March 2022 REPORT

A report compiled by Mokhohloa Terence (Electrical and instruments Attaché)

Checked by

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Supervisor Signature Date

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[Date]
Training advisor Signature Date

Table of Contents
Introduction................................................................................................................................... 2
Three phase Ac induction motor...............................................................................................2
Stator of Three Phase Induction Motor..........................................................................................3
Stator Core................................................................................................................................. 4
Stator Winding or Field Winding..................................................................................................4
Name plate............................................................................................................................. 5
Connecting a three phase ac induction motor.................................................................................9
Star Delta Starter Wiring Diagram 3 Phase....................................................................................9
Direct Online Starter Animation Diagrams - DOL Starter..............................................................11
Three phase AC induction motor maintenance.............................................................................13
Inspections........................................................................................................................... 14
Flooding of Motors............................................................................................................... 15
Conclusion................................................................................................................................. 16
Recommendations.................................................................................................................... 16
Introduction
This report covers all the
activities that were done
during the month of March
but mostly activities that are
concerned with an AC
induction motor. Covering
just briefly on the following
issues to make sure that there
is basic understanding with
in the aspect of ac induction
motor connection, running
and maintenance.

Three phase Ac induction motor

An electrical motor is an electromechanical device that converts electrical energy into mechanical energy.

In the case of three-phase AC (Alternating Current) operation, the most widely used motor around the
RZM Murowa area is a 3 phase induction motor, as this type of motor does not require an additional
starting device. These types of motors are known as
self-starting induction motors.

A 3 phase induction motor consists of two major

parts:
A stator
A rotor

Stator of 3 Phase Induction Motor

The stator of three phase induction motor is made up
of numbers of slots to construct a 3 phase winding
circuit which we connect with 3 phase AC source.
We arrange the three-phase winding in such a
manner in the slots that they produce one rotating
magnetic
field
when we switch on the three-phase AC supply source.
Rotor of 3 Phase Induction Motor
The rotor of three phase induction motor consists of a cylindrical laminated core with parallel slots that
can carry conductors. The conductors are heavy copper or aluminium bars fitted in each slot and short-
circuited by the end rings. The slots are not exactly made parallel to the axis of the shaft but are slotted a
little skewed because this arrangement reduces magnetic humming noise and can avoid stalling of the
motor.

Working of Three Phase Induction Motor

Production of Rotating Magnetic Field
The stator of the motor consists of overlapping winding offset by an electrical angle of 120 degrees.
When we connect the primary winding, or the stator to a 3 phase AC source, it establishes rotating
magnetic field which rotates at the synchronous speed.
Secrets Behind the Rotation: -

According to Faraday’s law an emf induced in any circuit is due to the rate of change of magnetic flux
linkage through the circuit. As the rotor winding in an induction motor are either closed through an
external resistance or directly shorted by end ring, and cut the stator rotating magnetic field, an emf is
induced in the rotor copper bar and due to this emf a current flows through the rotor conductor.
At this point the relative speed between the rotating flux and static rotor conductor is the cause of current
generation; hence as per Lenz’s law, the rotor will rotate in the same direction to reduce the cause, i.e., the
relative velocity.
Thus from the working principle of three phase induction motor, it may be observed that the rotor speed
should not reach the synchronous speed produced by the stator. If the speeds become equal, there would
be no such relative speed, so no emf induced in the rotor, and no current would be flowing, and therefore
there is no motion. The rotor cannot reach the synchronous speed. There is a difference between the stator
(synchronous speed) and rotor speeds this is called the slip. The rotation of the magnetic field in an
induction motor has the advantage that no electrical connections need to be made to the rotor.
Thus the three phase induction motor is:

 Self-starting.
 Less armature reaction and brush sparking because of the absence of commutators and brushes
that may cause sparks.
 Robust in construction.
 Economical.
 Easier to maintain.

