initial insulation resistance reading to
be taken on each machine component. Low readings would be expected with
badly contaminated machines, but failure would indicate electrical damage
calling for repair, not just cleaning.

MAY 2009 Page 105 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

STEAM CLEANING

The steam jenny which sprays a high-velocity jet of steam and water containing a
mild detergent is normally effective in cleaning windings. This is followed by
multiple sprays of steam without detergent for rinsing. After drying the
equipment, insulation resistance readings should be taken to determine the
adequacy of the operation. Re-varnish treatment is recommended to restore a
protective coating to the part.

SOLVENT CLEANING

In cases where dirt incrustations are not removable by steam cleaning and
electrical circuit insulation is not restored, solvent cleaning is employed.

Actual immersion in Trechlorethane or Perchlorethylene with air agitation or

suspension of the part in a vapor degreaser will soften dirt accumulations,
permitting compressed air removal. Repeated cleanings in this manner may
restore the insulated circuits. Hydrocarbon solvent cleaning by spraying or
submerging is finally supplied as a last resort. However, an appreciable
percentage of complex structures (such as the armature) may never recover with
submerged solvent cleaning, because conducting contaminants become trapped
in critical fissures.

Where electrical circuit insulation is restored by submerged solvent cleaning, re-

varnish treatment is required.

CAUTION: DO NOT CLEAN THE COMMUTATOR BY SUBMERGING IT IN THE

SOLVENT. CONDUCTING CONTAMINANTS MAY BE CARRIED INTO
INACCESSIBLE, BUT CRITICAL, AREAS SUCH AS BETWEEN THE CONE
AND THE COPPER SEGMENTS OR IN GLASS BOUND COMMUTATORS
BETWEEN THE GLASS BAND AND THE COPPER).

OTHER CLEANING METHODS

Ground-up corn cobs, peanuts husks and the like have been employed for mild
abrasive-type cleaning of contaminated electrical components. Where visual
contamination is removable in this manner, its use is highly recommended.
Abrasive cleaning of complicated structures is inadequate because hidden areas
remain contaminated.

MAY 2009 Page 106 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Eight

Brush Maintenance

MAY 2009 Page 107 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

BRUSH MAINTENANCE

Good brush performance is dependent to a large degree on the care used in

fitting and adjusting the brushes before the machines are put on service. An initial
inspection and frequent subsequent inspections are required to obtain
satisfactory performance. The following points are important in regard to
assuring proper brush service.

WARNING: HIGH VOLTAGE AND ROTATING MACHINERY CAN CAUSE SERIOUS

OR FATAL INJURY. BRUSHES SHOULD NOT BE TOUCHED OR
REPLACED WHILE THE MACHINE IS ENERGIZED OR ROTATING.

1. Make sure the pigtail screw is tight and that the pigtail does not interfere
with free movement of the brush.
2. Be certain the pigtail cannot touch un-insulated parts of the machine.
3. Check that the brushes are free in the holder with the springs positioned
correctly and functioning properly.
4. The brush-holders should be uniformly spaced about .075 (1.9mm) from
the commutator surface.
5. Check brush fit and, if necessary, use a seater stone while the machine is
running to obtain acceptable fit.
6. Running a machine at no load (such as during start up) and the lack of
proper filming on a new commutator sometimes leads to a short life for
the first sets of brushes. Before investigating or changing the brush
grade, wait and see how the first set of replacement brushes perform.
7. Check spare brush supplies during installation to be sure that the
replacement brushes are in hand.

Replacement brushes should have their commutator contact surfaces curved to

exactly fit the commutator surface. This is accomplished by “sanding in” the
brushes in each brush-holder separately. Draw a sheet of non-metallic
sandpaper under the brushes with the rough side toward the brush, while the
brushes are pressed firmly toward the commutator. When sanding brushes, do
not get carbon dust into the windings. The generator should be thoroughly blown
out after sanding the brushes.

CAUTION: DO NOT USE LIQUID SOLVENTS OF ANY KIND. SOLVENTS WILL NOT
REMOVE CARBON DUST ACCUMULATIONS, BUT WILL SPREAD THEM
AND WASH THEM INTO CRITICAL AREAS.

The replacement of brushes can be simplifies in two ways. First, in most cases, up
to 20% of the brushes on one stud can be replaced without requiring “sanding in”.
Second, the use of the brushes fluted contact faces simplified the process of
sanding brushes.

MAY 2009 Page 108 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Nine

Commutation Adjustment – Brush

Potential Measurement

MAY 2009 Page 109 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATION ADJUSTMENT BY BRUSH POTENTIAL MEASUREMENT

PURPOSE: When taken properly, the brush potential curve furnishes the engineer
with a wealth of information. From them he can tell if the brush position is
correct, if the band is weak or strong. If the machine is motoring or generating
properly, what the bandwidth is, the shape of the commutating pole flux, etc.

METHOD: The brush Potential curve is taken as follows:

1. Prepare for the curve as follows:

A. Measure the actual brush width. The actual brush width is the
width of the brush per stud and includes both brushes of a split
brush, etc.
B. Make a device with holes punched in it for the pencil point to fit
through. There should be nine holes at least. The distance between
the holes is equal to one half of the brush width as measured in “A”.
The device should be a long thin strip of textolite or some similar
insulating material. It should be very flexible. The holes should be
punched so that when the strip is laid around the commutator, the
line of holes will be perpendicular to the line of brushes. Tie the strip
so it rides the commutator at the end of the brush stud. With the
holes numbered from zero to eight, the number four hole should fall
at the center of the brush. This should be done for any two
adjacent brush studs.

In some cases, a card marked as above and just held beside the
brush will suffice. This lacks the accuracy of a permanent device as
it cannot be held perfectly in position.

2. Run the machine at the rated voltage, current and speed.

3. Set a voltmeter on the high voltage scale and check the two studs as to
which is positive with respect to the other. This will give you the positive
and negative stud.

RECORDING DATA: the voltage drop at any point under the brush is an indication
of the current density in the brush at that point while the portions of the curve
beyond the brush edges will indicate the location of the brush in the commutating
neutral. The curve formed by all the points under the brush indicates roughly the
distribution of current across the face of the brush, and is termed “current
distribution curve.

Before any adjustment or changes are made on a machine, a curve of this type
should be taken. This will provide a reference curve from which changes can be
noted as commutating field or brush position are varied. These curves should be

MAY 2009 Page 110 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

taken on a smooth commutator and only after the brushes have run a sufficient
time to develop a commutator film.

Brush potential curves can be more easily interpreted if the curves are plotted
neglecting polarity, but referring curves for a generator in the lower quadrant and
those for a motor in the upper quadrant as shown in Figure 39. The first three of
this series of typical curves, for both motor and generator operation, show
brushes centered on the commutating neutral with different field strengths, while
the latter two curves (d & e) show the brushes shifted out of proper neutral.

Figure 39 Typical brush potential curves for a DC motor

The basic rules to follow in interpreting the curves are: whenever the absolute
potential on leading edge is greater than on the trailing edge, the commutating
field is strong; conversely, whenever the potential on the leading edge is less than
that on the trailing edge, the commutating field is weak.

An Ideal curve will be flat across the face of the brush, but because of certain
factors affecting the collection of current in a machine, the curve on a normally
adjusted machine will have a slightly greater potential on the leading edge than
on the trailing edge of the brush.

Strengthening the commutating field of the machine is obtained by shifting

brushes with rotation on generator and against on a motor. Care must be
exercised not to distort the overall brush potential curve by shifting out of the
proper commutating zone. The commutating field can also be strengthened by
decreasing the commutating pole air gap, commutating-pole non-magnetic
shims, and the amount of current shunted from the commutating field circuits. To
weaken the commutating field, the opposite of the above is required.

MAY 2009 Page 111 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

REMARK: The value of this curve is absolutely worthless if it is not taken with great
care. The accuracy of the data must be perfect. Be certain all of the necessary
information is included on the sheet. A curve can be used to help iron out many of
the difficulties in a machine if it is properly taken.

SETTING ELECTRICAL NEUTRAL

PURPOSE: On a reversing machine it is necessary to have the same general

conditions in the machines regardless of the rotation. This is of prime importance
in the proper operation of the equipment that will be driven by the machines in
the field. This test consists of setting the machine by moving its brush rigging to
the point where this balance of condition exists. This point is called electrical
neutral.

METHOD: there are several methods for setting electrical neutral and the order in
which they are used is determined by the particular machine being tested.

THE FIELD CURRENT OR SPEED METHOD

A. Bring the machine to rated speed, voltage, and current in one direction and
allow it to level. Record the field current.
B. Shut the machine down and run it in the other direction at rated voltage
and current and the field current obtained in step “A” until its levels again.
Record the speed.
C. Shift the brushes in the direction of the least speed and repeat steps “A”
and “B” until the speed in step “B” matches the speed of step “A” within the
regulation requirements.