The rotor is a rotating part of induction motor. The rotor is connected to the mechanical load through the
shaft. The rotors of the three phase induction motor are further classified as:
Squirrel Cage Rotor
Slip Ring Rotor or Wound Rotor or Phase Wound Rotor
Depending upon the type of rotor used the three-phase induction motor is classified as:
Squirrel Cage Induction Motor
Slip Ring Induction Motor or Wound Rotor Induction Motor or Phase Wound Induction Motor
The construction of stator for both the kind of three phase induction motor remains the same.

Stator of Three Phase Induction Motor

The stator of the three phase induction motor consists of three main parts:
Stator frame
Stator core
Stator winding or field winding
Stator Frame
It is the outer part of the three-phase induction motor. Its main function is to support the stator core and
the field winding. It acts as a covering and provides protection and mechanical strength to all the inner
parts of the machine. The frame is either made up of die-cast or fabricated steel, but at Murowa we have
die cast. The frame of three phase induction motor should be strong and rigid as the air gap length of three
phase induction motor is very small. Otherwise, rotor will not remain concentric with stator which will
give rise to unbalanced magnetic pull.

Stator Core
The main function of the stator core is to carry alternating flux. In order to reduce the eddy current losses
the stator core is laminated. All the stamping are stamped together to form the stator core, which is then
housed in a stator frame. The stampings are generally made up of silicon steel, which reduces the
hysteresis loss.

Stator Winding or Field Winding

The slots on the periphery of stator core of the three phase induction motor carries three phase windings.
This three phase winding is supplied by three phase ac supply. The three phases of the winding are
connected either in star or delta depending upon which type of starting method is used.
The squirrel cage motor is mostly started by star-delta stated and hence the stator of squirrel cage motor is
delta connected. The slip ring three phase
induction motor are started by inserting
resistances so, the stator winding can be
connected either in star or delta. The winding
wound on the stator of three phase induction
motor is also called field winding and when this
winding is excited by three phase ac supply it
produces a rotating magnetic field.

The number of poles shows whether the ac

induction motor has more torque or speed
This can be proven mathematically and even
practically by the formula

Speed
(Hz x 60 x 2) / Number of poles = no-load RPM
Torque
T=P/ω
Here omega ω is equal to 2 x pi x N (rpm) / 60
Since from the formula we have speed being inversely proportional to number of poles and at the same
time, torque is inversely proportional to the angular speed showing that if there is a relationship between
the torque and speed of the motor.
If there are more poles there is a greater amount of torque and less speed and if there are a few poles
there is higher speed and low torque.
Here at Murowa there are high speed and low torque motors that are used for high torque demanding
parts such as conveyors but we use gear boxes to counter and convert the high speed motor output into
high torque and slower speed motors by the use of gear ratios.

High speed motors are used for water pumping like the Ngezi pump, Darashuro booster pump and all
water reticulation pumps including the two other motors driving the scrubber in the plant and around it.
Name plate
In order to understand the working of a motor its tolerances and extremes we need to understand the name
plate that comes with the motor.
A nameplate contains a large amount of useful information relating to the motor including the type, RPM,
frame size and power of the motor.

Whilst the exact layout and format of the motor nameplate will be dependent on the manufacturer and
what standards are being adhered to (IEC or NEMA).

Number of Phases
This shows the type of power supply for which the motor is designed. There are single phase and three
phase motors. In this example, the number is ‘3’ as the motor is a three phase motor.

Rated Operating Voltage (Volts)

This shows at which voltage is the motor is designed to operate most efficiently. Motors are designed to
operate at +/-10% tolerance of this value.
Other parameters shown on the nameplate including: power factor, efficiency, torque and current are at
rated voltage and frequency. Using the motor at voltage outside this tolerance will most probably lead to
different performance.
Service Duty
In this case, S1 shows that this is a continuous duty motor that works at a constant load for enough time to
reach temperature equilibrium.
The parameter Duty/Time rating represents the period of time during which the motor can run at its
nameplate rating/rated load safely and indicates whether the motor is rated for continuous duty.
This is shown as “CONT” for continuous duty 24/7 but they can also have a short-time rating from 5 to
60 minutes, most motors are rated for continuous duty.
The rating of the motor is the ambient temperature vs. the time it can operate at that temperature, the EIC
break this down into ten ratings.