REGULATION METHOD

A. Take regulation checks in both directions and shift in the direction of the
curve which is most rising until the regulation checks are within one half of
a percent of actual regulation of each other.
B. Take level regulation curves in each direction are within limits specified by
the engineering design.

BASE SPEED NO-LOAD BUCK BOOST CENTER POINT

A. On some machines the center point at base speed no load on the buck and
boost band is an excellent indication of the electrical neutral. The machine
should be shifted until the no-load points are approximately the same.

LIMITS: For the regulation curve method, the curves in each direction
should be within limits specified by the engineer. (Example: If .5% is

MAY 2009 Page 112 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

required and clockwise regulation is 3.0%, then counter clockwise

regulation must be between 2.5% and 3.5%).

REMARKS: A Plot of regulation versus brush position in each direction can

be useful in setting electrical neutral. The point where curve for each
direction intersect is electrical neutral.

SETTING ELECTRICAL NEUTRAL BY FLASHING THE FIELD

PURPOSE

To set brush rigging so that the brushes are in the approximate position for best
commutation.

PREPARATION

A. The machine must be at a stand still through out the entire procedure. A
record sheet should be made out.
B. The brushes on two adjacent studs should be sanded. If the machine is a
reversible machine, brushes should be sanded for both rotations.
C. A zero centered (100 milli-volt) meter should be wired. Every stud should
have all brushes in and down.
D. The metering leads should be tightly connected to the meter terminals and
also tightly secured to the pigtail of two of the brushes that were sanded.
E. If using an exciter for field, run it’s control down to residual volts.
F. Make sure that the aux field is not connected.

PROCEDURE

A. The resistance in the field control should be in position of maximum

resistance.
B. The record sheet should record (millivolt read) right and (millivolt read) left,
field amps, and brush position.
C. Close the field breaker – read and record the deflection on the motor (right
or left).
D. It is necessary to allow the maximum amps to build up before opening the
breaker. This is important in each case due to the slow rise of the field
amps based on the field circuit’s impedance. So, in each case, be
consistent in the amount the field rises before opening the breaker. Record
the field amps each time.
E. Open the field breaker. There will be sudden deflection on the Milli-volt
motor right or left. Read and record this deflection and also the brush
position.
F. The brush position should be changed to a new position and the same
above procedure repeated. If the new reading is read on the same (right or
left) side, but the amount is less as the breaker is opened, you are shifting

MAY 2009 Page 113 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

the brush yoke in the right direction. Record your readings and continue to
a new brush position and repeat the procedure.
G. Keep changing the brush position and repeating the procedure until the
meter reads nearly or absolute zero when the breaker is opened. Increase
field amps to about 10% of AFNL and repeat. Try about 20% field amps
and repeat if necessary. The object is to read nearly zero on the milli-volt
meter. When breaker is closed and opened.
H. This position should be temporarily marked and the yoke shifted farther in
the same direction to indicated the null point has been passed, which will
be indicated by a reading on the meter towards the opposite side.

MAY 2009 Page 114 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Ten

Mechanical Aspects of Commutator

Maintenance

MAY 2009 Page 115 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MECHANICAL ASPECTS OF COMMUTATOR MAINTENANCE

The successful commutation of DC machines depends in no small measure on the

quality of maintenance afforded to the commutator. This section describe the
various maintenance procedures in common use, and discusses the advantage
and limitations of each.

“Successful commutation” does not necessarily mean the same thing to everyone
associated with the operation of DC machines, but the purpose of this discussion,
SUCCESSFUL COMMUTATION is taken to mean operation under reasonable service
conditions such that harmful or destructive sparking is not experienced. Under
these conditions, then, acceptable brush life will also be obtained, and the
commutator will not be excessively marred by the brushes.

A stable, copper-oxide-carbon film, as distinguished from a pure copper surface,

on the commutator is an essential requirement for successful commutation. Such
a film may vary in color all the way from copper to straw, chocolate to black.

It should also be kept in mind that the machine has been installed to deliver a
load, either electrical or mechanical, and undue concern over the niceties of
satisfactory or ideal commutation should not preclude recognition of the unit’s
basic function.

It become apparent, then, that the color of the film is not the only criterion, by
which to judge successful commutation. If the machine continually performs its
function, if harmful sparking is not experienced, if satisfactory brush life is being
obtained, and if the commutator surface does not require excessive maintenance,
then the actual color of the commutator loses much of its significance.

Fumes and oil vapors tend to smudge, gum, and otherwise discolor the
commutator, chlorine, for example, usually causes a green discoloration, and
sulphuric fumes often produce a dark blue or blue gray surface. Gases, oil, and
grease often create a mottled appearance on the commutator surface film.

When the presence of atmospheric contaminates causes the formation of

unnatural (and unwanted) films in the commutator surface, it may be desirable to
wipe the commutator clean at regular intervals with a canvas wiper.

To clean a commutator properly, use a piece of dry canvas or other hard non-
linting material which is wound around and securely fastened to a wooden stick
and held against the commutator. Do not use a lubricant on the commutator,
either during or after the polishing period. If the commutator is clean and
polished, and the brushes have the perfect fit, the unit may be loaded at once,
provided the insulation resistance is satisfactory. If the commutator is not
polished, the machine should be run with a light load for several hours in order to
establish a high and uniform polish on the commutator surface, and a good fit on

MAY 2009 Page 116 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

the brush faces. Brushes can be fitted more quickly if the machine is carrying load
proportional to the percentage of contact surface of the brushes. As the brush fit
improves, the load can be increased depending on the amount of sparking and
heating.

A fundamental requirement for successful commutation is continuous contact

between commutator and brushes. The commutator must be mechanically true,
the unit in good balance, and the brushes free to move up and down in the orders.

It does happen, however, that successful commutation is not always initially

obtained, and the resulting commutator condition does not afford continuous
contact, or the surface becomes marred. In addition to correcting the conditions
that caused the commutator to deteriorate, the commutator itself may require
reconditioning.

Although a certain amount of judgment is required as to weather or not a

commutator should be reconditioned, there are certain benchmarks the can be
advantageously employed:

1. The commutator should be round, with no flat spots, high bars, or

low bars. When the observation is taken at low speeds, such as on
turning gear, dial indicator readings of 0.001 in. On high speed
machines to several thousandths on low speed machines may be
considered normal. A low speed machine may commutate
successfully with a slightly “egg shape” commutator because the
brushes will follow the commutator surface, but flat spots, or high
or low bars require too great a rate of change of brush position, and
arcing at the brushes usually ensues. Flat spots, high bars, and low
bars usually cannot be successfully relieved by hand stoning or
sandpapering. This procedure generally tends to make the
condition worse.
2. When condition or high mica occur, the mica must be undercut.
Usually, however, sustained operation with a high mica condition
results in other damage to the commutator, such as bar burning,
flat spots, etc., so as to require resurfacing. If caught early enough,
merely removing the high mica is sufficient. (commutators which
have recently been resurfaced should be carefully observe during
initial operation to detect any high mica which may remain after
the undercutting operation.)
3. Dirty slots may conceal a deterioration of the mica. The presence of
oil or grease will aid the accumulation of minute particles of carbon
and copper or other contaminates and lead to arc-over between
bas and / or arcing at the brushes with subsequent damage to the
commutator. In additions to restoring the commutator to good
condition, the cause of the difficulty should be eliminated or
reduced.

MAY 2009 Page 117 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Unfortunately, a significant amount of commutator maintenance is

the result of inadequate attention to the bearing lubrication system.
Over greasing to the extent that lubricant is pushed inward along
the shaft toward the commutator is probably the most common
ball-bearing lubrication problem; but factors common to sleeve
bearing lubrication systems are legion:

a. Oversize or worn shaft seals (or oil deflectors).

b. Oversize (worn or incorrectly bored) bearings.
c. Improper fit at bearing split, bearing cap split, and shaft
seals / oil deflector split.
d. Leaking oil fitting, drain hole plugs, sight glasses,
inspection covers, etc.
e. Clogged oil return holes in bearings.
f. Improper grades of oil.
g. Improper bearing design.
h. Others.
The crux of the problem is that free oil, and / or oil vapor on the
outside of the machine seems destined to work its way into the
commutating zone with decidedly adverse effects. In commutation,
as in so many other things, “ Cleanliness is next to Godliness”.
4. Grooving of the commutator, caused by the use of too abrasive
brushes, or abrasive materials in the atmosphere, or incorrect
staggering of the brushes may necessitate resurfacing the
commutator. (It should be kept in mind that staggering the brushes
does not stop commutator wear, but rather distributes the wear
more evenly over the surface of the commutator).
5. Threading of the commutator in itself does not always justify
resurfacing the commutator. If the commutator is still round and
concentric, and if the threading is not to deep, continued operation
may be acceptable. Other factors entering into the decision include
the rate of commutator wear, brush life, period or required
operation until next maintenance shutdown, etc.

MAY 2009 Page 118 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATOR RESURFACING

Various methods are used to resurface worn commutators. These include

sandpapering, hand stoning, grinding, and turning. Some resurfacing procedures,
while in common practice, nevertheless can easily contribute to additional
commutation difficulties. It is hoped the discussion following, which applies
mainly to “larger” machines, will clarify some of the more common
misunderstandings and eventually result in better operating commutators.

Note: Before any major resurfacing operation is started, the windings should be
protected from the entry of copper and / or abrasive dust particles.

SANDPAPERING

Because of its ready availability, and because it so easily removes existing

commutator films and hence creates the appearance of what at first seems to be
a polished commutator, sandpaper is often the first thing that comes to mind
when looking at a mottled, streaked, or slightly threaded commutator.

Improper use of the sandpaper, or use of the wrong kind of sandpaper, however,
causes other problems:

a. On an unslotted commutator (as after a resurfacing operation),

sandpaper, because of its flexibility, has a tendency to flatten the
center of the bars.
b. On a slotted commutator (as on a machine in use), sandpaper,
again because of its flexibility, has a tendency to round the edges of
the bars. This bar rounding or crowning may occur even though the
sandpaper is used with a block curved to fit the commutator.
c. Many sandpapers now available employ plastic base adhesives.
Use of this type of sandpaper often leaves an unnoticed film on the
commutator that has an adverse effect on commutation. Burning a
small piece of the sandpaper will establish whether or not a plastic
binder was used in as much as the characteristic odor of burning
plastic is easily recognized.

Generally speaking, it would appear that the in discriminate use of

sandpaper on a commutator should be discouraged. Various stone are
available which may be used to accomplish the same purpose.

If possible, brushes should be sanded to remove impurities in the brush

face after the commutator film has been removed in an attempt to
improve commutation. The use of garnet paper is suggested because
of the better bond between the abrasive and the backing reduce the
tendency of the grit to become imbedded in the brushes.

MAY 2009 Page 119 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

HAND STONING

The success of hand stoning depends in no small measure on the skill of the
operator. Properly used, the hand stone can restore a true cylindrical surface, but
cannot be relied upon to eliminate eccentricity, high bars, or low bars. The stone
should be formed or worn to the curvature of the commutator and have a span of
contact substantially greater than that of the broadest flat spot to be removed.
Hand stoning is indicated for removing minor commutator irregularities, and is
most apt to be successful when the commutator is concentric. Before stoning a
commutator, all traces of oil or grease should be removed from the commutator
and stone. (If safety regulations permit and after suitable precautions have been
taken, the use of alcohol or a similar solvent as a wash may prove helpful in
obtaining adequate cleanliness). The brushes, of course, should be lifted during
the stoning operation whenever possible, and the machine is usually operated at
rated speed.

The stone, which must be firmly braced against a solid support, should be worked
from end to end of the commutator so that the surface is ground down evenly.
Successively finer stones are used to obtain the high polish required.

The use of a solid support when hand stoning is stressed, because severe damage
to the commutator may result if adequate control of the stone is lost even
momentarily. The resulting gouge may be removed by turning with the resultant
loss of commutator life, or it may be necessary to replace the commutator
entirely.

Unfortunately, the results of hand stoning can be misleading because the

commutator often appears at first glance to be in good condition, where as closer
inspection may determine it to be conical, saddle shaped, keg shape, wavy, etc.

MAY 2009 Page 120 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

GRINDING

When correctly performed, grinding is regarded by many as the most satisfactory

method of obtaining a good commutator can often be resurfaced without
disabling the machine if careful planning of the job is done prior to shutdown.
Grinding should not be attempted while the machine is carrying load, or has
voltage on the commutator. After removing armature and shunt field power,
grinding may then be performed while the machine is coasting to rest. Thus, it
may be necessary to bring the machine up to rated speed several times before
completing the job.

Cutting the speeds of fixed stone rigs are usually on the order of 1000 to 1500
rpm. Light cuts should be taken to avoid non-cylindrical profiles resulting from the
stone’s wearing away during the traverse across the commutator. The stone
should be supported near the cutting end the to avoid chatter and / or breakage.
Every effort should be made to provide a rigid support for the fixture.

Set the compound so that the top of the stone is below the axis of maximum
commutator diameter so that if slippage or breaking occurs, the pieces will swing
away from and not into the commutator, and make sure that the axis travel of the
stone is parallel to the axis of the shaft. Do not assume that the commutator is
cylindrical.

The portion of the commutator near the string band and near the risers are the
extremes of the brush surface, but are not usually worn by the brushes. The use
of calipers and a dial indicator is helpful when rigging a grinder for use on a
machine in place.

Care should be taken to adjust the gib keys on the compound slide so as to obtain
smooth, easy movement of the head without any “play” that could caused chatter,
and the use of graphite rather than oil to lubricate the moving parts of the grinder
is suggested. Oil “catches” the gritty materials from the grinding operation, and
hence cause undue wear of the equipment.

A close check on the grinding operation can be accomplished without shutting

down the unit by using a “Strobotac”, (or some similar device), or a small pieces of
carbon may be used as a probe to evaluate the progress being made.

A fine stone, rather than sandpaper, is used to obtain the final polish.

Some operators prefer to use a rotating abrasive wheel, which is direct driven
either by a small motor or a flexible shaft, because it is thought to be less liable to
chatter or dig into the commutator. Light finishing cuts taken with every fine
abrasive wheel that is driven at its recommended speed while the commutator is
turning at the rated speed yield the best results.

MAY 2009 Page 121 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

The rotating wheel is considered faster than the fixed stone, but it is apt to leave
ripples in the commutator surface resulting from slight vibration and “play” in the
bearings. Ripples may also occur when the grinder speed is either an even or odd
multiple of the machine speed. The fixed stone has an advantage in this regard.

TURNING

a. Machine must be dissembled (and then reassembled).

b. Low cutting speed required (500 – 600rpm) may preclude refinishing
larger commutators at rated surface speed, although higher cutting
speed are possible with modern cutting materials.
c. Heavy initial cut often required to get under the work – hardened surface.
Hence, more copper is often removed than is actual necessary, and
commutator life is reduced.

It should be recognized that small machines generally do not afford much room
around the commutator for the proper utilization of grinding apparatus, but
disassembly is relatively easily accomplished. Consequently, the commutators of
small armatures are usually resurfaced by being turned in the lathe.

During maintenance shutdowns, it is often not possible to operate the equipment

from normal sources of power. Under these conditions, the use of a lathe to
rotate the armature is almost mandatory. The commutator can be “roughed” into
shape by turning, if desired, and the final resurfacing and polishing can then be
done by grinding with a stone mounted on the lathe toll post. As previously noted,
the use of sand paper may tend to “flat” the bars.

The decidedly greater accessibility of the commutator for the undercutting

operation may save enough time in itself to justify disassembling the machine.

If it is decided to turn the commutator, the use of a “diamond – pointed” tool, or

one with a fairly sharp point is suggested. The tool point should be rounded
sufficiently, however, so that the cuts will overlap and not leave what amounts to
a thread on the commutator surface.

It has also been found that placing reliance on the accuracy of the shaft centers
sometimes results in eccentric commutators. Rather take run out readings on the
shaft journals, and support the armature accordingly.

After the armature has been reinstalled in the machine, the commutator should
be “indicated”, using a dial indicator as a final check on the accuracy of the lathe
work. (A lot of commutation problems are incorrectly blame on brushes, and a
poor resurfacing job makes the resolution problem that much more difficult)!

MAY 2009 Page 122 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COMMUTATOR UNDERCUTTING

After the commutator has been satisfactorily resurfaced, the mica insulation
separating the copper segments must be undercut. Undercutting is one
operation that is most easily accomplished with the armature removed from the
machine. Various tools are available, however, that enable undercutting to be
performed on a commutator “in place” without undue hardship.

Of the various undercutting practices used, only the two most common methods
will be discussed herein.

THE U – SLOT

The U-slot is generally preferred if the slots are accessible for easy cleaning.
These slots have the advantage, if done carefully, of being effective until the
commutator has worn down the full depth of the undercut. The slot should be cut
to a depth of 1/32 inch, or not more than 3/64 inch. If cut too deep, accumulated
dust will not be thrown out by the centrifugal action of the rotating commutator.

A suitable undercutter for forming U-slots by hand can easily be made from a
power hacksaw blade. It is important that only sharp blades be used with any
undercutting method so as to avoid tearing the mica, or leaving irregular surface
that will catch and hold dirt.

When the volume of work justifies the additional expense, various types of power-
driven under-cutters are available. Properly operated, these produce better work
in less time.

When using a rotary cutter, the width of the cutter is chosen to exceed slightly the
thickness of the mica. Consequently, some copper is cut or dragged off the bar
during undercutting. In addition to leaving a jagged edge projecting from the
commutator bar, the edge of the bar becomes somewhat work-hardened and
hence will not wear down uniform. Therefore, the edges of the bars must be
chamfered by using a suitable slotting file or a specially shaped scraper.

A chamfered face of approximately 1/64 inch is usually adequate to remove any

roughness or edge hardening that could be disturbing to the brush faces, (A
satisfactory chamfering tool can be also be easily made from a power hacksaw
blade).