Efficiency Code
This shows the percentage of the input power that is actually converted to work output from the motor
shaft.
The motor will have a “nominal” efficiency shown on the plate, this is the average efficiency. The closer
this value is to 100%, the lower the electricity consumption cost is going to be.
The four levels of motor efficiency are
IE1 – Standard Efficiency
IE 2 – High Efficiency
IE 3 – Premium Efficiency
IE 4 – Super Premium Efficiency
In our example, we are shown an IE Code of IE3 which indicating premium efficiency.

Frame Size
This shows the frame size. The frame size determines the mounting dimensions such as the foot openings
pattern and the shaft height.
The dimension of the electric motor based on the NEMA system for fractional hp motors (micro motors)
have two digits and represent the shaft height from the base’s bottom in sixteenths of one inch.
For large motors the frame size has three digits, the first two digits stand for the shaft height in one
quarter of an inch. The third digit is the bolt mounting holes dimension, the longer the motor body, the
longer the distance between mounting bolt holes in the base. Finally, the letter is the type of frame.
The same concept applies for IEC type motors (metric motors) but the height is measured in millimetres
instead of inches.

Degree of Protection
The IEC uses a two-digit ingress protection (IP) rating to measure how well the motor is protected from
the environment. NEMA uses an enclosure description that is of a similar standard.

In the example below an IP of 55 tells us that the motor is ‘protected against dust’ and ‘protected against
jets of water from all directions.

Insulation Class
The highest temperature in the motor’s hottest spot has a serious impact on the life of the electric motor.
The temperature that occurs at that spot is a combination of motor design temperature and the ambient
temperature. The insulation class shows the motor’s ability to withstand temperatures over time.
 The motors have different insulation capabilities. The insulation codes show their thermal tolerance or
ability to survive at a specified temperature for a period of time. The higher the designated code letter, the
greater the heat capability.
It is based on the highest temperature the material can withstand continuously without degrading or
reducing motor life. IES specify 5 different types of insulation classes:

Class A Insulation:

 Maximum Temperature Rise: 60°C

 Hot-spot Over Temperature Allowance: 5°C
 Maximum Winding Temperature: 105°C
Class B Insulation:

 Maximum Temperature Rise: 80°C

 Hot-spot Over Temperature Allowance: 10°C
 Maximum Winding Temperature: 130°C
Class F Insulation:

 Maximum Temperature Rise: 105°C

 Hot-spot Over Temperature Allowance: 10°C
 Maximum Winding Temperature: 155°C
 Class H Insulation:

 Maximum Temperature Rise: 125°C

 Hot-spot Over Temperature Allowance: 15°C
 Maximum Winding Temperature: 180°C

In the example, we can see that the motor has an insulation class of F, indicating that the motor’s thermal
tolerance is 155℃.

Temperature Rise
Each class of insulation has a maximum motor winding temperature rise and a maximum temperature
rating. In addition, a hot spot temperature rise is specified which pertains to motor windings that are
surrounded by other windings.

Frequency (Hz)
This shows the input electricity frequency that the motor is designed to operate at.
Usually for motors, the input frequency is 50 or 60 Hz. If more than one frequency is marked on the
nameplate (like our example), then other parameters that will differ at different input frequencies have to
be indicated on the nameplate as well.

Motor Rated Power

kW is an expression of the motor’s mechanical output rating – its ability to deliver the torque needed for
the load at rated speed.