MAY 2009 Page 123 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

THE V – SLOT

V-slots usually keep free from dust accumulations at low speeds, and do not
require a separate operation for chamfering of the bar edges. V-slots are usually
made with either a slotting file, or a V-slot rotary cutter.

Usual practice is to use a rotary cutter having an including angle between cutting
edges such that a cut made 1/16 inch deep will also leave 1/32 inch free copper
above the mica. V-tooth rotary cutters are available with 40°, 50°, or 60° angles
between the cutting edges.

To obtain a 1/16 inch deep cut with 1/32 inch free copper above the mica, the
following table may be used:

Thickness of mica Angle of V-cutter

0.023 inch 40°

0.029 inch 50°
0.036 inch 60°

The necessity of accurately centering the cutter on the mica is readily apparent.
Mica fins in V-slots being wedge-shaped, are more difficult to remove than the fins
uniform thickness left at the sides of U-slots by inaccurate centering of the cutter.

After a commutator has been undercut, it should be very carefully inspected to

assure that all copper particles have been removed, that the bars have been
carefully chamfered, and that all sharp edges and burrs have been eliminated.
Then each slot should be individually checked and reworked as necessary to
remove any traces of fin or side mica.

Finally, the surface should be lightly polished with a fine-grain commutator stone.
(Incidentally, the use of maple blocks to burnish the commutator is not always
beneficial to successful commutation).

MAY 2009 Page 124 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

BRUSH AND BRUSH RIGGING

The brushes should be inspected for uniform and proper brush pressure, that they
are free to move up and down in the brush holders, that the brush shunts are
securely fastened and out of the way of the riser and the frame, and that there
are no foreign particle in the brush faces.

The brush holders should be examined carefully so as to assure that they are in
good mechanical condition, that the springs and reaction arms work smoothly
and freely, and that the brush holders are accurately space around the
commutator and aligned with the commutator bars.

There is tendency to space brush holders too far from the commutator. If specific
information is unavailable, 60 to 90 mill may be used for commutators up to 18
inches in diameter. Common practice is to use a 70 mil shim for spacing the
brush holder from the commutator , and then use 60 and 90 mil shims as “go” and
“ no go” gages, respectively. For the larger commutators, limits of 90 to 125 mils
may be use. In either case, if the brush holders are set too far from the
commutator, trailing brushes are apt to chatter, and the brushes in V-type holders
may interfere with one another.

In addition to setting the brush holders at the angle recommended by the

equipment manufacturer, the brushes themselves should conform physically to
the manufacturers specifications, although operating experience may dictate the
use of a brush grade different from that originally supplied.

Unless specific information to the contrary is available, the brush rigging should
be set on the “factory neutral” mark.

INITIAL OPERATION

Prior to energizing, the machine should be carefully cleaned, preferably by suction,

to remove every possible trace of cooper, carbon, mica and other dusts.

Avoid applying full load to the machine, if possible, until the brushes have had a
chance to fit the commutator and establish a film on the commutator.

MAY 2009 Page 125 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MAY 2009 Page 126 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Eleven

Vibration Identification

MAY 2009 Page 127 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

VIBRATION IDENTIFICATION
CAUSE AMPLITUDE FREQUENCY PHASE REMARKS
Unbalance Proportional 1 x RPM Single Most common cause of
to unbalance. reference vibration.
Largest in mark
radial
direction
Misalignment Large in axial 1 x RPM usual Single, double Best found by appearance of
coupling or direction 50% 2 & 3 x RPM or triple large axial vibration. Use dial
bearings and or more of sometimes indicators or other method for
bent shaft. radial mechanical positive diagnosis. If sleeve
vibration looseness bearing machine and no
coupling misalignment
balance the rotor.
Bad bearings Unsteady-use Very high Erratic Bearing responsible most
anti-friction velocity several times likely the one nearest point of
type measurement RPM largest high-frequency
if possible vibration.
Eccentric Unsteady-use 1 x RPM Single mark If on gear largest vibration in
journals velocity line with gear centers. If on
measurement motor or generator vibration
if possible disappears when power is
turned off. If on pump or
blower attempt to balance.
Bad gear or Low-use Very high Erratic
gear noise velocity gear teeth
measure if times RPM
possible
Mechanical 2 x RPM Two Usually accompanied by
looseness reference unbalance and / or
marks. misalignment.
Slightly
erratic.
Bad drive belts Erratic or 1,2,3,&4 x One or two Strobe light best tool to freeze
pulsing RPM of belts depending on faulty belt.
frequency.
Usually
unsteady.
Electrical Disappears 1 x RPM or 1 Single or If vibration amplitude drops
when power or 2 x rotating off instantly when power is
is turned off. synchronous double mark. turned off cause is electrical.
frequency
Aerodynamic 1 x RPM or Rare as a cause of trouble
hydraulic number of except in cases of resonance.
forces blades on fan
or impeller x
RPM
Reciprocating 1,2 & higher Inherent in reciprocating
forces orders x RPM machines can only be
reduced by design changes or
isolation.

MAY 2009 Page 128 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Twelve

Troubleshooting a Commutation
Problem

MAY 2009 Page 129 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

TROUBLESHOOTING A COMMUTATION PROBLEM (EXCESSIVE SPARKING)

1. CHECK OUTSIDE CONTRIBUTING FACTORS

• Excessive vibration of complete machine.
• Overload or possibly too light of load for long periods.
• Motor too hot – insufficient cooling air.

2. CHECK CONDITION OF COMMUTATOR

• .003 Maximum run out below 5000 feet per minute, .002 Max above
5000 PP.
• .0002 Maximum bar to bar difference (shouldn’t span more than 10
bars).
• No mica fins, high mica, copper drag, heavy slot bar marking,
threading grooving, oil, silicone, or other contaminants.

3. CHECK BRUSHES
• All fully seated, not burned, cracked or too short.
• All the same grade.
• Free to move within the brush-holder, not sticking.
• Minimal Brush vibration (check with strobe light or insulated stick).
• Proper and equal spring pressure (usually about 3 to 5 pounds per
square inch).
• Equally space circumferentially around the commutator within .050
inch.
• Brush-holders properly spaced .070” to .080” from the commutator.
• No frayed brush shunts or pigtails.
• Proper current density for that brush grade (usually 35 to 80 AMPS
per square inch).

4. CHECK COMMUTATING COILS AND POLES (INTERPOLES)

• AC voltage drops should be equal within 5%. (Armature must be
out of stator totally or located by the bearing brackets for uniform
air gaps) (Also best to check while coils are still mounted in the
frame and connected in one circuit).
• Properly connected per the connection diagram (this might be the
problem if the motor was recently serviced or taken apart).
• Equal air gaps within .007” (.005” on CD 500AT and smaller sizes).
• Same number of magnetic or non-magnetic shims under each pole
and proper location of magnetic & non-magnetic shims (pole – thick
steel –thick aluminum – thin aluminum – thin steel – frame).
• Equal pole spacing – within .125” from pole tip to pole tip.
• Stainless steel comm. Pole bolts for CD580 frame and larger.

MAY 2009 Page 130 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

5. CHECK MAIN COILS AND POLES

• Equal main coils resistance or DC voltage drops within 5%.
• Equal air gaps within .007” pole to armature core.
• Same number of shims under each pole.
• Equal main coil AC voltage drops (see similar notes above).
• Equal main pole spacing within .125” pole tip to tip

6. MEGGER AND HIGHPOT ALL WINDINGS

• 1.5 Mega-ohms minimum at 40 C.
• High-pot at twice armature voltage.

TROUBLESHOOTING DC MOTORS

MOTOR WILL NOT START

• Open circuit in control.
• Low terminal voltage.
• Bearing frozen or seized shaft.
• Excessive friction or brake engaged.

MOTOR STOP AFTER RUNNING A SHORT TIME

• Motor not getting power, blow fuse or open breaker.

MOTOR ATTEMPTS TO START BUT OVERLOAD RELAYS OPERATE

• Motor is started with weak or no field.
• Motor torque is insufficient to drive load.

MOTOR RUNS TOO SLOW UNDER LOAD

• Armature voltage too low.
• Shunt field current too high.
• Brushes moved ahead of neutral.
• Motor overloaded.

MOTOR RUNS TOO FAST UNDER LOAD

• Armature voltage too high.
• Shunt field current too low.
• Series field not connected in if stabilized shunt or compound.
• Brushes moved back of neutral.

FIELD COILS OVERHEAT

• Short circuit betweens turns or layers.
• Field current greater than stated on nameplate.
• Ventilating air is off or restricted.

MAY 2009 Page 131 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

ARMATURE OVERHEATS
• Motor overloaded.
• Ventilating air is off or restricted.
• Armature winding is shorted.
• Excessive spring pressure on brushes.