Full Load Speed (RPM)

Full-load speed is the speed at which rated full-load torque is delivered at rated power output; this speed
is sometimes called slip-speed or actual rotor speed.
In the example nameplate, this is declared as min-1, but generally it is declared in RPM; both these
measurements are the same.

Rated Operating Current

This corresponds to the rated power output together with voltage and frequency. The current may deviate
from the nameplate amperes if the phases are unbalanced or if the voltage turns out to be lower than
indicated.

Power Factor
Power factor is indicated on the nameplate as either “PF” or “P .F” or cos φ. Power factor is an expression
of the ratio of active power (W) to apparent power (VA) expressed as a percentage.

Ambient Temperature
The maximum ambient temperature (AMB) lists the temperature at which the motor can operate and still
be within the tolerance of the insulation class at the maximum temperature rise.
In this example, the ambient temperature of the motor is 40c.

Service Factor
This Indicates the amount of overload a motor can handle. Electrical motors are often designed to handle
a temporary increase in demand, the ability of the motor to handle these demands are represented by the
service factor.
For example, a motor with 1.0 service factor cannot be expected to handle more than its nameplate kW. A
motor with service factor 1.15 can be expected to safely handle infrequent loads to 15% past its rated kW.
In general, it is bad practice to size motors to operate continuously above rated load in the service factor
area. Operating a motor at overloads allowed by the service factor for extended periods can result in
reduced speed, overheating, decreased efficiency, decreased power factor all of which affects the overall
life span of the motor.

Altitude
This indication shows the maximum height above sea level at which the motor will remain within its
design temperature rise, meeting all other nameplate data.
Below this altitude, the motor may run cooler. Above this temperature, the motor may run hotter.

Motor Weight
This shows the weight of the motor – 78kg in our example.
Serial Number
This shows the serial number of the motor. As it is unique to the motor, knowing this number can help
when liaising with manufacturers or M&E companies about the type of motor you have.

Connecting a three phase ac induction motor

There are several types and methods of connecting the motor in and around the plant these include:
 Star delta
Star/Delta starters are probably the most common reduced voltage starters. They are used in an
attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply.
 Direct online (DOL)
In a DOL Starter, an induction motor is connected directly across its 3-phase supply, and the
DOL starter applies the full line voltage to the motor terminals. Despite this direct connection, no
harm is done to the motor. A DOL motor starter contains protection devices, and in some cases,
condition monitoring.

Star Delta Starter Wiring Diagram 3 Phase


To make a star delta starter you need...

1 MCCB Circuit Breaker

3 magnetic contactors
3 phase motor thermal overload relay / Electronic overload relay OCR
An on daily timer (8 pin timer with 8 pin glass type relay socket/base)
1 Normally close push button switch
1 Normally open push button switch
 Electric wires for main motor wiring
 Electric wires for controlling wiring
 Star Delta Starter Wiring For 3 Phase Motor Diagram

Here I have shown the complete star delta starter wiring diagram 3 phase. The three-phase supply
shown with RED, Yellow, And Blue Coolers. - All connections with a 3 phase induction motor.
This is the connection that I was shown and tested it and it worked:
The above is a star delta starter wiring diagram 3 phase motor for the main wiring. Now let's see the star
delta starter control circuit diagram with timer, NC/NO push button switches.
Star delta starter control circuit diagram

In the star delta starter control circuit wiring diagram with timer and normally close push button/normally
open push button switch. In the control wiring diagram, all magnetic contactors coils are rated 220 VAC.
An 8 pin timer is used. The on delay timer diagram is also shown in the diagram.
This type of connection is found within the plant at the jaw crusher, scrubber and all other conveyors just
to mention a few.

For low load three phase motor we use a direct online starter for controlling. But how a direct online
works and how to wire a direct online starter for a 3 phase motor.

Direct Online Starter Animation Diagrams - DOL Starter

The magnetic contactor, thermal overcurrent protection relay, normally close push button switch,
normally open push button switch. In the diagram, the contactor which is used is 380 to 440 ACV. A
thermal overload relay is used for protection during the overcurrent flow to the motor. (In thermal
overload relay the NC and NO contacts shown) A red normally close push button switches shown and
normally open push button shown.

In the direct online starter a 3 phase, 440 volts supply is shown which is connected to the magnetic
contactor main contacts. From the blue wire, a wire goes to the thermal overload relay normally close
contacts and from there the wire goes to the contactor
coil A1 terminal.

From the red line wire, a wire goes to the normally

close push button switch. From the NC push button
switch, the wire goes to normally open push button
input terminals, and from the same place, a wire goes
to the normally open auxiliary contacts of the
contactor. This wire will be called hold wire.
From the NO switch output terminals a wire goes to another side of the NO auxiliary contacts of the
contactor and from the same point, the wire goes to the contactor coil A2 terminal. This wire will be
called touch wire in simple words.

Here is the first look of 3 phase motor direct online starter wiring diagram in which the motor is not
started.

In the diagram. I show that the motor is not started and NO push button switches in normal state. Now in
the next step, the normally open
push button switch is ON and the
motor is also ON.
As you know that we use normally
open push button switch only for
touch current or starting time
current.

In the above 3 phase, motor

controlling diagram the normally
open switch is in close state, in the
next diagram the normally open
switch in the open state but the

motor is started because the other line wire

goes to the contactor in hold wire through
the contactor normally open contacts
(because now contactor normally open
auxiliary contacts is close).
Now if we want to switch off the motor, then we need to push the normally close push button switch and
when we push the normally close push button switch. The supply which goes to contactor through the
holding wire (blue wire from the normally open switch) with cut and the magnetic contactor will be De
energizing. As I have shown in the below direct online starter diagram.

Now after pushing the

red push button
switch (NC switch)
the circuit will turn
normal state as I
showed in the first
diagram.
Three phase AC induction motor maintenance
In the day to day running of the company we usually do checks on all motors in the beginning of the shift
to ensure that they are running smoothly but during planned maintenance we do intensified check-up and
repair the steps that we follow during this exercise are:

 Visual inspections within the MCC to insure that there are no burning cables or shorts with in the
panels
 Tighten all loose connections
 Checking that the relay functions properly and checking that the pre-set value has not been
changed in order for the relay to trip if there is over current.
 Cleaning up of the panels and making sure that there is no liquid or dust in the panels as they
may cause a fault
 Isolating by switching off all power sources to the subject of our work.
 Locking out the affected panel so that no one accidentally powers the are unknowingly
 Checking all field stop switches, testing if the function and react to either a pull or push by an
operator in the field
 Doing visual checks around the motor checking for safety of our cables, fastening where needed.
 Checking for any abnormalities and loose connections with in the connection panel
 If everything is ok we seal the panel with silicon to ensure that water does not sip into our motor

In the event that our motor has shorted it needed intensive maintenance either done by an external
contractor or by the Murowa engineering team.

There are only a few simple rules for the maintenance of these motors:

1. Maintain high insulation resistance at all time and measure the insulation resistance by megger
regularly.
2. Keep the bearings lubricated properly and change the bearings at the recommended intervals.
3. Maintain a uniform air gap.
4. Keep the motor clean and dry always. Protect it from moisture.

If these simple rules are followed, your motor will run indefinitely and never give you any
trouble. For the motors, cleaning is the most important maintenance that can be done. Regular
cleaning must be done both on the outside and the inside of the motor. The winding should be
cleaned with chemical agents like electro-solve and dried. In case insulation readings are low,
then the windings can be dried by heating with an electric heater or by supplying a small
intensity current through the windings, and then followed by varnishing the windings.

In case compressed air is used for blowing the dust away, make sure that it is dry and has been
passed through the dehumidifier. However prudent engineers do not use compressed air as the
pressure of the air forced the dust and the contaminants inside the windings. It is better to use a
long handle dog leg brush for the cleaning. Alternatively a vacuum cleaned can be used.