BRUSHES WEAR TOO FAST

• Rough commutator – greater than .003” run out.
• Excessive sparking.
• Silicon vapor or abrasive dust contaminant.
• Incorrect brush grade

MAY 2009 Page 132 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

GRADING OF COMMUTATION

1
BLACK

No Sparking

PS PINPOINT
SPARKING
The point at which pinpoint
sparking first occurs on 1 or
more brushes

1 SPARKING ON A
¼ FEW BRUSHES

The point at which pinpoint

sparking first occurs on 1 or
more brushes.

1 SPARKING ON
½ HALF OF BRUSHES

The point where half of the

brushes or half the total edge
sparks.

2 SPARKING ON
MOST BRUSHES

The point where sparking is

Sparking will be mostly yellow
with a few white spots. No
Streamers.
3 DESTRUCTIVE
SPARKING

Any sparking with streamers

is destructive and the
machine must never be run
with this type of sparking.
Heavy white sparks may also
emit crackling sounds.

MAY 2009 Page 133 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MACHINE CHARACTERISTICS

CHANGE COMM POLE BRUSH SHIFT MAIN POLE

GAP NON.MAG. GAP

EFFECT ON SHIMS

INC DEC ADD REM WITH AGST INC DEC

GENERATOR

VOLTAGE REG H L H L H L L H

VOLTAGE (F.L.) L H L H L H L H

EXCITATION FL H L H L H L H L

MOTOR

SPEED REG H L H L H L H L

SPEED (F.L.) L H L H L H H L

EXCITATION FL L H L H L H H L

I = Increase ; D = Decrease ; H = Higher ; L = Lower

Causes of Poor Commutation

Streaking - Light electrical load, light brush pressure,

abrasive and porous brushes, gas and abrasive
dust contamination.

Threading - Light electrical load, light brush pressure,

porous brushes, gas contamination.

Grooving - Abrasive Brush, Abrasive Dust Contamination.

Copper Drag - Light brush pressure, vibration, abrasive
brush, gas contamination
Pitch Bar Marking - Armature connection, unbalanced shunt field,
light brush pressure, vibration, abrasive brush.
Slot Bar Marking - Electrical adjustment, electrical overload, gas
contamination.

MAY 2009 Page 134 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Thirteen

Armature Change Out Instruction

MAY 2009 Page 135 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

ARMATURE CHANGE OUT INSTRUCTION

When replacing an armature in a pedestal sleeve bearing MG set, the procedure

to provide good operation with the new armature is outlined as follows:

1. Remove pedestal cap. Match mark all pedestals, pedestal gaps and
bearing halves.

2. Remove Cradle straps and top half of bearings.

3. Inspect / replace plastic tubing. See separate instruction.

4. Assembly of replacement leather seals. See separate instruction.

5. Check the bore of the main poles. Opposite poles should be 30.500 inches
+.005 to -.010 for 1045 KW and 836 KW generators. This is the
measurement for the armature diameter plus twice the air gap. Add or
subtract steel shims to correct pole bores.

6. Check the bore of the commutating coils. Opposite poles should be 30.830
inches +.010 to -.005 for 1045 KW and 836 KW generator. Again, this is the
measurement for the armature diameter plus twice the air gap. Add or
remove steel shims only to correct pole bores.

7. Check the pole spacing. The distance from each adjacent main and
commutating pole center point must not differ more than .12 inches. Take
measurement at both ends of the poles.

8. Clean one core tooth of each new armature on each for approximately 2”
and mark tooth and armature band in line with it with chalk or paint.

9. Assemble armature taking care not to damage banding, coils or

commutator. Laying a thin .02 inch melamine sheet in the bottom of the
frame will protect the armature.

10. Raise coupling with a crane, oil rabbet fit and pull coupling halves together
with all coupling bolts being very careful to start together without shearing.

11. Check the position of the shaft journal in the sleeve bearing. It should be
centered within plus or minus 1/8 inch. If not, the pedestal should be
moved and re-doweled. There is 3/16” clearance on pedestal hold down
bolts. Total bearing endplay is ½ inch.

MAY 2009 Page 136 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

12. Check the position of the armature iron in the field pole iron. It should be
centered within plus or minus 1/8 inch to prevent excessive axial forces. If
not, correct by loosening the frame hold-down bolts and moving it. There
is 3/16 clearance on frame hold-down bolts.

13. All units must be placed on the base before the final lineup is made as the
weight of these armature will deflect the base and change the lineup.
Leave approximately 0.020 inch gap between coupling faces.

14. Check the alignment of couplings. See separate instruction.

15. Check air gaps in each generator between the marked tooth on the core
and comm. Poles at both ends. Loosen the foot bolts and bump the frame
to even the gaps within .005”. Loosen one side at a time and lift with a
hydraulic jack to change shims. Always remove all shims and carefully add
or subtract shims as required. Insert the proper number of shims around
the bolts keeping them flat and well lined up. Measure and write them on
the frame in chalk. Gaps should check with plus or minus .010 inches with
the following:

Main Pole gap = .250 inches

Comm Pole gap = .420 inches

Add or remove steel shims to correct gaps.

16. Set brush boxes to approximately .070 inches from the commutator
surface.

17. Check brush spacing to be within 3 / 64 inch variation.

18. Sledge all mounting bolts tight.

19. Dowel all units.

20. Rotate MG sets by hand and listen for rubbing sounds.

21. Seat brushes with seater stone. See separate instruction concerning
brush seater from Ideal Industries, Inc.

22. On start-up check vibration (.003”max.).

23. Check electrical adjustment by P.V.N.

MAY 2009 Page 137 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

CHECKING ALIGNMENT OF COUPLINGS

When checking coupling alignment, the base of the motor-generator set should
always be bolted securely to the deck of the excavator in the position in which it
will be expected to operate. It is important to follow the step-by-step procedure
and accurately record all readings. When checking more than one coupling of
motor-generator sets always start at the coupling nearest the two-bearing unit
(usually the motor).

Solidly Coupled Sets.

The procedure for solidly coupled sets is as follows:

1. Loosen all coupling bolts enough to insure that they are not holding the
coupling together.

2. Turn the set over to minimize sag and bindings in the couplings.

3. Start with a coupling next to the two-bearing unit (usually the motor) or
near the middle of a long set. Two diametrically opposite bolts should be
carefully adjusted to be loose and yet not allow the coupling rabbet to
disengage. Spread the coupling about 0.005 inch to 0.015 inch (.13 mm to
.38 mm) using two jacking screws or by rapping the flange with a fiber
mallet.

4. Measure the gap between the coupling faces at four points spaced 90
degrees around the coupling rim using a feeler gage, measuring to the
nearest 0.001 inch (.03mm). the maximum variations between any two
readings should not exceed 0.002 inch (.05mm).

5. Rotate the coupling 90, 180, 270 and 360 degrees and take similar
readings. Note that the 360 degree reading repeated the first set of
reading to show the data is reliable. The maximum variation should not
exceed 0.002 inch (.05mm) between the four readings taken at each
coupling position.

6. Correct horizontal misalignment by loosening foot bolts, removing dowel

pins, and bumping the frame into position. Correct vertical misalignment
by shimming under the feet. Check and maintain all internal clearances
(such as air gaps, bearing covers, fan and baffle clearances) equally
around the circumference. To be adequately centered, the air gaps
between poles and armature should be within plus or minus percent of the
average air gap.

7. Repeat steps 2, 3, 4, and 5 for each coupling, working out away from the
two-bearing unit.

MAY 2009 Page 138 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

8. Recheck the couplings sets with more than two units on either side of the
two bearing unit after completing the previously mentioned checks,
because shimming on subsequent units may affect those already checked.
After the set has been aligned within the specified limits, tighten all
coupling bolts by sledging. Experience shows that coupling bolts sledged
tight will not loosen, whereas those torqued to specified values do loosen.

The following Table shows typical readings of a properly aligned coupling and an
example of each of the three possible cases of misalignment.

MAY 2009 Page 139 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

COUPLING POSITION
Feeler 0 0 0 0
Position Right Top Left Bottom

Right 12 (.30) 14 (.35) 13 (.33) 14 (.35)

Top 12 (.30) 13 (.33) 14 (.35) 14 (.35)
Left 13 (.33) 14 (.35) 13 (.33) 15 (.38)
Bottom 13 (.33) 13 (.33) 14 (.35) 15 (.38)

Coupling in line. Gradually changing readings indicate coupling is opening slightly with rotation.

COUPLING POSITION
Feller 0 0 0 0
Position Right Top Left Bottom

Right 12* (.30*) 14* (.35*) 14* (.35*) 16* (.41*)

Top 15 (.38) 17 (.43) 17 (.43) 19 (.48)
Left 18* (.46*) 21* (.53*) 20 (.51) 23* (.58*)
Bottom 15 (.38) 18 (.46) 17 (.43) 20 (.51)

Coupling out of line sideways. Note that right and left readings* show constant difference of 6 to 7
thousandths (.15 to .18 mm), Top and Bottom readings at right.

COUPLING POSITION
Feeler 0 0 0 0
Position Right Top Left Bottom

Right 14 (.35) 14 (.35) 16 (.41) 17 (.43)

Top 10* (.25*) 10* (.25*) 11* (.28*) 12* (.30*)
Left 15 (.38) 14 (.35) 17 (.43) 17 (.43)
Bottom 19* (.48*) 19 (.48*) 22* (.56*) 22* (.56*)

Coupling out of line vertically. Note that top and bottom reading* show constant difference of 90
to 10 thousandths (.23 to 25 mm), left and right reading all right.

COUPLING POSITION
Feeler 0 0 0 0
Position Right Top Left Bottom

Right 14 (.35) 11* (.28*) 16 (.41) 20* (.51*)

Top 18* (.46*) 15 (.48) 11* (.28*) 16 (.41)
Left 14 (.35) 19* (.48*) 15 (.38) 12* (.30)
Bottom 10* (.25*) 16 (.41) 20* (.51*) 15 (.38)

Bad coupling face or bent shaft indicated. Note how tight and loose spots* travel with rotation of
coupling. Necessary to remove both rotor-sand true-up coupling faces or replace the rotor with
bent shaft.

MAY 2009 Page 140 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Fourteen

Selective Maintenance for Electrical

Rotating Equipment

MAY 2009 Page 141 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

SELECTIVE MAINTENANCE FOR ELECTRICAL ROTATING EQUIPMENT

Determination of the productivity rating and reliability index of electrical rotating

equipment is the basis for selecting units, which have the greatest need and
justification for maintenance to eliminate emergency failures.

In any continuous production process, you can usually control investment costs,
material costs, labor costs, etc. However, the most important variable costs are
the most difficult to control; maintenance and the production losses due to
unscheduled breakdowns of production machinery. In many instances, the cost
attributable to the lost production far exceeds the actual costs of a full year’s
maintenance plus emergency repairs. More importantly, repeated equipment
failure may spell the difference between profit and loss.

Any discussion of maintenance reaches the obvious conclusion that you cannot
hope to grow and keep pace with an expanding and highly competitive economy
unless you learn to control maintenance costs. This means learning to minimize
and, wherever possible, eliminate the emergency breakdown. In other words, find
the weak links in your productive chain and fix them before they fail.

About ten years ago, the General Electric Company presented a program to
industry called “productive maintenance” which stressed the need for planned
maintenance instead of emergency repairs. This program outlined a method of
establishing a logical basis for scheduling maintenance, and requirements for
stocking of spare units or parts.

In the years since productive maintenance was first conceived, GE has watched it
work in many plants and has continuously studied, expanded, and improved the
program. Finally, the company introduced a new concept and believes it to be a
big step forward in the search for the optimum maintenance program. This
maintenance concept applies sound engineering and mathematical principles to
establishing a reasonable method for:

Determining the importance of a piece of equipment in the productive process,

and assigning it to one of a number of categories, each of which is identified by a
letter of the alphabet. Once it is so classified, it can be readily compared to other
units in the same process. This classification is called “productivity rating”.

Determining the overall reliability of the unit by assigning finite numbers for each
factor, which affects its reliability. The sum of these numbers becomes a
“reliability index”.

Once these two ratings have been correctly established, we will then have a
sound basis for making decisions and for selecting those units in the production
line, which have the greatest need and justification for a maintenance
expenditure. For this reason, this new plan is called “selective maintenance”.

MAY 2009 Page 142 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

The productivity rating, a comparative measure of the importance of a unit to the

overall production process, is generally arrived at by consideration of:

What happens to the process if this unit fails?

What percentage of production will be lost?

How much will each hour of lost production cost?

What is the maximum time, which can be permitted to get the equipment back
into operation?

What spare parts are available?

An application may be absolutely vital to a process. For example, with a 500-hp

drive motor on a papermaking machine, if there are three machines doing the
same job, its loss will only cause a 33% loss of production. This motor is less
important than a 250-kw DC generator which powers the heating elements on all
three papermaking machines and which, by its failure, would cause 100% loss of
production. In most processes, a number of units will have identical ratings while
only a few extremely critical ones will carry very high ratings.

The determination of the “reliability index” is much more complicated, although it

utilizes many of the basic maintenance functions. The five reliability factors are:

1. Visual inspection
2. A battery of electrical tests
3. Age and history of the machine
4. Environment
5. Duty cycle

Each reliability factor is broken down into a list of specific checkpoints, which are
assigned weight numbers. These values may vary considerably for different type
of equipment. Once all checkpoints are evaluated, the sum becomes the reliability
index, which can then be compared with indices of every other machine in the
process. The result is a priority listing of equipment requiring maintenance.

MAY 2009 Page 143 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

GIVE DIRECTION TO MAINTENANCE

Undoubtedly, maintenance programs presently in use are already doing many of

the things proposed by selective maintenance. Moreover, you probably have
experienced and competent maintenance men who know your equipment and its
operation, and you may have maintenance records, test data and inspection
reports. But are you using this knowledge effectively? It is advisable to evaluate
and correlate all data in a logical, mathematical manner, which will allow you to
intelligently select those areas where you should direct your maintenance effort.

It would be presumptuous to infer that the selective maintenance program will

immediately eliminate all emergency failures. However, if you use your
knowledge and maintenance tools effectively and judiciously to develop
“productivity ratings” and “reliability indices” for your equipment, and have
schedule maintenance to eliminate the weak links, you will have taken important
steps toward meeting this objective.

Still another important benefit to the maintenance engineer may be found in the
selective maintenance concept. Since it is based on well kept records and
measurable numerical data, it becomes a valuable and potent device for
demonstrating the importance of maintenance to your company management.
Historically, maintenance has been considered an expense item and has ranked in
importance far below the other basic functions of manufacturing, engineering,
marketing, finance, employee relations, etc. Actually, maintenance is a basic cost
factor of production and maintenance personnel should be a part of the
management team.

There are strong pressures at work today that are forcing many of our industries
toward completely automated production. Industry has the technical
competency and adequate funds to do this. However, unless we learn to deal
more effectively with the maintenance problems associated with these complex
facilities, the growth pattern will be greatly retarded.

Maintenance men today can proudly point to progress that has been made over
the past years, and rightfully so. There is no question that maintenance
organizations today use better tools, more sophisticated methods, higher quality
materials, better planning and have more control over their basic functions. But
maintenance must accelerate this growth pattern to keep pace with the
phenomenal technical advances in production concepts and production
machinery.

MAY 2009 Page 144 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MOTOR TROUBLESHOOTING

Effective motor troubleshooting requires an analytical approach. An accurate

description of the trouble will lead to the probable cause. For each probable
cause, there is an appropriate remedy.

Maintenance experience is a valuable asset, which should be logically applied to

motor theory and machine design to get to the cause of the problem quickly. The
following tables use this approach.

Table 1. AC Induction Motors

Table 2. AC Synchronous Motors

Table 3. DC Motors and Generators

Table 4. Practical Tools and Equipment for Motor Maintenance.

MAY 2009 Page 145 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

TABLE 1
AC Induction Motors

TROUBLE PROBABLE CAUSE MAINTENANCE

Motor will not start. Overload control trip. Wait for overload to cool. Try
starting again. If motor still
does not start, check all the
causes as outlined below.

Power not connected to motor. Connect power to control,

check control sequence, and
power to motor.

Check connections.

Faulty (open) fuses. Test fuses and circuit breakers.

Low voltage. Check motor-nameplate

values with power supply. Also
check voltage at motor
terminals with motor under
load to be sure wire size is
adequate.
Wrong control connections.
Check connections with control
wiring diagram.
Loose terminal-lead
connection. Tighten connections.

Driven machine locked. Disconnect motor from load. If

motor starts satisfactorily,
check driven machine.

Open circuit in stator or rotor Check for open circuits.

winding.

Short circuit in stator winding. Check for shorted coil.

Winding grounded. Test for grounded winding.

Bearings stiff. Free bearings or replace.

Grease too stiff. Use special lubricant for

special conditions.

Faulty control. Troubleshoot the control.

Overload. Reduce load.

Motor noisy. Motor running single phase. Stop motor, they try to start. It
will not start on single phase.

Check for “open” in one of the

lines or circuits.

MAY 2009 Page 146 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Electrical load unbalanced. Check current balance.

Shaft bumping (sleeve-bearing Check alignment and condition

motors). of belt. On pedestal-mounted
bearing, check cord play and
axial centering of motor.

Motor vibrates. Vibration from unbalance or Balance or align machine.

misalignment.

Possible mechanical system Remove motor from load. If

resonance. motor is still noisy, rebalance
rotor.

Air gap not uniform. Center the rotor and if

necessary replace bearings.

Noisy ball bearings. Check lubrication. Replace

bearings if noise is persistent
excessive.

Loose punchings, or loose Tighten all holding bolts.

rotor on shaft.

Rotor rubbing on stator. Center the rotor and replace

bearing if necessary.

Object caught between fan Disassemble motor and clean

and end shields. it. Any rubbish around motor
should be removed.

Motor loose on foundation. Tighten holding-down bolts.

Motor may possibly have to be
realigned.