The motors become dirty from the outside in industries and then the overzealous staff paints
them bright before the inspections. However it must be remembered that each additional layer of
paint is reducing the heat transfer of the motor casing and fins. Years of painting lead to the
overheating and the failure of the insulation and eventual burning of the motor. In case you find
that the motor have become dirty it is a better option to clean them with a heavy duty cleaner
than re painting.

In case you find that a motor is very hot when all the other parameters including the current
drawn are normal, then a simple procedure of removing all the old layers of paint by a scraper
will bring immediate relief.

Contamination of the windings due to the grease escaping from the ball bearings also
contaminates the windings. In the bearings where a bearing covers are not available sealed ZZ
type of bearings should be used. In the sealed bearings optimum quantity of grease is put and the
same grease melts, lubricates and again gels.

Some engineers remove the shielding of the ZZ type of bearings to put additional grease. This
action does uncountable damage to the bearings as well as the windings. In case there is evidence
that the winding has been subjected to the onslaught of grease and oils, the same should be
washed with cleaning agents like electro solve and Electra clean, etc.

Inspections

When a motor is opened up for overhaul it should be thoroughly inspected so that the faults can
be diagnosed before the breakdown takes place.

The stator can be damaged if the rotor is not properly inserted as the clearances are low. It is
damaged on numerous cases and the motor left to run and no body informed. Look at the stator
windings for any damages, overheating, rubbing signs, etc.

The rubbing marks can be caused by a worn bearing or due to misalignment. In case the bearing
is due for replacement or if you find some fault it should be replaced right away. The insertion of
bearing must be by heating in an oil bath as it is very gentle to the bearings.

In case the bearings are due and you find that the motor is running properly, the condition of the
bearing can be done by condition monitoring equipment like Shock Pulse Measurement. The
other method is to monitor the temperature around the bearing area by infra-red remote
thermometer.

When replacing the bearings the correct amount of grease must be used. If you use less then you
can damage the bearing as it can run dry. In case excess grease has been put it will cause
churning and friction which results in overheating.

In case the bearings are to be reused they should be cleaned by inserting and washing in solvents
like kerosene. After the bearings are washed they must be dried by compressed air. However
care should be taken to not let the bearing rotate on air jet as it can damage the battery.
Flooding of Motors

In coastal areas and marine applications it is often that the motors get flooded with water. If it is
fresh water the danger is not as great as the salt quantity to cause conduction and shorting of the
motor and subsequent burn out is less. But if the motor has been flooded by salt water then they
can be brought back to life by the following process:

1. Wash the motor with distilled water to remove all the salt and the minerals.
2. Any grease and oil deposits must be removed by a suitable electric grade solvent like electro
solve.
3. Dry the stator windings with low power source or lamps.
4. The repair must be done in an open space or with extractor fans to remove the water vapours.
5. With the windings clean and dry re varnish the windings thoroughly.
6. Dry the windings and check the insulation resistance.

Squirrel cage motors are very sturdy and hardly give trouble. They have to be monitored for
performance and their maintenance done from time to time which is also simple. Few
precautions as discussed above give them long life and ensure their trouble free operation.
Challenges faced
Muddy and slippery flows
Hot weather
Lack of supplies and proper tools to use

Conclusion
In brief we have understood that most motors used within the Murowa area are squirrel cage three phase
ac induction motors, most of these are connected in the star/ delta or direct on line method of connection
and even some with soft starters in order to protect or circuits from the harm demand of the induction
motor. Our motors are maintained on a regular basis to make sure that the production of our precious
product is as smooth as possible without any glitches or mishaps

Recommendations
There should be availability of extra spares for motors and bearings for motors, at we have harsh weather
conditions, unplanned power cuts and unexpected surges within our systems.
Continuous checks within the mine area to insure that we prevent as many break downs as we can
possibly can