Coupling loose. Check coupling joint, check

alignment.
Tighten coupling.

At higher than normal Overload. Measure motor loading with

temperature or smoking. ammeter. Reduce load.

Electrical load unbalance. Check for voltage unbalance or

single phasing.

(Fuse blown, faulty control etc.) Check for “open” in one of the
lines or circuits.

Restricted ventilation. Clean air passages and

windings.

Incorrect voltage and Check motor-nameplate

frequency. values with power supply. Also

MAY 2009 Page 147 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

check voltage at motor

terminals with motor under full
load.

Remove power from motor.

Motor stalled by driven Check machine for cause of
machines or by tight bearings. stalling.

Use insulation testing

Stator winding shorted. procedures.

Use insulation testing

Stator winding grounded. procedures.

Tighten, if possible, or replace

Rotor winding with loose with another rotor.
connections.
Remove excessive pressure or
Belt too tight. bearings.

BEARING HOT. Replace with motor designed

Motor used for rapid reversing for this service.
service.
Make sure end shields fit
End shields loose or not squarely and are properly
replace properly. tightened.

Reduce belt tension, or gear

Excessive belt tension or pressure, and realign shafts.
excessive gear side thrust. See that thrust is not being
transferred to motor bearing.

Sleeve bearings. Straighten shaft, or send to G-E

Bent shaft. service shop.

Add oil – if oil supply is very

Insufficient oil. low, drain, flush, and refill.

Drain oil. Flush, and re-

Foreign material in oil or poor lubricate using industrial
grade of oil. lubricant recommended by a
reliable oil company.

Oil too heavy; drain and

Oil rings rotating slowly of not replace.
rotating at all.
Oil rings has worn spot; replace
with new ring.

Motor tilted too far. Level motor or reduce tilt and

realign, if necessary.

Rings bent or otherwise Replace rings.

damaged in reassembling.

MAY 2009 Page 148 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Ring out of slot (oil ring Adjust or replace retaining clip.

retaining clip out of place).

Ball bearings. Defective bearings or rough Replace bearings. Resurface

shaft. shaft.

Remove relief plug, and let

Too much grease. motor run. If excess grease
does not come out, flush and
re-lubricate.

Wrong grade of grease. Add proper grease.

Insufficient grade of grease. Remove relief plug and re-

grease bearing.

Foreign material in grease. Flush bearings, re-lubricate;

make sure that grease supply
is clean. (Keep covered when
not in use).

Bearings misaligned. Align motor and check

bearing-housing assembly.
See that races are exactly 90
degrees with shaft.
Bearing damage (corrosion,
etc.). Replace bearings.

WOUND-ROTOR MOTOR
TROUBLES.

Motor runs at low speed with Wires to control too small. Use larger cable to control.
external resistance cut out.
Control to far from motor. Bring control nearer motor.

Open circuit in rotor circuit Test to find open circuit and

(including cable to control). repair.

Brushes sparking. Check for looseness, overload,

or dirt.

Dirt between brush and ring. Clean rings and insulation

assembly.

Brushes stuck in holders. Use right size brush, clean

holders.

Incorrect brush tension. Check brush tension and

correct.

Rough collector rings. Sand and polish.

Eccentric rings. Turn n lathe or use portable

MAY 2009 Page 149 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

tool to true up rings without

disassembling motor.

Excessive vibration and noise. Open rotor circuit. Correct open connections or
control.

Current density of brushes too Reduce load. (if brushes have

high (overload). been replaced, make sure they
are of the same grade as
originally furnished.).

Ring threading. Low current density. Consult

GE Company for different
brush recommendation.

MAY 2009 Page 150 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

TABLE 2
AC Synchronous Motors

TROUBLE PROBABLE CAUSE MAINTENANCE

Motor will not start Fault connection. Inspect for open or poor connection.
Open circuit one phase. Test, locate, and repair.
Short circuit one phase Open and repair.
Voltage falls to low. Reduce the impendence of the external
circuit.
Friction high. Make sure bearings are properly
lubricated.
Check bearing tightness.
Check belt tension.
Check load friction.
Check alignment.
Field excited. Be sure field-applying contactor is open
and field-discharge contactor is closed
through discharge resistance.
Load to great. Remove part of load.
Automatic field relay not
working Check power supply to solenoid.
Check contactor tips.
Check connections.
Wrong direction of rotation. Reverse any two main leads of 3 - phase
motor.
Single - phase, reverse starting winding
leads.
Motor will not come up Excessive load
to speed Decrease the load.
Check operation of unloading device (if
any) on driven machine.
Low voltage. Increase voltage
Field excited. Be sure field-applying contactor is open
and field-discharge contactor is closed
through discharge resistance.
Fails to pull into step No field excitation Check Circuit connections. Be sure field-
applying contactor is operating.
Check for open circuit in field or exciter.
Check exciter output.
Check rheostat.
Set rheostat to give rated field current
when field is applied.
Check contacts of switches.
Load excessive. Reduce load
Check operation of unloading device (if
any) on driven machine.
Inertia of load excessive. May be a misapplication - consult
manufacturer.

MAY 2009 Page 151 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Motor pulls out of step or Exciter voltage low. Increase excitation.

trips breaker
Examine exciter as shown in DC motors.
Check field ammeter and its shunt, to be
sure reading is not higher than actual
current.
Open circuit in field and Located and repair break.
exciter circuit.
Short circuit in field Check with low voltage and polarity
indicator and repair field.
Reversed field spool. Check with low voltage and polarity
indicator and reverse incorrect leads.
Load fluctuates widely. See motor "hunts" below.
Excessive torque peak. Check driven machine for bad
adjustment, or consult motor
manufacturer.
Power fails. Re-establish power circuit.
Line voltage too low. Increase if possible. Raise excitation.
Correct excessive torque peak at driven
Motor "Hunts" Fluctuating load. machine or consult motor
manufacturer.
If driven machine is a compressor, check
valve operations.
Increase or decrease flywheel size.
Try decreasing or increasing motor field
current.
Stator overheats Rotor not centered. Realign and shim stator or bearings.
Open phase. Check connections and correct.
Unbalanced currents. Loose connections, Improper Internal
connections.
Field overheats Short circuit in a field coil. Replace or repair.
Excessive field current. Reduce excitation until field current is at
nameplate value.
All parts overheat Overload Reduce load or increase motor size.
Check friction and belt tension, or
alignment.
Over or under excitation Adjust excitation to nameplate rating.
No field excitation Check circuit and exciter.
Improper voltage See that nameplate voltage is applied.
Improper ventilation. Remove any obstruction and clean out
dirt.
Excessive room temperature Supply cooler air.

MAY 2009 Page 152 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

TABLE 3
Direct-Current Motors and Generators

TROUBLE PROBABLE CAUSE MAINTENANCE

Motor will not start Open circuit in control. Check control for open in starting circuit,
open contacts, fuse, or breaker.
Low terminal voltage. Check voltage with nameplate rating.
Bearing Frozen. Recondition shaft and replace bearing.
Overload. Reduce load or use larger motor.
Excessive friction Check lubrication in bearings to make
sure that the oil has been replaced after
installing motor.
Disconnect motor from driven machine,
and turn motor by hand to see if trouble
is in motor.
Strip and reassemble motor; then check
part by part for proper location and fit.
Straighten or replace bent or sprung
shaft (machine under 5 hp).
Motor stop after running Motor is not getting power. Check voltage qt the motor terminals;
short time also fused and overload relay.
Motor attempts to start Motor is started with weak or If adjustable-speed motor, Check
but overload relays no field rheostat for correct setting. If correct,
operate check condition of rheostat.
Check field coils for open winding.
Check wiring for loose or broken
connection.
Motor torque insufficient to Check line voltage with nameplate
drive load. rating.
Use larger motor or one with suitable
characteristic to match load.
Motor runs to slow under Line voltage too low. Check and remove any excess
load resistance in supply line, connections or
control.
Brushes ahead of neutral. Set brushes on neutral.
Overload. Check to see that load does not exceed
allow-able load on motor.
Motor runs to fast under Weak field. Check for resistance in shunt-field
load circuits.
Check for grounds.
Line voltage to high. Correct high-voltage condition.
Brushes back of neutral Set brushes on neutral.

MAY 2009 Page 153 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

BRUSHES
Commutator in bad
Sparking at brushes condition. Clean and reset brushes.
Eccentric or rough Grind and true commutator, also undercut
commutator. mica.
Excessive vibration. Balance armature.
Check brushes to make sure they ride
freely in the holders.
Broken or sluggish acting Replace spring, and adjust pressure to
brush-holder spring. manufacturer's recommendations.
Brushes too short. Replace brushes.
Machine overloaded. Reduce load, or install larger motor.
Short circuit in armature Check commutator, and remove any
metallic particle between segments.
Check for short between adjacent
commutator risers.
Test for internal shorts in armature and
repair.
Brush chatter or hissing Excessive clearance of Adjust holders.
noise brush holders.
Incorrect angle of brushes. Adjust to the correct angle.
Incorrect brushes for the Get manufacturer's recommendations.
service.
High Mica. Undercut mica.
Incorrect brush-spring Adjust to correct value.
pressure.
Selective commutation Adjust to correct pressure, making sure
(one brush takes more Insufficient brush-spring brushes ride free in holders.
load than it should) pressure.
Unbalance circuits in
armature. Eliminate high resistance in defective
joints by inserting armature or equalizer
circuit or commutator risers. Check for
poor contacts between bus and bus rings.
Poor brush fit on
Excessive sparking commutator. Sand in brushes, and polish commutator
surface.
Brushes binding in the Remove and clean holders and brushes
brush holder. with carbon tetrachloride.
Remove any irregularities on surface of
brush holders or rough spots on the
brushes.
Insufficient or excessive Adjust brush-spring pressure.
pressure on brushes.
Brushes off neutral Set brushes on neutral.
Sparking at light loads Paint spray, chemical, oil or
grease, or other foreign Use motor designed for application. Clean
material on commutator. commutator, and provide protection
against foreign matter. Install an enclosed
motor designed for the application.
Field coils overheat Short circuit between turns Replace defective coil.
or layers

MAY 2009 Page 154 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Commutator overheats Brushes off neutral. Adjust brushes.

Excess spring pressure on Decrease brush-spring pressure but not to
brushes. the point where sparking is introduced.
Grooving of commutator Brushes not properly Stagger brushes.
staggered.
Brushes wear rapidly Rough commutator. Resurface commutator and undercut
mica.
Excessive sparking. Make sure brushes are in line with
commutating fields.
Armature overheats Motor overloaded. Reduce load to correspond to allowable
load.
Motor installed in location
where ventilating is Arrange for free circulation of air around
restricted. motor.
Armature winding shorted. Check commutator, and remove any
metallic particle between segments. .
Test for internal shorts in armature and
repair.

MAY 2009 Page 155 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

TABLE 4
PRACTICAL TOOLS AND EQUIPMENT FOR MOTOR MAINTENANCE

TOOLS OR EQUIPMENT APPLICATION

1. Portable multimeter, voltmeter, ohmmeter, Measure circuit voltage, resistance, current and
clamp-on ammeter, wattmeters, clamp-on power. Useful for circuit tracing and troubleshooting.
P.F meter
2. Potential and current transformers, meter Increase range of test instruments to permit reading
shunts. of high-voltage and high-current circuits.
3. Tachometer (preferably hand held) Checks rotating machinery speeds.
4. Recording meters, instrumentals (as
needed) Provide permanent record of voltage, current, power,
temperature, etc., on charts for analytic study.
5. Megohmeter resistance tester (500 or 1000 Test and monitor insulation resistance; use
volts), thermometer, psychrometer, thermometer and psychrometer for temperature
humidity correction.
6. Kelvin bridge Check resistance of windings.
7. Dial indicator with mounting fixtures. To detect and measure misalignment.
8. Stethoscope Detect faulty rotating machinery bearings; leaky
valves.
9. Vibration Indicator To detect and analyze imbalance or misalignment.

10. Air gap feeler gages Check motor or generator air gap between rotor and
stator.
Checks brush pressure on DC motor commutators or
11. Spring tension scale (o to 20 lb approx) on AC motor slip rings; test electrical contact
pressure on relays, starters or contactors.
12. Magnifying glass Use magnifying glass to examine brushes,
commutators or small electrical contacts or parts.

13. Hand tools: pliers, cutters, wrenches, To do the maintenance.

sockets; solder or welding equipment
14. Vacuum cleaner, brusher, cloths To clean equipment tools.
15. Safety equipment (rubber gloves, safety Provides for safe and efficient electrical
glasses, mats; grounding sticks) maintenance.

MAY 2009 Page 156 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Fifteen

Reliability Factors of Electrical Rotating

Equipment

MAY 2009 Page 157 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

RELIABILITY FACTORS OF ELECTRICAL ROTATING EQUIPMENT

1. VISUAL INSPECTION

A thorough visual inspection can only be meaningful when it is made by an

experienced competent individual, who can evaluate the physical changes which
have taken place and knows where to look for signs of degradation.

Insulation:

• Is the exposed insulation checked, cracked, brittle?

• Is the surface dirty, oily, wet, and is there any evidence of excessive
temperature, abrasive action, chemical action or corona?
• Is there evidence of coil movement or looseness of wedges, filters, ties or
blocking? Age and temperature cause most systems to shrink. This results
in looseness of the coils in the slots, movement and chafing, with ultimate
failure at pressure points.
• Are there any tape separations or girt cracks, particularly in the area near
the ends of the slot cells?
• On DC machines is there evidence of thrown solder, loose bands, carbon
build up, poor commutation?
• Are ventilation ducts open and clean?

Signs of mechanical distress:

• Are the bearings hot or noisy?

• Does the machine vibrate excessively?
• Are there any signs of oil or grease leakage either at the bearings or
coupling?
• Are there any loose bolts, vibration air deflectors, cracked fan blades or
evidence of abnormal rust or chemical action on mechanical parts?

2. ELECTRICAL TEST

• Insulation resistance (Megger) test. A widely used maintenance test for

many years. Not always conclusive, but useful in showing a trend when
applied at regular intervals.
• Polarization Index (P1). This is a ratio of the insulation resistances at 10
minutes and at one minute, usually obtained at 500 or 1000 volts, DC. This
test is useful in appraising the dryness and cleanliness of a winding.
• High-voltage DC insulation testing. One of the most commonly used is the
high voltage DC leakage test where voltage is applied between winding
and ground or between phases, usually in equal voltage increments. The
result of this test is a curve of leakage current vs. voltage which has real

MAY 2009 Page 158 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

value for analysis and indication of a trend. It is always necessary to carry

a DC test up to a voltage that represents an over-potential test. Maximum
test voltage should be chosen before the test and should be on rated
voltage and age of the insulation.
• Another commonly used adaptation of the DC test is the HVDC absorption
test where a fairly high DC voltage is applied between winding and ground
and a curve of leakage current vs. time is plotted.
• On very large capacity rotating equipment, principally steam-turbine or
waterwheel generators, it is becoming very common to use the “Schlief
Method”. This version combines the high voltage DC leakage test and
absorption test and uses varying time increments to eliminate the effect of
the reactive or charging portion of the current from the current vs. voltage
curve.
• The last in the high voltage DC category is the DC over-potential test. This
is a proof test usually applied at the end of a DC leakage test.
• AC over-potential test. This is a go or no-go test and a well established
standard for proof testing. This test can usually be applied with reasonable
safety, if other preceding test and visual inspection indicate good dielectric
properties.
• Many utilities use a power factor test as an indication of insulation
reliability. Change of power factor in service is a measure of insulation
degradation. The most popular test of this characteristic is the “Doble
Method” which involves measurement of the power factor of an insulation
system by watt, volt-ampere determinations.

3. AGE AND HISTORY

• How many years has it been in service?

• What is its and class of insulation?
• Most standard design, electrical rotation machines will have a know life
expectancy which can be fitted to a mortality curve. Where does the
machine being evaluated fit on this mortality curve?
• What has been the history of failures on the machine? What caused these
failures?

MAY 2009 Page 159 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

4. ENVIRONMENT

• Does it operate in a clean, dry atmosphere, or is it subjected to moisture,

acidic or caustic chemicals, aromatic solvents, or oils?
• Is the machine in an area contaminated with abrasive dust, carbon dust, or
any dust-type particles, which can erode insulation, contaminate
lubricants, build up on coils, or plug ventilation ducts?
• Does it operate in an area of abnormal ambient temperatures?
• Is the equipment in motion during operation or is it subjected to unusual
vibration from associated equipment?
• How well has the unit been maintained?

5. DUTY CYCLE

• What is its starting cycle? On most induction or synchronous type motors

there is an inverse relation between the life of the insulation and the
number of starts. The extremely high in-rush current during the starting
cycle and the transient voltage stresses possible during each application or
interruption of current have a significant effect on the insulation system.
These effects are more severe on high speed motors.
• Is the load fairly steady or is it cyclic? Is the load reversing or plugging? A
surging type load such as on a slow speed reciprocating compressor can
cause continuous coil movement, hence, loosening of ties, wedges and
fillers.
• What is the average load on the machine? Is it operating within its rating?
• Does it operate within its rated temperature rise?
On DC equipment, the operator plays an important role in its life expectancy.
Over-speed, plugging, high loading during acceleration, and general rough
operation can have an effect on life expectancy.

MAY 2009 Page 160 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

Resource Material

Section Sixteen

C - SHEETS

MAY 2009 Page 161 of 162

 General Electric
EXCAVATOR SYSTEM TRAINING

MACHINE C SHEETS

Machine C – Sheets are a critical part of a successful dragline commissioning and

a vital part of the long-term health of a machine.

The C-Sheet covers all critical settings for the drive system to ensure no motion
exceeds the mechanical or electrical operational limitations.

MAY 2009 Page 162 of 162